GAS Hoval Responsibility for energy and environment. Hoval heating technology Hoval residential ventilation Hoval indoor climate systems GAS

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1 GAS Complete Complete high high efficient efficient system system solutions solutions for domestic, for domestic, commercial and industrial and industrial applications.

2 Gas Page Wall-hanging gas condensing boiler Hoval opgas comfort 10, 16, 22 kw Description 3 Part N 5 echnical data 11 Dimensions 13 Engineering 16 Examples 18 Hoval opgas classic 12, 18, 24 kw Description 19 Part N 20 echnical data 27 Dimensions 30 Engineering 33 Examples 35 Hoval opgas combi 21/18, 26/23, 32/28 kw Description 37 Part N 38 echnical data 41 Dimensions 43 Engineering 44 Examples 45 Hoval opgas kw Description 47 Part N 48 echnical data 53 Dimensions 55 Engineering 56 Examples 58 Hoval opgas 80 kw Description 59 Part N 60 echnical data 65 Dimensions 67 Engineering 68 Examples 70 1

3 Gas Page Floor standing gas condensing boiler Hoval UltraGas kw Description 71 Part N 72 echnical data 82 Dimensions 85 Engineering 88 Examples 90 Hoval UltraGas Cascades CL/R kw Description 93 Part N 94 echnical data 99 Dimensions 101 Engineering 106 Examples 109 Hoval UltraGas kw Description 111 Part N 112 echnical data 120 Dimensions 124 Engineering 129 Examples 132 Hoval UltraGas kw Description 135 Part N 136 echnical data 143 Dimensions 147 Engineering 151 Examples 154 Floor standing gas calorific value boiler Hoval CompactGas kw Description 157 Part N 158 echnical data 163 Dimensions 165 Base size 166 Engineering 167 Examples 168 Standard terms and conditions of delivery 169 2

4 Hoval opgas comfort (10, 16, 22) Wall-hanging gas condensing boiler with or without water heating Description Hoval opgas comfort (10, 16, 22) Wall-hanging gas condensing boiler With condensing boiler technology Heat exchanger made of corrosion resistant aluminium alloy with integrated forced flow copper coil, flue gas side: aluminium water side: copper+ Minimal water circulation necessary (see technical data) Integrated: Pre-mixing burner with Venturi and NI surface burner Automatic ignition and ionisation monitoring High-efficiency pump Biral AX13 resp. AXS15-4 Automatic quick aspirator Safety valve 3 bar Pressure gauge One primary flow socket and one return flow socket for heating circuit and hot water production Flue gas duct with corrosion free plastic device for draining condensation water Condensate collecting tray for draining condensation water including siphon Flue gas temperature limiter Reverse switch, overflow valve, filling and draining cock, connection for expansion tank Connections: Heating system flow and return with locking ring fitting D22 (barrel nipple G¾ ) Flow and return hot water with locking ring fitting D18 (barrel nipple G¾ ), gas connection with locking ring fitting D15 (barrel nipple G½ ) Factory setting for natural gas H Boiler fully cased with varnished white steel plates and red plastic sections Basic boiler control panel N4.2 Control unit for gas burner BIC335 for ignition and monitoring of the burner Modulating burner control Main switch I/O Operation- and fault indication Regulation of hot water production by means of sensor or by thermostatic demand. For connecting a maximum of 1 room control device or 1 remote control with room sensor. Control (device) for an external gas valve. Optional Propane modification Free standing calorifier opval (130,160) Gas cock Weather-controlled regulation for mixing operation Listed details as accessoires. Installation: On-site Delivery Wall-hanging gas condensing boiler fully cased Mounting material Instruction package System manual Range Output range opgas comfort at 40/30 C ype kw (10) 2,0-10 (16) 2,9-16 (22) 4,5-22 Heating regulator set RS-O For 1 heating circuit without mixing operation Controlled by atmospheric conditions for gliding boiler water temperature RS-O with overplugable room temperature sensor located in the boiler- or living room. Can optimally be installed in the boiler control panel. Outdoor sensor AF 120 Calorifier sensor F 25 / 12K BMS-Module 0-10 V/O (Openherm) (Building management system) For boiler control as part of a building management system. External temperature control 0-10 V. 0-1,0 V no requirment 1,0-9,5 V... 0 C C Can be installed in the boiler control panel! Permissions boilers opgas comfort (10, 16, 22): CE-Product-ID-No: CE-0085BR0482 Heating regulator set ZN3 As supplement for basic boiler control panel N4.2 (can be build in). Consisting of: Heating regulator Hoval opronic /N for 1 heating circuit without mixing operation 1 mixer circuit Domestic hot water loading circuit Function extension possibility via different key modules. Large LCD-Display Rotary push button Buttons for daytime room temperature night room temperature hot water temperature operating mode selection (holiday, absent, heating operation prolongation, automatic, summer, continuous - reduced - frost protection) adjusting the heating curves system information emission measurement and manual operation Outdoor sensor AF200 Clamp-on flow sensor VF204 Calorifier sensor KV20/5/6 Cable set ZN3 for connecting the heating regulator opronic / N with the boiler control. Connection available for room station RS- Delivery Heating regulator set separately packed, mounting on-site Subject to alterations,

5 Hoval opgas comfort (10, 16, 22) Wall-hanging gas condensing boiler with or without water heating Description Mounted below/free standing calorifier opval (130, 160) Water heater with smooth pipe heat ex changer made of enamelled steel, fixed build-in. As calorifier placed below for Hoval opgas comfort (10, 16, 22). Magnesium protection anode hermal insulation using HCFC free PU foam, with foil mantle, white Delivery Calorifier compl. mounted Calorifier CombiVal ERW (200), white Calorifier made of steel, enamelled inside. Smooth pipe heat exchanger enameled, built in. As free standing calorifier for Hoval opgas comfort (10, 16, 22). Magnesium protection anode integrated. Flange for electrical heating inset. hermal insulation made of Polyurethan foamed on the calorifier, dismantable foil casing, white, comple. mounted. Pocket welded in including thermometer On request Electrical heating inset Delivery Calorifier compl. mounted 4 Subject to alterations,

6 Hoval opgas comfort (10, 16, 22) Part N Wall-hanging gas condensing boiler Hoval opgas comfort (10, 16, 22) Part N Heat exchanger made of corrosion free aluminium alloy with integrated forced flow copper coil. With a modulating, premixing, stainless steel surface burner. Including basic boiler con trol N4.2 and connecting screws / bolts, completely cased. High-efficiency pump opgas comfort Output ype kw 1 (10) 2,0-10,0 (16) 2,9-16,0 (22) 4,5-22, kw = modulation range for 40/30 C Accessories Gas filter with measurement nozzle before and behind the filter inset (diameter: 9 mm) Pore width of the filter inset < 50 mm Max. pressure difference 10 mbar Max. inlet pressure 100 mbar ype Connection 70612/6B Rp ¾" Modification set for propane for UltraGas (15-70), opgas comfort (10-22), opgas (30-60) Output range see technical data Ø 81 Ø 124 Ø Zuluft Separating piece C80/125 -> 2xE80PP for ambient air independent operation for separate conduction of flue gas and combustion air. Only in combination with connection set for ambient air independent operation Visible console for opgas comfort for preinstallation of connections for gas R½" heating flow and return connections G¾" flat sealing Ball valve set - flow and return Consisting of: 2 ball valves for flow and return 2 seals Connection ¾" Subject to alterations,

7 Hoval opgas comfort (10, 16, 22) Part N Accessories Part N Calorifier opval (130, 160) Calorifier placed below, with integrated heater battery made of steel, enamelled inside. opval ype Content Litres (130) (160) Connection set flexible piping between opval (130,160) and opgas comfort (10-22) with non-return flap in the primary flow to prevent single pipe circulation including sealing material Calorifier CombiVal ERW (200), white Calorifier made of steel enamelled inside. With enamelled smooth pipe heat exchan ger built-in, foil sheath white. CombiVal ype Content Litres ERW (200) Subject to alterations,

8 Hoval opgas comfort (10, 16, 22) Part N Control panel with heating regulator opronic Heating regulator set RS-O (Not for mixing operation!) For 1 heating circuit without mixing operation Flow temperature control controlled by atmospheric conditions with outer temperature sensor AF 120 water heater sensor F 25 / 12K and overridable room temperature sensor. Can be implemented as a room temperature control without outdoor sensor. opgas comfort (10-22) opgas (30-60) For integration into boiler control panel: Mounting set RS-O must be ordered. opgas classic and combi Only wall mounting possible! Part N Mounting set RS-O Assembly set for mounting of heating regulator set RS-O into boiler BMS module 0-10 V/O - Openherm (building management system) no control unit opronic necessary power supply via O bus opgas classic Cannot be installed in the boiler control panel! opgas (30-60) Can be installed in the boiler control panel! Heating regulator set ZN3 Can be built in as supplement for basic boiler controller N4.2! Consisting of: Heating regulator opronic /N for - 1 mixer circuit - 1 heating circuit without mixer - hot water loading Outdoor sensor AF200 Flow sensor VF204 with 4 m cable 1 immersion sensor KV20/5/6 for calorifier with 5 m cable Cable set ZN3 for connecting the heating regulator opronic / N with the boiler controller Room station RS- for opronic effective on one mixing circuit Remote control RFF- for opronic effective on one mixing circuit Subject to alterations,

9 Hoval opgas comfort (10, 16, 22) Part N Part N For RS-O and heating regulator opronic /N Flow temperature guard for underfloor heating (per heating circuit 1 guard) C, differential gap 6K, capillary tube max. 700 mm, setting (from the outside visibly) inside the housing cover. clamp-on thermostat RAK-W1000.S hermostat with strap, without cable and plug Gas valve, passage DN ½" with thermally releasing cut-off device Gas valve, corner version DN ½" with thermally releasing cut-off device Mud separator made of brass ype ø D Op. pressure max. emp. C kv-value m 3 /h DC 20 ¾ 10 bar , DC bar , Automatic quick release air vent with cut-off valve ½" Accessory for sludge separator Subject to alterations,

10 M M M M Hoval opgas comfort (10, 16, 22) Part N Accessories for regulator system opronic Part N 1-7 Key Module for Hoval opronic use to get more functions additional to standard functions. Key-Modul consiting of: Function key to plug in opronic incl. accessories Only one Key Module possible! Standard functions already included in opronic. - 1 mixing circuit - 1 heating circuit without mixing operation - domestic hot water loading circuit Functions of the Key-Modules Key- 2. mixing- solid-fuel- solar Module circuit storage tank bi-fuel M 1 Key-Module 1 for 2. mixing circuit Function 1, 1 flow sensor, 2 loose plugs Key-Module 2 for solid fuel / storage tank / bivalent installation Function key 2, 3 immersion sensors, 4 loose plugs Key-Module 3 for solar plants Function key 3, 1 collector sensor, 1 calorifier sensor, 4 losse plugs M 4 Key-Module 4 for 2. mixing circuit and solid fuel / storage tank/ bivalent installation Function key 4, 1 flow sensor, 3 immersion sensors, 6 loose plugs M 5 Key-Module 5 for 2. mixing circuit and solar plants Function key 5, 1 flow sensor, 1 collector sensor, 1 calorifier sensor, 6 loose plugs Key-Module 6 for solid fuel/storage tank/bivalent installation and solarplants Function key 6, 1 collector sensor, 4 immersion sensor, 6 loose plugs M System approaches and applications see Hoval CD 7 Key-Module 7 for 2. mixing circuit, soid fuel/storage tank / bivalent installation and solar plants Function key 7, 1 flow sensor, 1 collector sensor, 4 immersion sensors, 8 loose plugs Sensor type Immersion-/calorifier sensor : ype KV20/5/6 (L = 5 m) without immersion sleeve flow sensor ype VF204S with plug Collector sensor ype P1000 (Silicone) Subject to alterations,

11 Hoval opgas comfort (10, 16, 22) Part N Service Part N Commissioning Commissioning must be made by works service or Hoval trained authorized serviceman/ company is condition for warranty. For commissioning and other services please contact your Hoval sales office. 10 Subject to alterations,

12 Hoval opgas comfort (10, 16, 22) echnical data Hoval opgas comfort ype (10) (16) (22) Nominal output 80 / 60 C with natural gas 1 kw 1,8-9,1 2,8-14,6 4,1-20,1 Nominal output 40 / 30 C with natural gas 1 kw 2,0-10,0 3,1-16,0 4,5-22,0 Nominal output 80 / 60 C with propane 3 kw 4,8-9,1 5,8-14,6 7,7-20,1 Nominal output 40 / 30 C with propane 3 kw 5,3-10,0 6,3-16,0 8,4-22,0 Nominal load with natural gas 1 kw 1,9-9,5 2,9-15,2 4,2-21,0 Nominal load with propane 3 kw 5,0-9,5 6,0-15,2 8,0-21,0 Working pressure heating maximum/minimum bar 3 / 1 3 / 1 3 / 1 Working temperature maximum C Boiler water content l 1,4 1,7 2,0 Minimum water flow l/h Boiler weight (without water content) kg Boiler efficiency at partial load 30% (according to EN 303) % 105,9 / 95,4 106,0 / 95,5 106,1 / 95,6 (related to net / gross calorific value) Standard efficiency (according to DIN 4702, part 8) (related to net / gross calorific value) 40 / 30 C % 109 / 98,2 109 / 98,2 109 / 98,2 75 / 60 C % 104 / 93,7 104 / 93,7 104 / 93,7 Stand-by loss at 70 C Watt Standard emission rate Nitrogen oxides mg/kwh <25 <25 <25 Carbon monoxide CO mg/kwh <20 <20 <20 Content of CO 2 in the exhaust gas maximum/minimum output % 9,0 / 8,8 9,0 / 8,8 9,0 / 8,8 Dimensions see table of dimensions Connections Flow D22 with locking ring including barrel nipple G¾ Return D22 with locking ring including barrel nipple G¾ Hot water D18 with locking ring including barrel nipple G¾ Gas D15 with locking ring including barrel nipple G¾ Flue gas/combustion air (concentrically) mm 80 / / / 125 Gas flow pressure minimum/maximum Natural gas E/LL mbar Propane mbar Gas-connection value at 0 C / 1013 mbar: Natural gas E - (Wo = 15,0 kwh/m 3 ) H u = 9,97 kwh/m 3 m 3 /h 0,95 1,52 2,1 Natural gas LL- (Wo = 12,4 kwh/m 3 ) H u = 8,57 kwh/m 3 m 3 /h 1,11 1,77 2,45 Propane 3 (H u = 25,9 kwh/m 3 ) m 3 /h 0,37 0,59 0,81 Operation voltage V/Hz 230 / / / 50 Minimum/Maximum electrical power consumption (incl. pump) Watt 25 / / / 84 IP rating (integral protection) IPx2D Sound power level db(a) Sound pressure level db(a) (depending on installation conditions) Condensate quantity (natural gas) at 40 / 30 C l/h 0,9 1,4 2,0 ph value of the condensate ca. 4,2 ca. 4,2 ca. 4,2 Value for chimney calculation Requirement flue gas system, temperature class ype of connection B23, C13(x), C33(x), C53(x), C63(x) Flue gas mass flow kg/h 15,8 25,3 34,8 Flue gas temperature at nominal output and operation 80 / 60 C C Flue gas temperature at nominal output and operation 40 / 30 C C Feed pressure total at the combustion air/flue gas pipe Pa Maximum draught / depression at flue gas outlet Pa Data related to H u. he boiler series is tested for EE/H-settings. With a factory setting of the Wobbe coefficient of 15,0 kwh/m 3 operation at a Wobbe coefficient of 12,0 up to 15,7 kwh/m 3 is possible without new settings. 2 See also notes at Engineering. 3 Data related to H u. he opgas comfort can also be operated with propane. Subject to alterations,

13 Hoval opgas comfort (10, 16, 22) echnical data Residual overpressures of heating pump AX 13-4 Hoval opgas comfort (10) Hoval opgas comfort (16) Residual overpressure (mbar) hrough put (l/h) Residual overpressures of heating pump AXS15-4 Hoval opgas comfort (22) Residual overpressure (mbar) hrough put (l/h) Calorifier opval (130, 160) and CombiVal ERW (200) ype opval opval CombiVal ERW (130) (160) (200) Volume dm Working pressure / test pressure bar 6 /13 6 /13 6/13 Maximum working temperature: C Weight kg Dimensions Diameter mm Height mm Heater coils (integral) Heating surface m 2 0,96 1,01 0,95 Heating water dm 3 6,7 7,1 6,2 Flow resistance boiler 1 z-value Working pressure / test pressure bar 8/13 8 /13 8 /13 Flow temperature maximum C Flow resistante boiler in mbar = Flow rate (m³/h)² x z Residual overpressure (mbar) hrough put (l/h) Hot water output opval, CombiVal mit opgas comfort, Heating flow 80 C opgas comfort/ Hot water output Stand-by deficiency qb Calorifier dm 3 /10 min dm 3 /h Number (70 C) ype 45 C 45 C of flats Watt (10)/opVal (130) (16)/opVal (130) (22)/opVal (130) (10)/opVal (160) (16)/opVal (160) (22)/opVal (160) (10)/CombiVal ERW (200) (16)/CombiVal ERW (200) (22)/CombiVal ERW (200) Subject to alterations,

14 Hoval opgas comfort (10, 16, 22) Dimensions opgas comfort (10, 16, 22) Minimal Spaces (Dimensions in mm) Sideways 50 mm Space to ceiling dependent on the flue gas system Front 500 mm Drill a hole ø 10 mm (Flow/Return heating, Gas connection) (Flow/Return calorifier) Filling and draining valve Con. of expansion tank opgas comfort ype a b (10) (16) (22) Return heating D22 with locking ring including barrel nipple G¾" 2 Flow heating D22 with locking ring including barrel nipple G¾" 3 Gas connection D15 with locking ring including barrel nipple G½" 4 Flow calorifier D18 with locking ring including barrel nipple G¾" 5 Return calorifier D18 with locking ring including barrel nipple G¾" 6 Concentrical flue gas/combustion air connection D80/125 7 Wall rail 8 Condensate drain D32 (hose D25/21) 9 Connection of expansion tank G¾" 10 Filling and draining valve Subject to alterations,

15 Hoval opgas comfort (10, 16, 22) Dimensions opgas comfort (10, 16, 22) with opval (130, 160) placed below Minimal Spaces (Dimensions in mm) Hoval CombiVal ERW (200) see Calorifiers Sideways 50 mm Space to ceiling dependent on the flue gas system Front 500 mm Drill a hole ø 10 mm View from above opval (130, 160) without opgas opgas comfort/ opval ype ype a b c d e f (10) (130) (160) (16) (130) (160) (22) (130) (160) Return D22 with locking ring including barrel nipple G¾" 2 Flow D22 with locking ring including barrel nipple G¾" 3 Gas connection D15 with locking ring including barrel nipple G½" 4 Flow calorifier D18 with locking ring including barrel nipple G¾" 5 Return calorifier D18 with locking ring including barrel nipple G¾" 6 Concentrical flue gas / combustion air connection D80/125 7 Condensate drain D32 (hose D25/21) 8 Connection of expansion tank G¾" 9 Filling and draining valve 10 Calorifier opval (130,160) 11 Flow heating G ¾" AG 12 Return heating G ¾" AG 13 Hot water R ¾" AG 14 Cold Water R ¾" AG 15 Wall rail 14 Subject to alterations,

16 Hoval opgas comfort (10, 16, 22) Dimensions Measures for drill holes and visible console for preinstallation for opgas comfort with opval (130, 160) placed below (Dimensions in mm) 1 Return G¾" 2 Flow G¾" 3 Gas connection G½" opgas comfort/ opval ype ype A B H * C D (10) (130) (160) (16) (130) (160) (22) (130) (160) * Measures for drill hole Subject to alterations,

17 Hoval opgas comfort (10, 16, 22) Engineering Standards and guidelines he following standards and guidelines must be complied with: Hoval technical information and installation instructions. Hydraulic and technical control regulations of Hoval. Local building law Fire protection regulations DVGW regulations. DIN EN Safety-relevant requirements. DIN EN Heaters Rules for the calculation of the heat requirements of buildings. VDI 2035 Protection against damage by corrosion and boiler scale formation in heating and service water installations. VDE 0100 Local fire brigade regulations Water quality Heating water: he European Standard EN and the Directive VDI 2035 must be observed. Hoval boilers and calorifiers are designed for heating plants without significant oxygen intake (plant type I according to EN 14868). Plants with - continuous oxygen intake (e.g. underfloor heating systems without diffusion proof plastic piping) or - intermittent oxygen intake (e.g. where frequent refilling is necessary) must be equipped with separate circuits. reated heating water must be tested at least 1x yearly, according to the inhibitor manufacturer s instructions, more frequent testing may be necessary. A refilling is not necessary if the quality of the heating water in existing installations (e.g. exchange of boiler) conforms to VDI he Directive VDI 2035 applies equally to the replacement water. New if applicable existing installations must be adequately cleaned and flushed before be ing recharged! he boiler may only be fill ed after the heat ing system has been flushed. Parts of the boiler which have contact with water are made of copper. On account of the danger of spot corrosion the chloride, nitrate and sulfatge contents of the heating water must not exceed 200 mg/l in total. he ph value of the heating water should lie between 8,3 and 9,5 after 6-12 weeks of heat ing operation in order to avoid a handi cap of the flow through deposits from corro si on products of other materials from the plant. Filling and replacement water: For a plant using Hoval boilers untreated drinking water is generally best suited as filling and replacement water. However, the qual ity of the untreated drinking water must at least fulfil the standard set in VDI 2035 or be desalinated and/or be treat ed with inhibitors. he stipulations of EN must be observed. In order to maintain a high level of boiler ef fi ciency and to avoid overheating of the heat ing surfaces the values given in the table should not be exceeded (dependent on boil er performance ratings - for multi-boiler plants rating of smallest boiler applies - and on the water content of the plant). he total amount of filling and replacement water which is used throughout the total service life of the boiler must not exceed three times the water capacity of the plant. Heating room Gas boilers cannot be positioned in rooms in which halogen compounds can occur and into which combustion air can enter (e.g. wash-, dryer-, work rooms, hairdressers and so on). Halogen compounds can be caused by cleaning and degreasing solutions, dissolvents, glue and bleaching lyes. Combustion air supply he supply of combustion air must be guaranteed. here must be no possibility to close the air supply opening. Where the air supply is fed directly to the boiler (air-exhaust system) a separator C80/125 -> E80 PP can be used. he minimum free corss section for the combus tion air can be assumed simplified as follows! Room air-dependent operation: A minimal ventilation outlet of at least 150 cm 2 or 2 x 75 cm 2 cross-section is necessary for of boiler output up to 50 kw. For each further kw output 2 cm 2 more crosssection must be provided. Room air-independent operation with separate combustion air pipe to the boiler: 0,8 cm 2 per 1 kw of output. he pressure loss in the combustion air pipe must be considered for the calculation of the exhaust system. Gas connection Commissioning Start-up is to be carried out only by a specialist of Hoval. Burner setting values according to the installation instructions. Manual gas shut-off valve and gas filter Immediately in front of the boiler a manual gas shut-off device (valve) must be installed ac cording to relevant regulations. Should the local re gulations or conditions demand this, an approved gas fil ter must be installed in the gas supply pipe bet ween the gas tap (thermally releasing) and the boiler in order to prevent malfunction due to for eign particles being carried along with the gas. able 1: filling quantity based on VDI 2035 Available for boiler with < 0,3l/kW water capacity otal hardness of the filling water up to... [mol/m 3 ] 1 <0,1 0,5 1 1,5 2 2,5 3 >3,0 f H < >30 d H <0,56 2,8 5,6 8,4 11,2 14,0 16,8 >16,8 e H <0,71 3,6 7,1 10,7 14,2 17,8 21,3 >21,3 ~mg/l <10 50,0 100,0 150,0 200,0 250,0 300,0 >300 Conductance 2 <20 100,0 200,0 300,0 400,0 500,0 600,0 >600 Boiler size of the individual boiler maximum filling quantity without desalination up to 28 kw NO DEMAND 50 l/kw 20 l/kw ype of gas he boiler is only to be operated with the type of gas stated on the rating plate. A gas pressure controller to reduce the boiler inlet pressure must be installed on-site for propane. Gas pressure Necessary flow pressure at the boiler inlet: natural gas min. 18 mbar, max. 50 mbar. propane min. 37 mbar, max. 50 mbar. 1 otal of alkaline earths 2 If the conductance in µs/cm exceeds the tabular value an analysis of the water is necessary. 16 Subject to alterations,

18 Hoval opgas comfort (10, 16, 22) Engineering Mud collector he fitting of a mud collector at the gas boiler return is recommendable. Pump after-run time During the burner mode the circulation pump must always be in function and the minimum heating water circulation must be guaranteed. he circulation pump must continue to run for at least 2 minutes each time the burner is guarded off (is provided for by the boiler control unit). Heating boiler in the attic he gas boiler opgas comfort is equipped with a safety mechanism to guard against water loss and can therefore be installed in upper stories. Condensate drainage he allowance to lead the flue gas condensate into the cnalisation must be obtained from the responsible authority. he condensate from the exhaust system can be discharged through the boiler. A condensate trap is not needed anymore with the exhaust system. he condensate must be openly lead into the canalisation (tunnel) Expansion tank An adequately dimensioned expansion tank must be provided. he expansion tank has to be installed at the connection of expansion tank (pump intake side) (see Dimensions ). Starting from 70 C, a connecting container is necessary. Noise level he sound power level value is dependent on local and spacial circumstances. he sound pressure level is dependent on the installation conditions and can e.g. be 10 to 15 db(a) lower than the sound power level at a distance of 1 m. DIN 4109 must be observed when installing in domestic living areas. Flue gas system Gas boilers must be connected to a certified and approved flue gas system such as flue gas lines. Flue gas lines must be gas-, condensateand over pressure-tight. he flue gas system must be connected with an angle, so that the resulting condensate of the exhaust system can flow back to the boiler and can be neutralized there before discharging into the canalization. Gas boilers with condensation heat utilisation are to be connected to a flue gas line min. temperature class 120. A flue gas temperature limiter is integrated into the boiler. Subject to alterations,

19 Hoval opgas comfort (10, 16, 22) Examples opgas comfort (10, 16, 22) with opval (130, 160) placed below Gas boiler with Free standing calorifier opval placed below a direct heating circuit Hydraulic schematic BCK020 BA opgas comfort (10, 16, 22) with Calorifier (CombiVal) and two heating circuits Gas boiler with Free standing calorifier wall distributors a direct heating circuit and 1-2 mixed heating circuits Hydraulic schematic BCK050 RS - O B 1 AF 1 opronic VF1 B1 VF2 B1 RS- DHW WW CW KW DHW WW Y Dies opgas ist ein unerlaubter comfort Weg! Gehen Sie einen Schritt zurück oder löschen Sie dieses Shape! Sie haben die Möglichkeit P ein M 2 neues Shape zu nehmen!!! hovhovalhovalhoval Y7 M hovalhovalhovalhov Dies ist ein unerlaubter Weg! Gehen Sie einen Schritt zurück oder löschen Sie dieses Shape! Sie haben die Möglichkeit ein neues Shape zu nehmen!!! hovhovalhovalhoval hovalhovalhovalhov opval BW Dies opgas ist ein unerlaubter Weg! Gehen comfort Sie einen Schritt zurück oder löschen Sie dieses Shape! Sie haben die Möglichkeit P M 2 ein neues Shape zu nehmen!!! hovhovalhovalhoval Y7 M hovalhovalhovalhov DKP YK1 M MK1 MK2 YK2 M CW KW SF Dies ist ein unerlaubter Weg! Gehen Sie einen Schritt zurück oder löschen Sie dieses Shape! Sie haben die Möglichkeit ein neues Shape zu nehmen!!! hovhovalhoval hovalhovalhov alhovalhovalho valhovalhovalh ovalhovalhoval hovalhovalhov alhovalhovalho valhovalhovalh ovalhovalhoval hovalhovalhov alhovalhovalho valh opgas comfort (10, 16, 22) with calorifier and part-solar water heating Gas boiler with solar Water heating, a direct heating circuit Hydraulic schematic BCK090 CW DHW RS- Room station RS-O Room station (Openherm) DKP Pump for heating cycle without mixer SOP Solar circulation pump MK1 Pump mixing circuit 1 MK2 Pump mixing circuit 2 YK1 Actuator mixer 1 YK2 Actuator mixer 2 Y7 Water deflector valve for calorifier (single wire system) AF, BA Outdoor sensor SF, BW Calorifier heater sensor B1 Flow temperature guard (on demand) VF1 Flow sensor 1 VF2 Flow sensor 2 S1 Differential control sensor 1 S2 Differential control sensor 2 CW Cold Water DHW Domestic Hot Water Important notes Bypass valve installed in the device his hydraulic schematic is a principle schematic. It does not contain all details for installation. he installation must be done according to local conditions, di mensioning and regulations For underfloor heating, a flow temperature monitor must be built-in. Shut-off devices to the safety valve (pressurized expansion tank, safety valve, etc.) are to safe against unintended closing! Anti thermal siphon dip has to be installed. 18 Subject to alterations,

20 Hoval opgas classic (12,18,24) Wall-hanging gas condensing boiler with or without water heating Description Hoval opgas classic (12,18,24) Wall-hanging gas condensing boiler With condensing boiler technology Heat exchanger made of corrosion resistant aluminium alloy with integrated forced flow copper coil; flue gas side: aluminium water side: copper Minimal water circulation nessecary (see technical data). Integrated: Heating circuit pump Pressure gauge Hand aspirator Flue gas temperature limiter Pre-mixing surface burner made of stainless steel Modulating with gas/air group control Automatic ignition Ionisation guard Boiler fully cased with varnished white steel plates Basic boiler control panel N4.3 Gas firing sequence controller with monitoring unit BIC 300 Modulating burner control Main switch I/O Operation- and fault indication Regulation of hot water production by means of sensor or by thermostatic demand. For connecting a maximum of 1 room control device or 1 remote control with room sensor. Optional Free standing calorifier opval (130, 160) Gas valve With mounting frame With mounting frame and expansion Connection set Delivery Wall-hanging gas boiler fully cased mounting material Instruction package Appliance handbook Heating regulator set RS-O For 1 heating circuit without mixing operation Controlled by atmospheric conditions for gli - ding boiler water temperature RS-O with overplugable room temperature sensor located in boiler-/living room Outdoor sensor AF 120 Calorifier heater sensor F 25 / 12K Cannot be installed in the boiler! BMS-Module 0-10 V/O (Openherm) (Building management system) For boiler control as part of a building management system. External temperature control 0-10 V. 0-1,0 V no requirement 1,0-9,5 V C Cannot be installed in the boiler! Model range Output range opgas classic at 40/30 C ype kw classic (12) 3,8-12,0 classic (18) 5,7-18,0 classic (24) 7,7-24,0 Heating regulator set N1 Only possible in wall mounted casing. Consisting of: Hoval opronic /N heating regulator for 1 heating circuit without mixing operation 1 mixer circuit domestic hot water loading circuit Function extension possibility via different key modules Large LCD-Displays Rotary pushbutton Button for daytime room temperature night room temperature hot water temperature operating mode selection (holiday, absent, heating operation prolongation, automatic, summer, continuous - reduced - frost protection) adjusting the heating curves system information emission measurement and manual operation Outdoor sensor AF200 Flow Sensor VF204 Calorifier heater sensor KV20/5/6 Connection available for room station Delivery Heating regulator with regulator set separat packed and delivered Permissions boilers Hoval opgas classic (12, 18, 24): CE-Product-ID-No. 0063BQ3155t Mounted below/ free standing calorifier opval (130,160) Water heater with fixed, smooth pipe enamel led stainless steel heat exchanger. As calorifier placed below for Hoval opgas classic (12, 18, 24). Magnesium protection anode hermal insulation using HCFC free PU foam, with foil mantle, white Delivery Calorifier compl. mounted Calorifier CombiVal ERW (200), white Calorifier made of steel, enamelled inside. Smooth pipe heat exchanger enamelled, built in. As free standing calorifier for Hoval opgas classic (12,18,24). Magnesium protection anode integrated. Flange for electrical heating inset. hermal insulation made of Polyurethan foamed on the calorifier, dismantable foil casing, white, compl. mounted. Pocket welded in including thermometer On request Electrical heating inset Delivery Calorifier with foil mantle, compl. mounted Subject to alterations,

21 Hoval opgas classic (12,18,24) Part N Wall-hanging gas condensing boiler Hoval opgas classic (12,18,24) Part N Heat exchanger made of corrosion free aluminium alloy with integrated forced flow copper coil. With a modulating, premixing, stainless steel surface burner. Including basic boiler con trol N4.2 and connecting screws / bolts, complete with casing. opgas classic Output range at 40/30 C ype kw 1 classic (12) 3,8-12,0 classic (18) 5,7-18,0 classic (24) 7,7-24, Accessories Gas filter with measurement nozzle before and behind the filter inset (diameter: 9 mm) Pore width of the filter inset < 50 mm Max. pressure difference 10 mbar Max. inlet pressure 100 mbar ype Connection 70612/6B Rp ¾" Modification set for propane no external main gas valve possible! opgas classic ype min. output kw (80/60 C) opgas classic (12) 3, opgas classic (18) 5, opgas classic (24) 7, Simple flue gas connecting piece E80 for separate conduction of flue gas and combustion air Automatic quick release air vent 3/8" with cut-off valve Visible console for preinstallation for preinstallation of gas, heating flow and return, cold and hot water connections Possible with all mounting frames or directly on the wall! Connection set 3 for Hoval opgas classic without calorifier without/with mounting frame Consisting of: flow fitting, return flow fitting with integrated bypass valve, safety valve 3 bar Filling/drain valve, expansion connection, 2 ball stop valves Inner bore for heating flow/return flow Rp ¾" Clamp ring screwing for gas connection Subject to alterations,

22 Hoval opgas classic (12,18,24) Part N Accessories Screen for opgas classic, opgas combi to cover the connection range gas, heating flow and return for opgas classic (12, 18, 24) opgas combi (21/18, 26/23, 32/28), in connection with connection set 3 Combination with/without mounting frame MR50/MR110 possible Part N Mounting frame MR50 without expansion tank For increasing the space to wall in order to simplify installation (e.g. flue gas duct direct on wall). Not essential. opgas classic (12) opgas classic (18) opgas classic (24) Mounting frame MR110 with expansion tank and corrugated pipe tubing for connecting to connecting set 3, 4 or 10 Frame for fixation of the Hoval opgas classic with integrated expansion tank and connecting hose content 12 l / pre-pressure 0,75 bar opgas classic (12) opgas classic (18) opgas classic (24) Connection set 10 for Hoval opgas and mounted below calorifier opval without/with mounting frame MR50/MR110 Consisting of: flow fitting, return flow fitting with integrated bypass valve Safety valve 3 bar Filling/drain valve, expansion connection 3-way valve Rp ¾" 2 ball stop valves Inner bore for heating flow/return flow Rp ¾" Subject to alterations,

23 Hoval opgas classic (12,18,24) Part N Accessories Part N Calorifier opval (130,160) Free standing calorifier with heating register made of steel built-in, enamelled inside. opval ype Volume Litre (130) (160) Connection set 4 for Hoval opgas and free standing calorifier CombiVal with/without mounting frame MR50/MR110 Consisting of: flow fitting, return flow fitting with integrated bypass valve Safety valve 3 bar Filling/drain valve, expansion connection 3-way valve Rp ¾" 2 ball stop valves Inner bore for heating flow/return flow Rp ¾" Clamp ring screwing for gas connection Calorifier CombiVal ERW (200), white Calorifier made of steel, enamelled inside. With enamelled plain ended pipe heat exchanger built-in, foil sheath white. CombiVal ype Volume Litre ERW (200) Subject to alterations,

24 Hoval opgas classic (12,18,24) Part N Accessories Heating regulator set RS-O (Not for mixing operation!) For 1 heating circuit without mixing operation Flow temperature control controlled by atmospheric conditions with outer temperature sensor AF 120 water heater sensor F 25 / 12K and overridable room temperature sensor. Can be implemented as a room temperature control without outdoor sensor. opgas comfort (10-22) opgas (30-60) For integration into boiler control panel: Mounting set RS-O must be ordered. opgas classic and combi Only wall mounting possible! Part N BMS module 0-10 V/O - Openherm (building management system) no control unit opronic necessary power supply via O bus opgas classic Cannot be installed in the boiler control panel! opgas (30-60) Can be installed in the boiler control panel! Heating regulator set N2 Consisting of: Heating regulator opronic /N for - 1 mixer circuit - 1 domestic hot water loading circuit Outdoor sensor AF200 Flow sensor VF204 with 4 m cable 2 immersion sensors KV20/5/6 for calorifier and buffer storage unit with 5 m cable Delivery: Heating regulator set separately packed, mounting on-site Cannot be installed in the boiler control panel! Control unit case WG1 for installation of heating regulator opronic /N Plastic casing with clear plastic cover Colour light grey incl. pre-wiring on terminal bar Fine fuse: 6.3 A Dimensions: 365 x 320 x 160 mm For heating regulator opronic /N Room station RS- for opronic effective on one mixing circuit Subject to alterations,

25 Hoval opgas classic (12,18,24) Part N Accessories Remote control RFF- for opronic effective on one mixing circuit Part N For RS-O and heating regulator opronic /N Flow temperature guard for floor heating (per heating circuit 1 guard) C, differential gap 6K, capillary tube max. 700 mm, setting (from the outside visibly) inside the housing cover. Clamp-on thermostat RAK-W1000.S hermostat with strap, without cable and plug Gas valve, passage DN ½" with thermally releasing cut-off device Gas valve, corner version DN ½" with thermally releasing cut-off device Clamp ring screwing (½" external thread x 15) For gas cock when no connection set or finery panel is used for pre-installation Clamp ring screwing (¾" external thread x 22) For flow/return when no connection set or finery panel is used for pre-installation Mud separator made of brass ype ø D Op. pressure max. emp. C kv-value m 3 /h DC 20 ¾" 10 bar , DC 25 1" 10 bar , Automatic quick release air vent with cut-off valve ½" Accessory for sludge separator way reversing valve VC 4012 ¾" for calorifier external thread ¾" 230 V / 50 Hz single wire control running time 7 sec incl. 1 m cable Expansion Chambers see separate brochure 24 Subject to alterations,

26 M M M M Hoval opgas classic (12,18,24) Part N Accessories opgas classic Part N 1-7 Key Module for Hoval opronic use to get more functions additional to standard functions. Key-Modul consiting of: Function key to plug in opronic incl. accessories Only one Key Module possible! Standard functions already included in opronic. - 1 mixing circuit - 1 heating circuit without mixing operation - domestic hot water loading circuit Functions of the Key-Modules Key- 2. mixing- solid-fuel- solar Module circuit storage tank bi-fuel M 1 Key-Module 1 for 2. mixing circuit Function 1, 1 flow sensor, 2 loose plugs Key-Module 2 for solid fuel / storage tank / bivalent installation Function key 2, 3 immersion sensors, 4 loose plugs Key-Module 3 for solar plants Function key 3, 1 collector sensor, 1 calorifier sensor, 4 losse plugs M 4 Key-Module 4 for 2. mixing circuit and solid fuel / storage tank/ bivalent installation Function key 4, 1 flow sensor, 3 immersion sensors, 6 loose plugs M 5 Key-Module 5 for 2. mixing circuit and solar plants Function key 5, 1 flow sensor, 1 collector sensor, 1 calorifier sensor, 6 loose plugs Key-Module 6 for solid fuel/storage tank/bivalent installation and solarplants Function key 6, 1 collector sensor, 4 immersion sensor, 6 loose plugs M System approaches and applications see Hoval CD 7 Key-Module 7 for 2. mixing circuit, soid fuel/storage tank / bivalent installation and solar plants Function key 7, 1 flow sensor, 1 collector sensor, 4 immersion sensors, 8 loose plugs Sensor type Immersion-/calorifier sensor: ype KV20/5/6 (L = 5 m) without immersion sleeve flow sensor ype VF204S with plug Collector sensor ype P1000 (Silicone) Subject to alterations,

27 Hoval opgas classic (12,18,24) Part N Service Part N Commissioning Commissioning must be made by works service or Hoval trained authorized serviceman/ company is condition for warranty. For commissioning and other services please contact your Hoval sales office. 26 Subject to alterations,

28 Hoval opgas classic (12,18,24) echnical data Hoval opgas classic (12,18,24) ype (12) (18) (24) Nominal output 80 / 60 C with natural gas 1 kw 3,4-11,5 5,2-17,3 7,0-22,9 Nominal output 40 / 30 C with natural gas 1 kw 3,8-12,0 5,7-18,0 7,7-24,0 Nominal output 80 / 60 C with propane 3 kw 3,5-11,5 5,8-17,3 7,4-22,9 Nominal output 40 / 30 C with propane 3 kw 3,4-12,0 6,3-18,9 8,0-24,0 Nominal load with natural gas 1 kw 3,5-11,8 5,3-17,8 7,1-23,5 Nominal load with propane 3 kw 3,6-11,8 5,9-17,8 7,5-23,5 Working pressure heating maximum/minimum bar 3 / 1 3 / 1 3 / 1 Working temperature maximum C Boiler water content l 1,4 1,7 2,0 Minimal water flow l/h Boiler weight (without water content) kg Boiler efficiency at partial load 30% (according to EN 303) % 104,0 / 93,7 104,0 / 93,7 104,0 / 93,7 (related to net / gross calorific value) Standard efficiency (according to DIN 4702, part 8) 40/30 C % 108,5 / 97,7 108,5 / 97,7 108,5 / 97,7 (related to net / gross calorific value) 75/60 C % 103,5 / 93,2 103,5 / 93,2 103,5 / 93,2 Stand-by loss at 70 C Watt Standard emission rate Nitrogen oxides mg/kwh Carbon monoxide CO mg/kwh Content of CO 2 in the exhaust gas maximum/minimum output % 9,0 / 8,8 9,0 / 8,8 9,8 / 8,8 Dimensions: see table of dimensions Connections Flow D22 Return D22 Gas D15 Flue gas / combustion air (concentrically) mm 80 / / / 125 in addition for direct combustion air mm Gas flow pressure minimum/maximum Natural gas E/LL mbar Propane mbar Gas-connection value at 0 C / 1013 mbar: Natural gas E - (Wo = 15,0 kwh/m 3 ) H u = 9,97 kwh/m 3 m 3 /h 1,18 1,78 2,35 Natural gas LL- (Wo = 12,4 kwh/m 3 ) H u = 8,57 kwh/m 3 m 3 /h 1,38 2,08 2,74 Propane 3 (H u = 25,9 kwh/m 3 ) m 3 /h 0,46 0,69 0,91 Operation voltage V/Hz 230 / / / 50 Minimum/Maximum electrical power consumption (incl.pump) Watt 13 / / / 130 IP rating (integral protection) IP Sound power level db(a) Sound pressure level db(a) (depending on installation conditions) 2 Condensate quantity (natural gas ) at 40 / 30 C l/h 1,1 1,6 2,1 ph value of the condensate ca. 4,2 ca. 4,2 ca. 4,2 Value for chimney calculation Requirement flue gas system, temperature class ype of connection B23, B33, C13(x), C33(x), C43(x), C53(x), C63(x) C83(x9) Flue gas mass flow kg/h 19,6 29,5 39,0 Flue gas temperature at nominal output 80 / 60 C C Flue gas temperature at nominal output 40 / 30 C C Feed pressure total at the combustion air/flue gas pipe Pa Maximum draught / depression at flue gas outlet Pa Data related to H u. he boiler series is tested for EE/H-settings. With a factory setting of the Wobbe coefficient of 15,0 kwh/m 3 operation at a Wobbe coefficient of 12,0 up to 15,7 kwh/m 3 is possible without new settings. 2 See also notes at Engineering. 3 Data related to H u. he opgas classic can also be operated with propane. Subject to alterations,

29 Hoval opgas classic (12,18,24) echnical data Residual overpressures of heating pumps Hoval opgas classic (12) Hoval opgas classic (18) Residual overpressure (mbar) hrough put (l/h) Residual overpressure (mbar) hrough put (l/h) Hoval opgas classic (24) Residual overpressure (mbar) hrough put (l/h) 1 Stage I 2 Stage II 3 Stage III Residual overpressures of heating pumps opgas classic with connection set 4 or connection set 10 (reversing valve included in the set) Hoval opgas classic (12) Hoval opgas classic (18) Residual overpressure (mbar) Residual overpressure (mbar) hrough put (l/h) Hoval opgas classic (24) hrough put (l/h) 28 Subject to alterations, Residual overpressure (mbar) 1 Stage I 2 Stage II 3 Stage III hrough put (l/h)

30 Hoval opgas classic (12,18,24) echnical data Calorifier opval (130, 160) and CombiVal ERW (200) ype opval opval CombiVal ERW (130) (160) (200) Capacity dm Operating pressure / test pressure bar 6 /13 6 /13 6/13 Max. operating temperature C Weight kg Dimensions Diameter mm Height mm Heating register (built-in) Heating surface m 2 0,96 1,01 0,95 Heating water dm 3 6,7 7,1 6,2 Flow resistance 1 z-value Operating pressure / test pressure bar 8/13 8 /13 8 /13 Working temperature maximal C Flow resistance boiler in mbar = Volume flow (m³/h)² x z Hot water output opval, CombiVal with opgas classic, Heating flow 80 C Stand-by Hot water output deficiency qb Boiler Calorifier dm 3 /10 min 1 dm 3 /h 2 Number 3 (70 C) ype ype 45 C 45 C of flats Watt classic (12) opval (130) (18) (130) (24) (130) classic (12) opval (160) (18) (160) (24) (160) classic (12) CombiVal ERW (200) (18) (200) (24) (200) Hot water peak perfomance in 10 min. according Procal test rules. 2 Hot water output per hour according Procal test rules. 3 Flat (3-4 rooms with 3-4 people,1 bathtub with ca. 150 Litre, 1 washbasin, 1 sink) Subject to alterations,

31 Hoval opgas classic (12,18,24) Dimensions Hoval opgas classic (12, 18, 24) Minimal Spaces (Dimensions in mm) Sideways 50 mm Space to ceiling dependent on the used flue gas system Front 500 mm Hose flexible ø 25 mm opgas classic ype a b1 b2 d e f g h i k l (12) (12) with mounting frame (MR50) (12) with mounting frame with expansion tank (MR110) (18) (18) with mounting frame (MR50) (18) with mounting frame with expansion tank (MR110) (24) (24) with mounting frame (MR50) (24) with mounting frame with expansion tank (MR110) Gas connection D15 (for clamp ring screwing) 2 Return Heating D22 (for clamp ring screwing) 3 Flow Heating D22 (for clamp ring screwing) 4 Concentrical flue gas delivery air connection C80/125 including measuring opening 4a Single flue gas connection E80, (optional), see accessoires 5 External delivery air D80 6 Condensate drain Ø 32 mm (Hose D25/21) 7 Syphon 8 Mounting frame, 50 mm or 110 mm with expansion tank optional, see accessoires 9a Drill hole D10 without mounting frame 9b Drill hole D10 with mounting frame 30 Subject to alterations,

32 Hoval opgas classic (12,18,24) Dimensions Hoval opgas classic (12, 18, 24) with calorfier opval (130, 160) placed below Minimal Spaces (Dimensions in mm) Sideways 50 mm Space to ceiling dependent on the flue gas system Front 500 mm Hoval CombiVal ERW (200) see Calorifiers View from the top without opgas foot adjusted to 6 mm 1 Gas connection D15 (for clamp ring screwing, on site) 2 Return heating D22 (for clamp ring screwing, on site) 3 Flow heating D22 (for clamp ring screwing, on site) 4 Concentrical flue gas / combustion air connection C80/125 including measurement vents 5 External delivery air D80 6 Condensate drain Ø 32 mm 7 Connection positions sideways heating flow Rp ¾" 8 Connection positions behind heating return Rp ¾" 9 Calorifier opval (130, 160) 10 Flow heating G ¾" AG 11 Return heating G ¾" AG 12 Hot water R ¾" AG 13 Cold water R ¾" AG 14a Drill hole D10 without mounting frame 14b Drill hole D10 with mounting frame opgas classic with opval 130 opgas classic ype a b c d e f g1 g2 h i (12) (12) with mounting frame (MR50) (12) with mounting frame with expansion tank (MR110) (18) (18) with mounting frame (MR50) (18) with mounting frame with expansion tank (MR110) (24) (24) with mounting frame (MR50) (24) with mounting frame with expansion tank (MR110) opgas classic with opval 160 opgas classic ype a b c d e f g1 g2 h i (12) (12) with mounting frame (MR50) (12) with mounting frame with expansion tank (MR110) (18) (18) with mounting frame (MR50) (18) with mounting frame with expansion tank (MR110) (24) (24) with mounting frame (MR50) (24) with mounting frame with expansion tank (MR110) Subject to alterations,

33 Hoval opgas classic (12,18,24) Dimensions Measures for drill holes and visible console for preinstallation without mounting frame (Dimensions in mm) 1 Gas connection D15 (for locking ring fitting, on-site) 2 Return (for locking ring fitting, on-site) 3 Flow (for locking ring fitting, on-site) opgas classic opval ype ype A B * H * C D (12) (130) (160) (18) (130) (160) (24) (130) (160) * Measures for drill hole Visible console for preinstallation with mounting frame (Dimensions in mm) With mounting frame MR50 opgas classic opval ype ype H * D (12) (130) (160) (18) (130) (160) (24) (130) (160) With mounting frame MR110 with expansion tank opgas classic opval ype ype H * D (12) (130) (160) (18) (130) (160) (24) (130) (160) * Measures for drill hole 1 Gas connection D15 (for locking ring fitting, on-site) 2 Return (for locking ring fitting, on-site) 3 Flow (for locking ring fitting, on-site) 32 Subject to alterations,

34 Hoval opgas classic (12,18,24) Engineering Standards and guidelines he following standards and guidelines must be complied with: Hoval technical information and installation instructions. Hydraulic and technical control regulations of Hoval. Local building law Fire protection regulations DVGW regulations. DIN EN Safety-relevant requirements. DIN EN Heaters Rules for the calculation of the heat requirements of buildings. VDI 2035 Protection against damage by corrosion and boiler scale formation in heating and service water installations. VDE 0100 Local fire brigade regulations Water quality Heating water: he European Standard EN and the Directive VDI 2035 must be observed. Hoval boilers and calorifiers are designed for heating plants without significant oxygen intake (plant type I according to EN 14868). Plants with - continuous oxygen intake (e.g. underfloor heating systems without diffusion proof plastic piping) or - intermittent oxygen intake (e.g. where frequent refilling is necessary) must be equipped with separate circuits. reated heating water must be tested at least 1x yearly, according to the inhibitor manufacturer s instructions, more frequent testing may be necessary. A refilling is not necessary if the quality of the heating water in existing installations (e.g. exchange of boiler) conforms to VDI he Directive VDI 2035 applies equally to the replacement water. New and if applicable existing installations must be adequately cleaned and flushed be fore being recharged! he boiler may only be filled after the heating system has been flushed. Parts of the boiler which have contact with water are made of copper. On account of the danger of spot corrosion the chloride, nitrate and sulfate contents of the heating water must not exceed 200 mg/l in total. he ph value of the heating water should lie between 8,3 and 9,5 after 6-12 weeks of heating operation in order to avoid a handi cap of the flow through deposits from cor ro sion pro ducts of other materials from the plant. Filling and replacement water: For a plant using Hoval boilers untreated drinking water is generally best suited as filling and replacement water. However, the quality of the untreated drinking water must at least fulfil the standard set in VDI 2035 or be desalinated and/or be treat ed with inhi bitors. he stipulations of EN must be observed. In order to maintain a high level of boiler ef ficiency and to avoid overheating of the heat ing surfaces the values given in the table should not be exceeded (dependent on boil er performance ratings - for multi-boiler plants rating of smallest boiler applies - and on the water content of the table). he total amount of filling and replacement water which is used throughout the total service life of the boiler must not exceed three times the water capacity of the plant. Heating room Gas boilers cannot be positioned in rooms in which halogen compounds can occur and into which combustion air can enter (e.g. wash-. dryer-, work rooms, hairdressers and so on). Halogen compounds can be caused by cleaning and degreasing solutions, dissolvents, glue and bleaching lyes. Combustion air supply he supply of combustion air must be guaranteed. here must be no possibility to close the air supply opening. An air pipe D = 80 for direct combustion air (air-exhaust system) can be directly connected to the boiler. he minimum free corss section for the combustion air can be assumed simplified as follows! Room air-dependent operation: A minimal ventilation outlet of at least 150 cm 2 or 2 x 75 cm 2 cross-section is necessary for of boiler output up to 50 kw. For each further kw output 2 cm 2 more crosssection must be provided. Room air-independent operation with separate combustion air pipe to the boiler: 0,8 cm 2 per 1 kw of output. he pressure loss in the combustion air pipe must be considered for the calculation of the exhaust system. Gas connection Commissioning Stat-up is to be carried out only by a specialist. Burner setting values according to the insallation instructions. Manual gas shut-off valve and gas filter Immediately in front of the boiler a manual gas shut-off device (valve) must be installed ac cord ing to relevant regulations. Should the local re gu lations or conditions demand this, an approved gas fil ter must be installed in the gas supply pipe bet ween the gas tap (thermally releasing) and the boiler in order to prevent malfunction due to for eign particles being carried along with the gas. able 1: Maximum filling capacity based on VDI 2035 Available for boiler with < 0,3 l/kw water capacity otal hardness of the filling water up to... [mol/m 3 ] 1 <0,1 0,5 1 1,5 2 2,5 3 >3,0 f H < >30 d H <0,56 2,8 5,6 8,4 11,2 14,0 16,8 >16,8 e H <0,71 3,6 7,1 10,7 14,2 17,8 21,3 >21,3 ~mg/l <10 50,0 100,0 150,0 200,0 250,0 300,0 >300 Conductance 2 <20 100,0 200,0 300,0 400,0 500,0 600,0 >600 Boiler size of the individual boiler maximum filling quantity without desalination up to 28 kw NO DEMAND 50 l/kw 20 l/kw 1 total of alkaline earths 2 If the conductance in µs/cm exceeds the tabular value an analysis of the water is necessary. Subject to alterations,

35 Hoval opgas classic (12,18,24) Engineering ype of gas he boiler is only to be operated with the type of gas stated on the rating plate. A gas pressure controller to reduce the boiler inlet pressure must be installed on-site for propane. Gas pressure Necessary flow pressure at the boiler inlet: natural gas min. 18 mbar, max. 50 mbar. propane min. 25 mbar, max. 50 mbar. Mud collector he fitting of a mud collector at the gas boiler return is recommendable. Minimum quantity of rotating water Depending upon type of boiler different mi ni mum quantities of rotating water are demand ed. See also technical data. During the burner mode the circulation pump must always be in function and the minimum heating water circulation must be guaranteed. Pump after-run time he circulation pump must continue to run for at least 2 minutes each time the burner is switched off (the pump after-run time is included in the boiler control with the opronic regulation). Heating boiler in the attic If the gas boiler opgas classic is built-in in a roof control room, an external water pressure guard must be provided. Condensate drainage he condensate from the exhaust system can be discharged through the boiler. A condensate trap is not needed anymore with the exhaust system. he allowance to lead the flue gas condensate into the canalisation must be obtained from the responsible authority. A siphon must be installed at the condensate outlet on the gas boiler (included in the boiler scope of delivery). he condensate must be openly lead into the canalisation. (funnel) Expansion tank An adequately dimensioned expansion tank must be provided. he expansion tank has to be installed at the connection of expansion tank at the con nection set 3,4 or 10 (pump intake side) (see Dimensions ). Starting from 70 C a connecting container is necessary. Noise level he sound power level value is dependent on local and spacial circumstances. he sound pressure level is dependent on the installation conditions and can e.g. be 10 to 15 db(a) lower than the sound power level at a distance of 1 m. Flue gas system Gas boilers must be connected to a certified and approved flue gas system such as flue gas lines. Flue gas lines must be gas-, condensateand over pressure-tight. he flue gas system must be connected with an angle, so that the resulting condensate of the exhaust system can flow back to the boiler and can be neutralized there before discharging into the canalization. Gas boilers with condensation heat utilisation are to be connected to a flue gas line min. temperature class 120. A flue gas temperature limiter is integrated into the boiler. 34 Subject to alterations,

36 Hoval opgas classic (12,18,24) Examples Hoval opgas classic (12,18,24) Gas boiler with - a direct heating circuit Hydraulic schematic BCL010 BA Hoval opgas classic (12,18,24) Gas boiler with - Free standing calorifier opval and - a direct heating circuit Hydraulic schematic BCL020 BA RS - O B 1 RS - O B 1 Dies ist ein unerlaubter opgas Weg! Gehen Sie einen Schritt classic zurück oder löschen Sie dieses Shape! Sie haben die Möglichkeit ein neues Shape zu nehmen!!! hovhovalhovalhoval hovalhovalhovalhov Gas P Dies ist ein unerlaubter Weg! DHW WW opgas Gehen Sie einen Schritt classic zurück oder löschen Sie dieses Shape! Sie haben die Möglichkeit ein neues Shape zu nehmen!!! hovhovalhovalhoval hovalhovalhovalhov P Gas MY 7 CW KW Y BW Dies ist ein unerlaubter Weg! Gehen opval Sie einen Schritt zurück oder löschen Sie dieses Shape! Sie haben die Möglichkeit ein neues Shape zu nehmen!!! hovhovalhovalhoval hovalhovalhovalhov Hoval opgas classic (12,18,24) Gas boiler with - Free standing calorifier, - a direct heating circuit Hydraulic schematic BCL030 BA Hoval opgas classic (12,18,24) Gas boiler with Heating regulator opronic in a wall casing - Free standing calorifier, - wall distributors. - a direct heating circuit mixed heating circuits Hydraulic schematic BCL050 RS - O B 1 AF 1 DHW WW opronic VF1 B1 VF2 B1 WG1 DHW WW Dies ist ein unerlaubter opgas Weg! Gehen Sie einen Schritt classic zurück oder löschen Sie dieses Shape! Sie haben die Möglichkeit ein neues Shape zu nehmen!!! hovhovalhovalhoval hovalhovalhovalhov Gas MY 7 P CW KW BW Dies ist ein unerlaubter Weg! Gehen Sie einen Schritt zurück oder löschen Sie dieses Shape! Sie haben die Möglichkeit ein neues Shape zu nehmen!!! hovhovalhoval hovalhovalhov alhovalhovalho valhovalhovalh ovalhovalhoval hovalhovalhov alhovalhovalho valhovalhovalh ovalhovalhoval hovalhovalhov alhovalhovalho valh RS- Dies ist ein unerlaubter opgas Weg! Gehen Sie einen Schritt classic zurück oder löschen Sie dieses Shape! Sie haben die Möglichkeit ein neues Shape zu nehmen!!! hovhovalhovalhoval hovalhovalhovalhov Gas P DKP YK1 M MK1 MK2 YK2 M SLP SF Dies ist ein unerlaubter Weg! Gehen Sie einen Schritt zurück oder löschen Sie dieses Shape! Sie haben die Möglichkeit ein neues Shape zu nehmen!!! hovhovalhoval hovalhovalhov alhovalhovalho valhovalhovalh ovalhovalhoval hovalhovalhov alhovalhovalho valhovalhovalh ovalhovalhoval hovalhovalhov alhovalhovalho valh CW KW RS-O RS- Room station (Openherm) Room station for opronic /N DKP Pump for heating circuit without mixing operation SLP Calorifier loading pump MK1 Pump mixing circuit 1 MK2 Pump mixing circuit 2 YK1 Actuator mixer 1 YK2 Actuator mixer 2 Y7 Water deflector valve for calorifier (Single wire system) AF, BA Outdoor sensor VF1 Flow sensor 1 VF2 Flow sensor 2 SF, BW Calorifier heater sensor B1 Flow temperature guard (if required) WG1 Wall mounted casing (Heating regulator) CW Cold Water DHW Domestic Hot Water Notice: - his hydraulic schematic is a principle schematic. It does not contain all details for installation. he installation must be done according to local conditions, di mensioning and regulations - For underfloor heating, a flow temperature monitor must be built-in. - Shut-off devices to the safety valve (pressurized expansion tank, safety valve, etc.) are to safe against unintended closing! - Anti thermal siphon dip has to be installed. Subject to alterations,

37 36

38 Hoval opgas combi (21/18, 26/23, 32/28) Wall-hanging gas condensing boiler with integrated water heating Description Hoval opgas combi (21/18, 26/23, 32/28) Wall-hanging gas condensing boiler With condensing boiler technology Heat exchanger made of corrosion resistant aluminium alloy with integrated forced flow copper coil: flue gas side: aluminium water side: copper Hot water is produced with the aid of a second copper coil integrated in the boiler. Integrated: Heating circuit pump Pressure gauge Hand aspirator Flue gas temperature limiter Pre-mixing surface burner made of stainless steel Modulating with gas/air group control Automatic ignition Ionisation guard Wall-hanging gas condensing boiler fully cased with white varnished steel plates Basic boiler control panel N4.4 Gas firing sequence controller with monitoring unit BIC 300 Modulating burner control Main switch I/O Operation- and fault indication Optional Gas valve Delivery Wall-hanging gas condensing boiler fully cased Siphon und mounting material in package Wall-hanging gas condensing boiler Heating regulator set RS-O For 1 heating circuit without mixing operation Weather-controlled regulation for continuous ly adjustable decreased boiler water temperature RS-O with room temperature sensor with switch-in facility located in boiler room or living room Outdoor sensor AF 120 Calorifier sensor F 25 / 12K Cannot be installed in the boiler control panel! Model range opgas ype Output range at 40/30 C kw combi (21/18) 5,9-18,6 combi (26/23) 7,6-23,4 combi (32/28) 7,8-27,1 Permissions boilers Hoval opgas combi (21/18, 26/23, 32/28): CE-Product-ID-No. 0063BQ3155 Note: opgas combi may only be operated where the water hardness is less than 13 d H (german degrees of hardness). Subject to alterations,

39 Hoval opgas combi (21/18, 26/23, 32/28) Part N Wall-hanging gas condensing boiler opgas combi (21/18 26/23, 32/28) Part N Heat exchanger made of corrosion free aluminium alloy with integrated forced flow copper coil. Hot water is produced with the aid of a copper coil integrated in the boiler. With a modulating, pre-mixing surface burner made of stainless steel. Including basic boiler control, ready cased. opgas Output range at 40/30 C ype kw combi (21/18) 5,9-18,6 combi (26/23) 7,6-23,4 combi (32/28) 7,8-27, Note: opgas combi may only be operated where the water hardness is less than 13 d H (german degrees of hardness). Accessories Gas filter with measurement nozzle before and behind the filter inset (diameter: 9 mm) Pore width of the filter inset < 50 mm Max. pressure difference 10 mbar Max. inlet pressure 100 mbar ype Connection 70612/6B Rp ¾" Modification set for propane for opgas combi (21/18) no external main gas valve possible! Modification set for propane opgas combi (26/23, 32/28) no external main gas valve possible! Simple flue gas connecting piece E80 for separate conduction of flue gas and combustion air Automatic quick release air vent 3/8" with cut-off valve Visible console for preinstallation for preinstallation of gas, heating flow and return, cold and hot water connections Possible with all mounting frames or directly on the wall! Connection set 3 for Hoval opgas classic without calorifier without/with mounting frame Consisting of: flow fitting, return flow fitting with integrated bypass valve, safety valve 3 bar Filling/drain valve, expansion connection, 2 ball stop valves Inner bore for heating flow/return flow Rp ¾" Clamp ring screwing for gas connection Subject to alterations,

40 Hoval opgas combi (21/18, 26/23, 32/28) Part N Part N Extension set sanitary tube for opgas combi essential for installation of connection set 3 2 pieces Mounting frame MR50 without expansion tank For increasing the space to wall in order to simplify installation (e.g. flue gas duct direct on wall). Not essential except for connection set above. opgas combi (21/18) opgas combi (26/23) opgas combi (32/28) Mounting frame MR110 with expansion tank and corrugated pipe hose for connecting to connection set 3. Connection for expansion tank on-site when connection set below! Frame for fixing Hoval opgas combi with expansion tank and connection hose Content 12 l / pre-pressure 0,75 bar opgas combi (21/18) opgas combi (26/23) opgas combi (32/28) Screen for opgas classic, opgas combi to cover the connection range gas, heating flow and return for opgas classic (12, 18, 24) opgas combi (21/18, 26/23, 32/28), in connection with connection set 3 Combination with/without mounting frame MR50/MR110 possible Heating regulator set RS-O (Not for mixing operation!) For 1 heating circuit without mixing operation Flow temperature control controlled by atmospheric conditions with outer temperature sensor AF 120 water heater sensor F 25 / 12K and overridable room temperature sensor. Can be implemented as a room temperature control without outdoor sensor. opgas comfort (10-22) opgas (30-60) For integration into boiler control panel: Mounting set RS-O must be ordered. opgas classic and combi Only wall mounting possible! Subject to alterations,

41 Hoval opgas combi (21/18, 26/23, 32/28) Part N Accessories Part N Flow temperature guard for underfloor heating (per heating circuit 1 guard) C, SD 6K, capillary max. 700 mm. Setting (from the outside visibly) inside the housing cover. Clamp-on thermostat RAK-W1000.S hermostat with strap, without cable and plug Gas valve, passage DN ½" with thermally releasing cut-off device Gas valve, corner version DN ½" with thermally releasing cut-off device Clamp ring screwing (½" external thread x 15) For gas cock when no connection set or finery panel is used for pre-installation Clamp ring screwing (¾" external thread x 22) For flow/return when no connection set or finery panel is used for pre-installation Mud separator made of brass ype ø D Op. pressure max. emp. C kv-value m 3 /h DC 20 ¾" 10 bar , DC 25 1" 10 bar , Automatic quick release air vent with cut-off valve ½" Accessory for sludge separator Service Commissioning Commissioning must be made by works service or Hoval trained authorized serviceman/ company is condition for warranty. For commissioning and other services please contact your Hoval sales office. 40 Subject to alterations,

42 Hoval opgas combi (21/18, 26/23, 32/28) echnical data Hoval opgas combi (21/18, 26/23, 32/28) ype (21/18) (26/23) (32/28) Nominal output 80 / 60 C with natural gas 1 kw 5,4-17,8 6,9-22,8 7,1-26,3 Nominal output 40 / 30 C with natural gas 1 kw 5,9-18,6 7,6-23,4 7,8-27,1 Nominal output 80 / 60 C with propane 3 kw 5,7-17,8 7,3-22,8 7,3-26,3 Nominal output 40 / 30 C with propane 3 kw 6,3-18,6 8,0-23,4 8,0-27,4 Nominal load with natural gas 1 kw 5,6-18,7 7,1-23,7 7,2-27,3 Nominal load with sanitary natural gas 1 kw 5,6-22,1 7,1-28,0 7,5-32,7 Nominal load with propane 3 kw 5,9-18,7 7,5-23,7 7,5-27,3 Working pressure heating maximum/minimum bar 3 / 1 3 / 1 3 / 1 Working temperature maximum C Boiler water content l 1,4 1,7 2,0 Storage tank content l Minimum water flow l/h Boiler weight (without water content) kg Boiler efficiency at partial load 30% (according to EN 303) % 101,0 / 91,0 101,0 / 91,0 101,0 / 91,0 (related to net / gross calorific value) Standard efficiency (according to DIN 4702, part 8) 40 / 30 C % 108 / 97,3 108 / 97,3 108 / 97,3 (related to net / gross calorific value) 75 / 60 C % 103,3 / 93,1 103,3 / 93,1 103,3 / 93,1 Stand-by loss at 70 C Watt Standard emission rate Nitrogen oxides NOx mg/kwh Carbon monoxide CO mg/kwh Content of CO 2 in the exhaust gas maximum/minimum output % 9,0 / 8,8 9,0 / 8,8 9,0 / 8,8 Dimensions: see Dimensions Connections Flow/Return D22 D22 D22 Cold/Hot water D15 D15 D15 Gas D15 D15 D15 Flue gas/combustion air (concentrically) mm 80 / / / 125 in addition for direct combustion air mm Gas flow pressure minimum/maximum Natural gas E/LL mbar Propane mbar Gas-connection value at 0 C / 1013 mbar: Natural gas E - (Wo = 15,0 kwh/m 3 ) H u = 9,97 kwh/m 3 m 3 /h 1,87 2,37 2,73 Natural gas LL- (Wo = 12,4 kwh/m 3 ) H u = 8,57 kwh/m 3 m 3 /h 2,18 2,77 3,19 Propane 3 (H u = 25,9 kwh/m 3 ) m 3 /h 0,72 0,92 1,05 Operation voltage V/Hz 230 / / / 50 Minimum/Maximum electrical power consumption (incl. pump) Watt 13 / / / 130 IP rating (integral protection) IP Sound power level db(a) Sound pressure level db(a) (depending on installation conditions) 2 Condensate quantity (Natural gas) at 40 / 30 C l/h 1,8 2,2 2,6 ph-value of the condensate ca. 4,2 ca. 4,2 ca. 4,2 Value for chimney calculation Requirement flue gas system, temperature class Flue gas mass flow kg/h 31,0 39,3 45,3 Flue gas temperature at nominal output 80 / 60 C C Flue gas temperature at nominal output 40 / 30 C C Feed pressure total at the combustion air / flue gas pipe Pa Maximum draught / depression at flue gas outlet Pa Data related to H u. he boiler series is tested for EE/H-settings. With a factory setting of the Wobbe coefficent of 15,0 kwh/ m 3 operation at a Wobbe coefficent of 12,0 up to 15,7 kwh/m 3 is possible without new settings. 2 See also notes at Engineering. 3 Data related to H u. opgas combi can also be operated with propane. Subject to alterations,

43 Hoval opgas combi (21/18, 26/23, 32/28) echnical data Maximum residual overpressure heating pump Hoval opgas combi (21/18) Hoval opgas combi (26/23) Residual overpressure (mbar) Residual overpressure (mbar) hrough put (l/h) hrough put (l/h) Hoval opgas combi (32/28) Residual overpressure (mbar) hrough put (l/h) 1 Stage 1 2 Stage 2 3 Stage 3 Hot water output with opgas combi Hot water output Max. flow rate Stand-by deficiency qb opgas combi dm 3 /10 min 1 dm 3 /h 2 dm 3 /10 min 1 dm 3 /h 2 through boiler Number of (70 C) ype 40 C 40 C 45 C 45 C dm 3 /10 min flats 3 Watt (21/18) (26/23) (32/28) Hot water peak perfomance in 10 min. according Procal test rules. Value can only be attained by addition of cold water to the boiler! 2 Hot water output per hour according Procal test rules. Value can only be attained by addition of cold water to the boiler! 3 Flat (3-4 rooms with 3-4 people,1 bathtub with ca. 150 litres, 1 washbasin, 1 sink) 4 Data indicated for hot water output valid at input pressure (drinking water/sanitary side) of 2 bar! Note: opgas combi may only be operated where the water hardness is less than 13 d H (german degrees of hardness). 42 Subject to alterations,

44 Hoval opgas combi (21/18, 26/23, 32/28) Dimensions Hoval opgas combi (21/18, 26/23, 32/28) Minimum Spaces (Dimensions in mm) Sideways 50 mm Space to ceiling dependent on the flue gas system Front 500 mm (cold/hot water) (flow, return, gas) Hose flexible d25 opgas combi ype a b1 b2 d e f g h i k l m (21/18) (21/18) with mounting frame (MR50) (21/18) with mounting frame with expansion tank (MR110) (26/23) (26/23) with mounting frame (MR50) (26/23) with mounting frame with expansion tank (MR110) (32/28) (32/28) with mounting frame (MR50) (32/28) with mounting frame with expansion tank (MR110) Gas connection D15 for clamp ring screwing Rp ½" 2 Return Heating D22 for clamp ring screwing Rp ¾" 3 Flow Heating D22 for clamp ring screwing Rp ¾" 4 Hot water D15 for clamp ring screwing Rp ½" 5 Cold water D15 for clamp ring screwing Rp ½" 6 Concentrical flue gas / combustion air connection C80/125 including measuring opening 6a Single combustion air connection E80 (optional) 7 External supply air D80 8 Condensate connection Ø 32 mm (hose D25/21) 9 Syphon 10 Mounting frame, width 50 mm or 110 mm with expansion tank optional, see accessoires 11a Drill hole D10 without mounting frame 11b Drill hole D10 with mounting frame Subject to alterations,

45 Hoval opgas combi (21/18, 26/23, 32/28) Engineering Standards and guidelines he following standards and guidelines must be complied with: Hoval technical information and installation instructions. Hydraulic and technical control regualtions of Hoval. Local building law Fire protection regulations DVGW regulations. DIN EN Safety-relevant requirements. DIN EN Heaters Rules for the calculation of the heat requirements of buildings. VDI 2035 Protection against damage by corrosion and boiler scale formation in heating and service water installations. VDE 0100 Local fire brigade regulations Water quality Heating water: he European Standard EN and the Directive VDI 2035 must be observed. Hoval boilers and calorifiers are designed for heating plants without significant oxygen intake (plant type I according to EN 14868). Plants with - continuous oxygen intake (e.g. underfloor heating systems without diffusion proof plastic piping) or - intermittent oxygen intake (e.g. where frequent refilling is necessary) must be equipped with separate circuits. reated heating water must be tested at least 1x yearly, according to the inhibitor manufacturer s instructions, more frequent testing may be necessary. A refilling is not necessary if the quality of the heating water in existing installations (e.g. exchange of boiler) conforms to VDI he Directive VDI 2035 applies equally to the replacement water. New and if applicable existing installations must be adequately cleaned and flushed before being recharged! he boiler may only be filled after the heating system has been flushed. Parts of the boiler which have contact with water are made of copper. On account of the danger of spot corrosion the chloride, nitrate and sulfate contents of the heating water must not exceed 200 mg/l in total. he ph value of the heating water should lie between 8,3 and 9,5 after 6-12 weeks of heating operation in order to avoid a handicap of the throughput deposits from corrosi on products of other materials from the plant. Filling and replacement water: For a plant using Hoval boilers untreated drink ing water is generally best suited as fill ing and replacement water. However, the qua lity of the untreated drinking water must at least fulfil the standard set in VDI 2035 or be desalinated and/or be treat ed with inhi bitors. he stipulations of EN must be observed. In order to maintain a high level of boiler ef fi ci ency and to avoid overheating of the heat ing surfaces the values given in the table should not be exceeded (dependent on boil er performance ratings - for multi-boiler plants rating of smallest boiler applies - and on the water content of the plant). he total amount of filling and replacement water which is used throughout the total service life of the boiler must not exceed three times the water capacity of the plant. Heating system Heating room Gas boilers cannot be positioned in rooms in which halogen compounds can occur and into which combustion air can enter (e.g. wash-, dryer-, work room, hairdressers and so on). Halogen compounds can be caused by cleaning and degreasing solutions, dissolvents, glue and bleaching lyes. Combustion air supply he supply of combustion air must be guaranteed. here must be no possibility to close the air supply opening. An air pipe D=80 for direct combustion air (air-exhaust system) can be directly connected to the boiler. he minimum free cross-section for the combustion air can be assumed simplified as follows! Room air-dependent operation: A minimal ventilation outlet of at least 150 cm 2 or 2 x 75 cm 2 cross-section is necessary for of boiler output up to 50 kw. For each further kw output 2 cm 2 more crosssection must be provided. Room air-independent operation with separate combustion air pipe to the boiler: 0,8 cm 2 per 1 kw of output. he pressure loss in the combustion air pipe must be consi dered for the calculation of the exhaust system. Gas connection Commissioning Start-up is to be carried out only by a specialist. Burner setting values according to the installation instructions. Manual gas shut-off valve and gas filter Immediately in front of the boiler a manual gas shut-off device (valve) must be installed ac cord ing to relevant regulations. Should the local re gulations or conditions demand this, an approved gas fil ter must be installed in the gas supply pipe bet ween the gas tap (thermally releasing) and the boiler in order to prevent malfunction due to for eign particles being carried along with the gas. ype of gas he boiler is only to be operated with the type of gas stated on the rating plate. A gas pressure controller to reduce the boiler inlet pressure must be installed on-site for propane). Gas pressure Necessary flow pressure at the boiler inlet: natural gas min. 18 mbar, max. 50 mbar. Propane min. 25 mbar, max. 50 mbar. able 1: Maximum filling capacity based on VDI 2035 Available for boiler with < 0,3 l/kw water capacity otal hardness of the filling water up to... [mol/m 3 ] 1 <0,1 0,5 1 1,5 2 2,5 3 >3,0 f H < >30 d H <0,56 2,8 5,6 8,4 11,2 14,0 16,8 >16,8 e H <0,71 3,6 7,1 10,7 14,2 17,8 21,3 >21,3 ~mg/l <10 50,0 100,0 150,0 200,0 250,0 300,0 >300 Conductance 2 <20 100,0 200,0 300,0 400,0 500,0 600,0 >600 Boiler size of the individual boiler maximum filling quantity without desalination up to 28 kw NO DEMAND 50 l/kw 20 l/kw 1 total of alkaline earths 2 If the conductance in µs/cm exceeds the tabular value an analysis of the water is necessary. 44 Subject to alterations,

46 Hoval opgas combi (21/18, 26/23, 32/28) Engineering Mud collector he fitting of a mud collector at the gas boiler return is recommendable. Minimum quantitiy of rotating water Depending on type of boiler, different minimum quantities of rotating water are demand ed. See also technical data During the burner mode the circulation pump must always be in function and the minimum heating water circulation must be guaranteed. Pump after-run time he circulation pump must continue to run for at least 2 minutes each time the burner is switched off (the pump after-run time is included in the boiler control with the opronic regulation). Condensate drainage he condensate from the exhaust system can be discharged through the boiler. A condensate trap is not needed anymore with the exhaust system. he allowance to lead the flue gas condensa te into the cnalisation must be ob tained from the responsible authority. A siphon must be installed at the condensa te outlet on the gas boiler (included in the boiler scope of delivery). he condensate must be openly lead into the canalisation. (funnel) Noise level he sound power level value is dependent on local and spacial circumstances. he sound pressure level is dependent on the installation conditions and can e.g. be 10 to 15 db(a) lower than the sound power level at a distance of 1 m. Expansion tank An adequately dimensioned expansion tank must be provided. he expansion tank has to be installed at the connection of expansion tank (pump intake side) (see Dimensions ). Starting from 70 C a connecting container is necessary. Flue gas system Gas boilers must be connected to a certified and approved flue gas system such as flue gas lines. Flue gas lines must be gas-, condensateand over pressure-tight. he flue gas system must be connected with an angle, so that the resulting condensate of the exhaust system can flow back to the boiler and can be neutralized there before discharging into the canalization. Gas boilers with condensation heat utilisation are to be connected to a flue gas line min. temperature class 120. A flue gas temperature limiter is integrated into the boiler. Examples Hoval opgas combi Gas boiler with - integrated continuous-flow water heater - a direct heating circuit Hydraulic schematic BCM010 BA RS - O B 1 WW DHW Dies ist ein unerlaubter opgas Weg! Gehen Sie einen Schritt combi zurück oder löschen Sie dieses Shape! Sie haben die Möglichkeit ein neues Shape zu nehmen!!! hovhovalhovalhoval hovalhovalhovalhov P RS-O BA B1 CW DHW Room station (Openherm) Outdoor sensor Flow temperature switch (on demand) Cold Water Domestic Hot Water Gas KW CW Notice: his hydraulic schematic is a principle schematic. It does not contain all details for installation. he installation must be done according to local conditions, di mensioning and regulations For underfloor heating, a flow temperature monitor must be built-in. Shut-off devices to the safety valve (pressurized expansion tank, safety valve, etc.) are to safe against unintended closing! Anti thermal siphon dip has to be installed. Subject to alterations,

47 46

48 Hoval opgas (30-60) Wall-hanging gas condensing boiler Description Hoval opgas Wall-hanging gas condensing boiler With condensing boiler technology Heat exchanger made of corrosion resistant aluminium-silicone cast alloy integrated into stainless steel heating water tank Built-in: Pressure gauge Water pressure guard for water shortage protection Flue gas temperature sensor with flue gas limiter function Aspirator Pre-mixing surface burner made of stainless steel Modulating with gas/air group control Automatic ignition Ionisation guard Gas pressure guard Minimum water flow necessary (see technical data) Wall-hanging gas condensing boiler fully cased with coated white steel plates, with red decorative strips Basic boiler control panel N4.1 Control unit for gas burner with monitoring unit BIC 335 Modulating burner control Main guard I/O Operation and fault indication Connection for external gas valve and fault indication Optional For propane Free standing calorifier Boiler burner control in different designs Delivery Wall-hanging gas condensing boiler fully cased Heating regulator set RS-O For 1 heating circuit without mixing operation Weather-controlled regulation for continuously adjustable decreased boiler water temperature RS-O with overplugable room temperature sensor, located in boiler room or living room. Can optimally be installed in the boiler control panel. Outdoor sensor AF 120 Calorifier heater sensor F 25 / 12K BMS-Module 0-10 V/O (Openherm) (Building management system) For boiler control as part of a building management system. External temperature control 0-10 V. 0-1,0 V no requirment 1,0-9,5 V C Can be installed in the boiler control panel! Model range Output range opgas at 40/30 C ype kw (30) 6,8-30,1 (35) 6,8-35,0 (45) 11,1-45,0 (60) 12,8-60,7 BMS-Module 0-10 V (Building management system) For boiler control as part of a building management system. External temperature control 0-10 V. 0-1,0 V Desired value 1,0-10,0 V... 11,5-115 C External temperature control with 0-10 V 0-0,4 V without temperature control (automatic) 0,5-0,9 V... Boiler off 0 % 1,0-10,0 V % Cannot be installed in the boiler control panel! Permissions boilers opgas (30-60): CE-Produkt-ID-Nr. CE-0085BQ0218 Heating regulator set ZN3 As supplement for basic boiler control panel N4.1. Consisting of: Heating regulator Hoval opronic /N for 1 heating circuit without mixing operation 1 mixer circuit domestic hot water loading circuit Function extension possibility via different key modules Large LCD-Displays Rotary pushbutton Buttons for daytime room temperature night room temperature hot water temperature operating mode selection (holiday, absent, heating operation prolongation, automatic, summer, continuous - reduced - frost protection) adjusting the heating curves system information emission measurement and manual operation Outdoor sensor AF200 Flow clamp on sensor VF204 Calorifier heater sensor KV20/5/6 Cable set ZN3 for connecting the heating regulator opronic /N with the boiler control Connection available for room station Delivery Heating regulator set separately packed, mounting on-site Subject to alterations,

49 Hoval opgas (30-60) Part N Wall-hanging gas condensing boiler Hoval opgas Part N Heat exchanger made of aluminum alloy. Modulating burner made of stainless steel and basic boiler control panel, completely cased opgas ype Output range at 40/30 C kw (30) 6,8-30,1 (35) 6,8-35,0 (45) 11,1-45,0 (60) 12,8-60, Accessories Gas filter with measurement nozzle before and behind the filter inset (diameter: 9 mm) Pore width of the filter inset < 50 mm Max. pressure difference 10 mbar Max. inlet pressure 100 mbar ype Connection 70612/6B Rp ¾" 70602/6B Rp 1" Modification set for propane for UltraGas (15-70), opgas comfort (10-22), opgas (30-60) Output range see technical data Connection set AS32-G consisting of: Return: - Shut-off valve with gland nut 2 and side outflow with boiler filling/-draining valve and fitting G ¾ (outside) for connection of an expansion tank. - circulating pump, different types Flow: - Fitting piece (180 mm) G2" with integrated non-return valve - Shut-off valve with gland nut 2" and side outflow with safety valve DN20 3 bar up to 100 kw incl. boiler filling-/draining valve Connection set ype Pump ype AS32-G/AX13-2 AX AS32-G/A14-2 A AS32-G/A15-2 A Subject to alterations,

50 Hoval opgas (30-60) Part N Accessories Part N D2 Adapter piece E80 -> E100 PP D1 Adapter piece C80/125 -> C100/150 PP Ø 81 Ø 124 Ø Zuluft Separating piece C80/125 -> 2xE80PP for ambient air independent operation for separate conduction of flue gas and combustion air. Only in combination with connection set for ambient air independent operation E 100 C 100/150 Ø Separating piece C100/150 -> 2xE100PP for UltraOil (35,50), opgas (30-60), UltraGas (50-90) for separate conduction of flue gas and combustion air (LAS-system) Recommendation: If the air inlet at the facade is near a noise sensitive place (window of bedroom, terrace etc.), we recommend to use a sound absorber at the direct combustion air inlet Boiler control panel with heating regulator opronic Heating regulator set RS-O (Not for mixing operation!) For 1 heating circuit without mixing operation Flow temperature control controlled by atmospheric conditions with outer temperature sensor AF 120 water heater sensor F 25 / 12K and overridable room temperature sensor. Can be implemented as a room temperature control without outdoor sensor. opgas comfort (10-22) opgas (30-60) For integration into boiler control panel: Mounting set RS-O must be ordered. opgas classic and combi Only wall mounting possible! Mounting set RS-O Assembly set for mounting of heating regulator set RS-O into boiler BMS module 0-10 V/O - Openherm (building management system) no control unit opronic necessary power supply via O bus opgas classic Cannot be installed in the boiler control panel! opgas (30-60) Can be installed in the boiler control panel! Subject to alterations,

51 Hoval opgas (30-60) Part N Boiler control panel with heating regulator opronic Heating regulator set ZN3 Can be built in as supplement for basic boiler controller N4.2! Consisting of: Heating regulator opronic /N for - 1 mixer circuit - 1 heating circuit without mixer - hot water loading Outdoor sensor AF200 Flow sensor VF204 with 4 m cable 1 immersion sensor KV20/5/6 for calorifier with 5 m cable Cable set ZN3 for connecting the heating regulator opronic / N with the boiler controller Part N Accessories o heating regulator opronic /N Room station RS- for opronic effective on one mixing circuit Remote control RFF- for opronic effective on one mixing circuit Set BMS-Module 0-10 V (Building management system) Control 1-10 V ^= 11,5-115 C Consisting of: BMS-Module and rafo Cannot be installed in the boiler control panel! Casing to accommodate the BMS-Module see Controls Communication modules/remote connection see Controls Flow temperature guard for underfloor heating (per heating circuit 1 guard) C, differential gap 6K, capillary tube max. 700 mm, setting (visible from the outside) inside the housing cover Clamp-on thermostat RAK-W1000.S hermostat with strap, without cable and plug Subject to alterations,

52 M M M M Hoval opgas (30-60) Part N Accessoires for heating reglator system Hoval opronic Part N 1-7 Key Module for Hoval opronic use to get more functions additional to standard functions. Key-Modul consisting of: Function key to plug in opronic incl. accessories Only one Key Module possible! Standard functions already included in opronic. - 1 mixing circuit - 1 heating circuit without mixing operation - domestic hot water loading circuit Functions of the Key-Modules Key- 2. mixing- solid-fuel- solar Module circuit storage tank bi-fuel Key-Module 1 for 2. mixing circuit Function 1, 1 flow sensor, 2 loose plugs M 2 Key-Module 2 for solid fuel / storage tank / bivalent installation Function key 2, 3 immersion sensors, 4 loose plugs Key-Module 3 for solar plants Function key 3, 1 collector sensor, 1 calorifier sensor, 4 losse plugs M 4 Key-Module 4 for 2. mixing circuit and solid fuel / storage tank / bivalent installation Function key 4, 1 flow sensor, 3 immersion sensors, 6 loose plugs M 5 Key-Module 5 for 2. mixing circuit and solar plants Function key 5, 1 flow sensor, 1 collector sensor, 1 calorifier sensor, 6 loose plugs Key-Module 6 for solid fuel/storage tank/bivalent installation and solarplants Function key 6, 1 collector sensor, 4 immersion sensor, 6 loose plugs M System approaches and applications see Hoval CD 7 Key-Module 7 for 2. mixing circuit, soid fuel/storage tank / bivalent installation and solar plants Function key 7, 1 flow sensor, 1 collector sensor, 4 immersion sensors, 8 loose plugs Sensor type Immersion-/calorifier sensor : ype KV20/5/6 (L = 5 m) without immersion sleeve flow sensor ype VF204S with plug Collector sensor ype P1000 (Silicone) Subject to alterations,

53 Hoval opgas (30-60) Part N Accessories Part N For RS-O and heating regulator opronic /N Flow temperature guard for underfloor heating systems (1 guard per heating circuit) C, differential gap 6 K, capillary tube max. 700 mm, setting (visible from the outside) inside the housing cover Clamp-on thermostat RAK-W1000.S hermostat with strap, without cable and plug Gas valve, passage DN ½" with thermally releasing cut-off device Gas valve, passage DN ¾" with thermally releasing cut-off device Gas valve, corner version DN ½" with thermally releasing cut-off device Gas valve, corner version DN ¾" with thermally releasing cut-off device Mud separator made of brass ype ø D Op. pressure emperatur kv-value max. C m 3 /h DC 32 1¼" 10 bar ,8 DC 40 1½" 10 bar , Automatic quick release air vent with cut-off valve ½" Accessory for sludge separator Service Commissioning Commissioning must be made by works service or Hoval trained authorized serviceman/ company is condition for warranty. For commissioning and other services please contact your Hoval sales office. 52 Subject to alterations,

54 Hoval opgas (30-60) echnical data opgas (30-60) ype (30) (35) (45) (60) Nominal output 80 / 60 C with natural gas 1 kw 6,0-27,4 6,0-31,8 10,0-41,0 11,7-55,3 Nominal output 40 / 30 C with natural gas 1 kw 6,8-30,1 6,8-35,0 11,1-45,0 12,8-60,7 Nominal output 80 / 60 C with propane 3 kw 6,6-27,4 6,6-31,9 10,8-41,0 13,1-54,9 Nominal output 40 / 30 C with propane 3 kw 7,3-30,2 7,3-35,2 11,9-45,0 14,1-60,3 Nominal load with natural gas 1 kw 6,4-28,3 6,4-33,0 10,6-42,5 12,2-57,3 Nominal load with propane 3 kw 7,0-28,5 7,0-33,2 11,4-42,5 13,6-56,9 Working pressure heating maximum/minimum bar 3,0 / 1,0 3,0 / 1,0 3,0 / 1,0 3,0 / 1,0 Working temperature maximum C Boiler water content l 4,5 4,5 4,5 6,0 Minimum water flow l/h Boiler weight (without water content, incl. casing) kg Boiler efficiency at partial load 30% (according to EN 303) (related to net / gross calorific value) % 107,4 / 96,8 107,1 / 96,5 106,9 / 96,3 106,9 / 96,3 Standard efficiency (according to DIN 4702 part 8) 40 / 30 C % 109,3 / 98,5 109,1 / 98,3 109,0 / 98,2 109,0 / 98,2 (related to net / gross calorific value) 75 / 60 C % 106,3 / 95,8 106,1 / 95,6 106,0 / 95,5 106,0 / 95,5 Stand-by loss at 70 C Watt Standard emission rate Nitrogen oxides mg/kwh 30,0 30,0 30,0 35,0 Carbon monoxide mg/kwh 9,0 9,0 11,0 13,0 Content of CO 2 in the exhaust gas maximum/minimum output % 9,0 / 8,8 9,0 / 8,8 9,0 / 8,8 9,0 / 8,8 Dimensions See table of dimensions Connections Flow/return Inches Rp 1 ¼" Rp 1 ¼" Rp 1 ¼" Rp 1 ¼" Gas Inches R ¾" R ¾" R ¾" R ¾" Flue gas/ mm combustion air Ø C80 / 125 C80 / 125 C80 / 125 C80 / 125 Gas flow pressure minimum/maximum Natural gas E/LL mbar Propane mbar Gas connection value at 0 C / 1013 mbar: Natural gas E - (Wo = 15,0 kwh/m 3 ) H u = 9,97 kwh/m 3 m 3 /h 2,83 3,3 4,3 5,8 Natural gas LL- (Wo = 12,4 kwh/m 3 ) H u = 8,57 kwh/m 3 m 3 /h 3,3 3,9 5,0 6,7 Propane 3 (H u = 25,9 kwh/m 3 ) m 3 /h 1,09 1,27 1,64 2,21 Operation voltage V/Hz 230 / / / / 50 Control voltage V/Hz 24 / / / / 50 Minimum/maximum electrical power consumption Watt 29 / / / / 102 Stand-by Watt IP rating (integral protection) IP Sound power level - Heating noise (EN part 1) (room air dependent) db(a) Exhaust noise is radiated from the mouth (DIN part 47) (room air dependent/room air independent db(a) Sound pressure level (depending on installation conditions) 2 db(a) Condensate quantity (Natural gas ) at 40 / 30 C l/h 2,7 3,1 4,0 5,4 ph value of the condensate ca. 4,2 ca. 4,2 ca. 4,2 ca. 4,2 Flue gas system: requirements, values ype of connection B23, C13(x), C33(x), C53(x), C63(x) Flue gas mass flow kg/h 47,0 54,8 70,6 95,1 Flue gas temperature at nominal output 80 / 60 C C Flue gas temperature at nominal output 40 / 30 C C Volume flow rate combustion air Nm 3 /h 35,4 41,3 53,1 71,6 Feed pressure total at the combustion air/flue gas pipe Pa Maximum draught / depression at flue gas outlet Pa Data related to H u. he boiler series is tested for EE/H-settings. With a factory setting of the Wobbe coefficient of 15.0 kwh/m 3 operation at a Wobbe coefficient of 12,0 up to 15,7 kwh/m 3 is possible without new settings. 2 See also notes at Engineering. 3 Data related to H u. opgas can also be operated with propane. Subject to alterations,

55 Hoval opgas (30-60) echnical data Boiler-flow resistance mbar Boiler incl. connection-set only boiler 0 0,0 0,5 1,0 1,5 2,0 2,5 3,0 3,5 4,0 4,5 5,0 5,5 m 3 /h m 3 /h = Volume flow rate mbar = Flow resistance Maximum residual overpressure opgas (30-60) with connection set AS32-G/AX13-2 (mbar) , , , , , , ,5 3.5 m3 /h Maximum residual overpressure opgas (30-60) with connection set AS32-G/A14-2 (mbar) , , , , , , , , ,5 4.5 m3 /h Maximum residual overpressure opgas (30-60) with connection set AS32-G/A (mbar) , , , , , , , , , ,0 5.0 m 3 /h 54 Subject to alterations,

56 Hoval opgas (30-60) Dimensions opgas (30-60) Minimum spaces (Dimensions in mm) Sideways 50 mm Space to ceiling dependent on the used flue gas system Front 500 mm View from bottom View from above 1 Gas connection R ¾" 2 Flow Rp 1¼" 3 Return Rp 1¼" 4 Condensate drain 32 5 LAS Flue gas-/combustion air connection DN 80/125 6 Automatic air vent 7 Cover control panel 8 Safety valve 9 Ball valve Subject to alterations,

57 Hoval opgas (30-60) Engineering Standards and guidelines he following standards and guidelines must be complied with: Hoval technical information and installation instructions. Hydraulic and technical control regualtions of Hoval. Local building law Fire protection regulations DVGW regulations. DIN EN Safety-relevant requirements. DIN EN Heaters Rules for the calculation of the heat requirements of buildings. VDI 2035 Protection against damage by cor rosion and boiler scale formation in hot water installations. VDE 0100 Local fire brigade regulations Water quality Heating water: he European Standard EN and the Directive VDI 2035 must be observed. Hoval boilers and calorifiers are designed for heating plants without significant oxygen intake (plant type I according to EN 14868). he following systems must be equipped with separate circuits: Systems with a specific water content of over 50 ltr./kw for the boiler (in cascades, for the smallest boiler) Plants with - continuous oxygen intake (e.g. underfloor heating systems without diffusion proof plastic piping or open expansion tank) or - intermittent oxygen intake (e.g. where frequent refilling is necessary) Older systems with formation of sludge in which increased concentrations of the metals which come into contact with the water are found in the existing heating water. Systems operated with softened water. reated heating water must be tested at least 1x yearly, according to the inhibitor manufacturer s instructions, more frequent testing may be necessary. A refilling is not necessary if the quality of the heating water in existing installations (e.g. exchange of boiler) conforms to VDI he Directive VDI 2035 applies equally to the replacement water. New and if applicable existing installations must be adequately cleaned and flushed before being recharged! he boiler may only be filled after the heat ing system has been flushed. Parts of the boiler which have contact with water are made of aluminium. On account of the danger of spot corrosion the chloride, nitrate and sulfate contents of the heating water must not exceed 200 mg/l in total. he ph value of the heating water should lie between 8,0 and 8,5 after 6-12 weeks of heating operation. Filling and replacement water: For a plant using Hoval boilers untreated drinking water is generally best suited as fil ling and replacement water. However, the quality of the untreated drinking water must at least fulfil the standard set in VDI 2035 or be desalinated and/or be treat ed with inhi bitors. he stipulations of EN must be observed. In order to maintain a high level of boiler ef ficiency and to avoid overheating of the heati ng surfaces the values given in the table should not be exceeded (dependent on boil er performance ratings - for multi-boiler plants rating of smallest boiler applies - and on the water content of the plant). he total amount of filling and replacement water which is used throughout the total service life of the boiler must not exceed three times the water capacity of the plant. Boilers with aluminum: generally inhibitors may be filled in only by a specialized company. If a reduction in water hardness is necessary we recommend a complete desalination (softening is not appropriate). Residual tap water might remain in the plant as a result of the preceding flushing process, entailing an increase in the sum of alkaline-earths to approx. 0,5 mol/m 3. During the filling procedure the conductance of the filling water should be supervised. his should be to approx. 100 µs/cm. After filling the conductance of the plant water should be between 50 and 200 µs/ cm. he ph value will adjust itself thereby from initially 6,5-7,5 after some weeks been in use on 8,0-8,5. If this should not be the case, then specialized company for the water treatment is to be assigned. his compa ny must as soon as the adjustment of the cor rect ph value has been completed by inhibitors, which are suitable for aluminum materials also regularly check the inhibitor concentration and the ph value. able 1: Maximum filling capacity based on VDI 2035 Available for boiler with < 0,3l/kW water capacity otal hardness of the filling water up to... [mol/m 3 ] 1 <0,1 0,5 1 1,5 2 2,5 3 >3,0 f H < >30 d H <0,56 2,8 5,6 8,4 11,2 14,0 16,8 >16,8 e H <0,71 3,6 7,1 10,7 14,2 17,8 21,3 >21,3 ~mg/l <10 50,0 100,0 150,0 200,0 250,0 300,0 >300 Conductance 2 <20 100,0 200,0 300,0 400,0 500,0 600,0 >600 boiler size of the individual boiler maximum filling quantity without desalination 30 to 50 kw 50 l/kw 50 l/kw 20 l/kw 20 l/kw 20 l/kw NO DEMAND 50 to 200 kw 50 l/kw 20 l/kw 20 l/kw always desalinate 1 total of alkaline earths 2 If the conductance in µs/cm exceeds the tabular value an analysis of the water is necessary. Frost protection agent he boiler must not be operated with frost pro tection agent in the heating water. Separate cir cuits are required in frost-protected systems. Space requirements see Dimensions. Heating room Gas boilers cannot be positioned in rooms in which halogen compounds can occur and into which combustion air can enter (e.g. wash-, dryer-, work room, hairdressers). Halogen compounds can be caused by cleaning and degreasing solutions, dissolvents, glue and bleaching lyes. 56 Subject to alterations,

58 Hoval opgas (30-60) Engineering Combustion air supply he supply of combustion air must be guaranteed. here must be no possibility to close the air supply opening. For a direct combustion air supply (LAS-system) insert connection C80/125 -> E80 PP or C100/150 -> E100PP. he minimum free cross-section for the combus tion air can be assumed simplified as follows: Considering nominal output! Room air-dependent operation: Minimum free cross-section of the opening into the open: 150 cm² or twice 75 cm² and additionally 2 cm² necessary for each kw of output over 50 KW for vent in to the open. Room air-independent operation with separate combustion air pipe to the boiler: 0.8 cm 2 per 1 kw of output. he pressure loss in the combustion air pipe must be con sidered for the calculation of the exhaust system. Gas connection Commissioning Start-up is to be carried out only by a speci a list. Burner setting values according to the installation instructions. Shut-off valve A shut-off valve must be built-in in front of every gas boiler. Manual gas shut-off cock and gas filter Immediately in front of the boiler a manual gas shut-off device (valve) must be installed ac cording to relevant regulations. Should the lo cal re gulations or conditions demand this, an approved gas fil ter must be installed in the gas supply pipe bet ween the gas valve (thermal released) and the boiler in order to prevent malfunction due to for eign particles being carried along with the gas. ype of gas he boiler is only to be operated with the type of gas stated on the rating plate. A gas pressure controller to reduce the boiler inlet pressure must be installed on-site for propane. Gas pressure Necessary flow pressure at the boiler inlet: natural gas min. 18 mbar, max. 24 mbar; propane min. 37 mbar, max. 50 mbar Mud collector he fitting of a mud collector at the gas boiler return is recommendable. Minimum water flow Depending upon type of boiler, different mi ni mum quantities of rotating water are deman ded. See also technical data. During the burner mode the circulation pump must always be in function and the minimum heating water circulating must be guaranteed. Pump after-run time he circulation pump must continue to run for at least 2 minutes each time the burner is switched off (the pump after-run time is included in the boiler control with the opronic regulation). Heating boiler in the attic A water pressure guard is built-in in the gas boil er, which automatically turns the gas boiler off in case of water shortage. Note: Mounting of an expansion tank in the boiler flow and pump in the boiler return. See also paragraph expansion tank! Condensate drainage he autorisation for the drain of the flue gas condensate in the canalisation must be obtained by the responsible authority. he condensate from the exhaust system can be discharged through the boiler. A condensate trap is not needed anymore with the exhaust system. A siphon must be installed at the condensate outlet on the gas boiler (included in the boiler scope of delivery). he condensate must be openly lead into the canalisation. (funnel) Expansion tank An adequately dimensioned expansion tank must be provided. he minimum pressure in the expansion tank has to be 1.2 bar and the minimum ope rating pressure in the boiler has to be 1.5 bar. he pump has to be installed in the boiler re turn and the expansion tank has to be instal led pump intake side). If the minimum operating pressure in the boi l er, specified above, cannot be kept by 1.5 bar (e.g. roof central heating installations), must the expansion tank has to be in stalled in the boiler flow. Starting from 70 C a connecting container is necessary. Noise level he sound power level value is dependent on local and spacial circumstances. he sound pressure level is dependent on the installation conditions and can e.g. be 10 to 15 db(a) lower than the sound power level at a distance of 1 m. DIN 4109 must be observed when installing in domestic living areas Flue gas system Gas boilers must be connected to a certified and approved flue gas system such as flue gas lines. Flue gas lines must be gas-, condensateand over pressure-tight. he flue gas system must be connected with an angle, so that the resulting condensate of the exhaust system can flow back to the boiler and can be neutralized there before discharging into the canalization. Gas boilers with condensation heat utilisation are to be connected to a flue gas line min. temperature class 120. A flue gas temperature limiter is integrated into the boiler. Subject to alterations,

59 Hoval opgas (30-60) Examples opgas (30-60) Gas boiler with main pump, free standing calorifier wall distributors a direct heating circuit Hydraulic schematic BCO030 BA RS - O 2 x SB-R1K B 1 DHW WW Dies ist ein unerlaubter Weg! Gehen opgas Sie einen Schritt zurück >30 oder löschen Sie dieses Shape! Sie haben die Möglichkeit Pein neues Shape zu nehmen!!! hovhovalhovalhoval hovalhovalhovalhov Gas M5 DKP SLP BW Dies ist ein unerlaubter Weg! Gehen Sie einen Schritt zurück oder löschen Sie dieses Shape! Sie haben die Möglichkeit ein neues Shape zu nehmen!!! hovhovalhoval hovalhovalhov alhovalhovalho valhovalhovalh ovalhovalhoval hovalhovalhov alhovalhovalho valhovalhovalh ovalhovalhoval hovalhovalhov alhovalhovalho valh P CW KW Option / Opzione opgas (30-60) Gas boiler with main pump, free standing calorifier wall distributors a direct heating circuit and 1-2 mixed heating circuits Hydraulic schematic BCO040 AF 1 opronic RS- VF1 B1 VF2 B1 DHW WW Notice: his hydraulic schematic is a principle sche matic. It does not contain all details for in stallation. he installation must be do ne according to local conditions, di men - sioning and regulations For underfloor heating, a flow temperature monitor must be built-in. Shut-off devices to the safety valve (pressurized expansion tank, safety valve, etc.) are to safe against uninten ded closing! Anti thermal siphon dip has to be installed. Dies ist ein unerlaubter Weg! Gehen opgas Sie einen Schritt zurück >30 oder löschen Sie dieses Shape! Sie haben die Möglichkeit Pein neues Shape zu nehmen!!! hovhovalhovalhoval hovalhovalhovalhov Gas M5 DKP YK1 M MK1 MK2 YK2 M P SLP CW KW SF Dies ist ein unerlaubter Weg! Gehen Sie einen Schritt zurück oder löschen Sie dieses Shape! Sie haben die Möglichkeit ein neues Shape zu nehmen!!! hovhovalhoval hovalhovalhov alhovalhovalho valhovalhovalh ovalhovalhoval hovalhovalhov alhovalhovalho valhovalhovalh ovalhovalhoval hovalhovalhov alhovalhovalho valh RS- Room station AF, BA Oudoor sensor VF1 Flow sensor 1 VF2 Flow sensor 2 SF, BW Calorifier heater sensor B1 Flow temperature guard (if required) MK1 Pump mixing circuit 1 MK2 Pump mixing circuit 2 DKP Pump for heating circuit without mixing operation SLP Calorifier loading pump M5 Boiler circuit pump YK1 Actuator mixer 1 YK2 Actuator mixer 2 CW Cold Water DHW Domestic Hot Water Option / Opzione 58 Subject to alterations,

60 Hoval opgas (80) Wall-hanging gas condensing boiler Description Hoval opgas Wall-hanging gas condensing boiler With condensing boiler technology Heat exchanger made of corrosion resistant aluminium alloy Built-in: Pressure gauge Water pressure guard for water shortage protection Flue gas temperature sensor with flue gas temperature limiting function Automatic aspirator Pre-mixing surface burner made of stainless steel Modulating with gas/air group control Automatic ignition Ionisation guard Gas pressure monitor Minimal water circulation nessecary (see technical data) Wall-hanging gas condensing boiler fully cased with coated white steel plates Basic boiler control panel N4.1 Control unit for gas burner with monitoring unit BIC 335 Modulating burner control Main guard I/O Operation- and fault indication Connection for external gas valve and fault indication Optional For propane Free standing calorifier Different designs of control panels Delivery Wall-hanging gas condensing boiler full cased Heating regulator set RS-O For 1 heating circuit without mixing operation Weather-controlled regulation for conti nuously adjustable decreased boiler water temperature RS-O with overplugable room temperature sensor, located in boiler room or living room Outdoor sensor AF 120 Calorifier heater sensor F 25 / 12K Cannot be installed in the boiler control panel! Model range opgas ype Output range kw (80) 17,3-80,0 BMS-Module 0-10 V/O (Openherm) (Building management system) For boiler control as part of a building management system. External temperature control 0-10 V. 0-1,0 V no requirment 1,0-9,5 V C Can be installed in the boiler control panel! BMS-Module 0-10 V (Building management system) For boiler control as part of a building management system. External temperature control 0-10 V. 0-1,0 V Desired value 1,0-10,0 V... 11,5-115 C External temperature control with 0-10 V 0-0,4 V without temperature control (automatic) 0,5-0,9 V... Boiler off 0 % 1,0-10,0 V % Cannot be installed in the boiler control panel! Permissions boilers opgas (80) CE-Product-ID-No. CE-0085BQ0218 Heating regulator set ZN3 As supplement for basic boiler control panel N4.1. Consisting of: Heating regulator Hoval opronic /N for 1 heating circuit without mixing operation 1 mixer circuit domestic hot water loading circuit Function extension possibility via different key modules Large LCD-Display Rotary pushbutton Buttons for Daytime room temperature Night room temperature Hot water temperature Operating mode selection (holiday, absent, heating operation prolongation, au tomatic, summer, continuous - reduced - frost protection) adjusting the heating curves system information emission measurement and manual operation Outdoor sensor AF200 Flow clamp on sensor VF204 Calorifier heater sensor KV20/5/6 Cable set ZN3 for connecting the heating regulator opronic /N with the boiler control. Connection available for room station Delivery Heating regulator set separately packed, mounting on-site Subject to alterations,

61 Hoval opgas (80) Part N Wall-hanging gas condensing boiler opgas Part N Heat exchanger made of aluminum alloy Modulating burner made of stainless steel and basic boiler control panel. opgas Output range ype kw 1 (80) 17,3-80, kw = modulation range Accessories Gas filter with measurement nozzle before and behind the filter inset (diameter: 9 mm) Pore width of the filter inset < 50 mm Max. pressure difference 10 mbar Max. inlet pressure 100 mbar ype Connection 70612/6B Rp ¾" 70602/6B Rp 1" Conversion kit propane to opgas (80) Connecting kit AS 32-G / A Connecting kit AS 32-G / A E 100 C 100/150 Ø Separating piece C100/150 -> 2xE100PP for UltraOil (35,50), opgas (30-60), UltraGas (50-90) for separate conduction of flue gas and combustion air (LAS-system) Recommendation: If the air inlet at the facade is near a noise sensitive place (window of bedroom, terrace etc.), we recommend to use a sound absorber at the direct combustion air inlet Subject to alterations,

62 Hoval opgas (80) Part N Boiler control panel with heating regulator opronic Heating regulator set RS-O (Not for mixing operation!) For 1 heating circuit without mixing operation Flow temperature control controlled by atmospheric conditions with outer temperature sensor AF 120 water heater sensor F 25 / 12K and overridable room temperature sensor. Can be implemented as a room temperature control without outdoor sensor. opgas comfort (10-22) opgas (30-60) For integration into boiler control panel: Mounting set RS-O must be ordered. opgas classic and combi Only wall mounting possible! Part N BMS module 0-10 V/O - Openherm (building management system) no control unit opronic necessary power supply via O bus opgas classic Cannot be installed in the boiler control panel! opgas (30-60) Can be installed in the boiler control panel! Heating regulator set ZN3 Can be built in as supplement for basic boiler controller N4.2! Consisting of: Heating regulator opronic /N for - 1 mixer circuit - 1 heating circuit without mixer - hot water loading Outdoor sensor AF200 Flow sensor VF204 with 4 m cable 1 immersion sensor KV20/5/6 for calorifier with 5 m cable Cable set ZN3 for connecting the heating regulator opronic / N with the boiler controller Subject to alterations,

63 Hoval opgas (80) Part N Accessories Part N o heating regulator opronic /N Room station RS- for opronic effective on one mixing circuit Remote control RFF- for opronic effective on one mixing circuit Set BMS-Module 0-10 V (Building management system) Consisting of: BMS-Module and rafo Cannot be installed in the boiler control panel! Casing to accommodate the BMS-Module see Controls Communication modules/remote connection see Controls for RS-O and heating regulator opronic /N Flow temperature guard for floor heating (per heating circuit 1 guard) C, differential gap 6K, capillary tube max. 700 mm, setting (from the outside visibly) inside the housing cover. Clamp-on thermostat RAK-W1000.S hermostat with strap, without cable and plug Subject to alterations,

64 M M M M Hoval opgas (80) Part N Accessoires for heating reglator system Hoval opronic Part N 1-7 Key Module for Hoval opronic use to get more functions additional to standard functions. Key-Modul consiting of: Function key to plug in opronic incl. accessories Only one Key Module possible! Standard functions already included in opronic. - 1 mixing circuit - 1 heating circuit without mixing operation - domestic hot water loading circuit Functions of the Key-Modules Key- 2. mixing- solid-fuel- solar Module circuit storage tank bi-fuel Key-Module 1 for 2. mixing circuit Function 1, 1 flow sensor, 2 loose plugs M 2 Key-Module 2 for solid fuel / storage tank / bivalent installation Function key 2, 3 immersion sensors, 4 loose plugs Key-Module 3 for solar plants Function key 3, 1 collector sensor, 1 calorifier sensor, 4 losse plugs M 4 Key-Module 4 for 2. mixing circuit and solid fuel / storage tank / bivalent installation Function key 4, 1 flow sensor, 3 immersion sensors, 6 loose plugs M 5 Key-Module 5 for 2. mixing circuit and solar plants Function key 5, 1 flow sensor, 1 collector sensor, 1 calorifier sensor, 6 loose plugs Key-Module 6 for solid fuel/storage tank/bivalent installation and solarplants Function key 6, 1 collector sensor, 4 immersion sensor, 6 loose plugs M System approaches and applications see Hoval CD 7 Key-Module 7 for 2. mixing circuit, soid fuel/storage tank / bivalent installation and solar plants Function key 7, 1 flow sensor, 1 collector sensor, 4 immersion sensors, 8 loose plugs Sensor type Immersion-/calorifier sensor: ype KV20/5/6 (L = 5 m) without immersion sleeve flow sensor: ype VF204S with plug Collector sensor: ype P1000 (Silicone) Subject to alterations,

65 Hoval opgas (80) Part N Accessories Gas valve, passage DN ¾" with thermally releasing cut-off device Part N Gas valve, corner version DN ¾" with thermally releasing cut-off device Mud separator DC 40-1½" Automatic quick release air vent with cut-off valve ½" Accessory for sludge separator Service Commissioning Commissioning must be made by works service or Hoval trained authorized serviceman/ company is condition for warranty. For commissioning and other services please contact your Hoval sales office. 64 Subject to alterations,

66 Hoval opgas (80) echnical data opgas (80) ype (80) Nominal output 80 / 60 C with natural gas 1 kw 15,8-72,4 Nominal output 40 / 30 C with natural gas 1 kw 17,3-80,0 Nominal output 80 / 60 C with propane 3 kw 19,5-72,4 Nominal output 40 / 30 C with propane 3 kw 21,6-80,0 Nominal load with natural gas 1 kw 16,5-75,0 Nominal load with propane 3 kw 20,0-75,0 Working pressure heating maximum/minimum bar 4,0 / 1,5 Working temperature maximum C 85 Boiler water content l 10 Minimum water flow l/h 800 Boiler weight (without water content) kg 107 Boiler efficiency at partial load 30% (according to EN 303) (related to net / gross calorific value) % 107,0 / 96,4 Standard efficiency (according to DIN 4702, part 8) 40 / 30 C % 109,4 (related to net / gross calorific value) 75 / 60 C % 106,1 Stand-by loss at 70 C Watt 95 Standard emission rate Nitrogen oxides mg/kwh 18 Carbon monoxide mg/kwh 27 Content of CO 2 in the exhaust gas maximum/minimum output % 9,0 / 8,8 Dimensions: see table of dimensions Connections Flow/Return Inches Rp 1¼" Gas Inches R ¾" Flue gas/combustion air (concentrically) mm C100 / 150 Gas flow pressure minimum/maximum Natural gas E/LL mbar Propane mbar Gas connection value at 0 C / 1013 mbar: Natural gas E - (Wo = 15,0 kwh/m 3 ) H u = 9,97 kwh/m 3 m 3 /h 1,65-7,5 Propane 3 (H u = 25,9 kwh/m 3 ) m 3 /h 0,77-2,90 Operation voltage V/Hz 230 / 50 Control voltage V/Hz 24 / 50 Minimum/maximum electrical power consumption Watt 23 / 130 Stand-by Watt 7 IP rating (integral protection) IP 20 Sound power level db(a) 63 Sound pressure level (depending on installation conditions) 2 db(a) 53 Condensate quantity (natural gas) at 40 / 30 C l/h 7,1 ph value of the condensate ca. 4,2 Value for chimney calculation Requirement flue gas system, temperature class 120 Flue gas mass flow kg/h 124,5 Flue gas temperature at nominal output 80 / 60 C C 79 Flue gas temperature at nominal output 40 / 30 C C 49 Feed pressure total at the combustion air/flue gas pipe Pa 140 Maximum draught / depression at flue gas outlet Pa Data related to H u. he boiler series is tested for EE/H-settings. With a factory setting of the Wobbe coefficient of 15.0 kwh/m 3 operation at a Wobbe coefficient of 12.0 up to 15.7 kwh/m 3 is possible without new settings. 2 See also notes at Engineering. 3 Data related to H u. Subject to alterations,

67 Hoval opgas (80) echnical data Boiler-flow resistance mbar Boiler incl. connection-set Boiler only m 3 /h Maximum residual overpressure opgas (80) with connection set AS32-G/M Stage 3 Stage 2 mbar Stage m 3 m/h 3 /h Maximum residual overpressure opgas (80) with connection set AS32-G/M Stage Stage mbar Stage m 3 /h m 3 /h = Volume flow rate mbar = Flow resistance 66 Subject to alterations,

68 Hoval opgas (80) Dimensions opgas (80) Minimum spaces (Dimensions in mm) Sideways 50 mm Space to ceiling dependent on the flue gas system Front 500 mm View from bottom View from top 1 Gas connection Rp ¾" 2 Heating flow Rp 1¼" 3 Heating return Rp 1¼" 4 Condensate drain DN 40 5 LAS Flue gas-/combustion air connection C 100/150 6 Cover control panel 7 Safety valve 8 Ball valve Subject to alterations,

69 Hoval opgas (80) Engineering Standards and guidelines he following standards and guidelines must be complied with: Hoval technical information and installation instructions. Hydraulic and technical control regualtions of Hoval. Local building law Fire protection regulations DVGW regulations. DIN EN Safety-relevant requirements. DIN EN Heaters Rules for the calculation of the heat requirements of buildings. VDI 2035 Protection against damage by corrosion and boiler scale formation in heating and service water installations. VDE 0100 Local fire brigade regulations Water quality Heating water: he European Standard EN and the Directive VDI 2035 must be observed. In par ticular, attention must be paid to the following stipulations: Hoval boilers and calorifiers are designed for heating plants without significant oxygen intake (plant type I according to EN 14868). he following systems must be equipped with separate circuits: Systems with a specific water content of over 50 ltr./kw for the boiler. (in cascades, for the smallest boiler) Plants with - continuous oxygen intake (e.g. underfloor heating systems without diffusion proof plastic piping) or - intermittent oxygen intake (e.g. where fre quent refilling is necessary) Older systems with formation of sludge in which increased concentrations of the metals which come into contact with the water are found in the existing heating water. Systems operated with softened water. reated heating water must be tested at least 1x yearly, according to the inhibitor ma nu facturer s instructions, more frequent testing may be necessary. A refilling is not necessary if the quality of the heating water in existing installations (e.g. exchange of boiler) conforms to VDI he Directive VDI 2035 applies equally to the replacement water. New and if applicable existing installations must be adequately cleaned and flushed before being recharged! he boiler may only be filled after the heat ing system has been flushed. Parts of the boiler which have contact with water are made of aluminium. On account of the danger of spot corrosion the chloride, nitrate and sulfate contents of the heating water must not exceed 200 mg/l in total. he ph value of the heating water should lie between 8,0 and 8,5 after 6-12 weeks of heating operation. Filling and replacement water: For a plant using Hoval boilers untreated drink ing water is generally best suited as fil ling and replacement water. However, the qual ity of the untreated drinking water must at least fulfil the standard set in VDI 2035 or be desalinated and/or be treat ed with inhibitors. he stipulations of EN must be observed. In order to maintain a high level of boiler effi ciency and to avoid overheating of the heati ng surfaces the values given in the table should not be exceeded (dependent on boil er performance ratings - for multi-boiler plants rating of smallest boiler applies - and on the water content of the plant). he total amount of filling and replacement water which is used throughout the total service life of the boiler must not exceed three times the water capacity of the plant. Boilers with aluminum: generally inhibitors may be filled in only by a specialized company. If a reduction in water hardness is necessary we recommend a complete desalination (softening is not appropriate). Residual tap water might remain in the plant as a result of the preceding flushing process, entailing an increase in the sum of alkaline-earths to approx. 0,5 mol/m 3. During the filling procedure the conductance of the filling water should be supervised. his should be to approx. 10 µs/cm. After filling the conductance of the plant wa ter should be between 50 and 200 µs/ cm. he ph value will adjust itself thereby from initially 6,5-7,5 after some weeks been in use on 8,0-8,5. If this should not be the ca se, then specialized company for the water treatment is to be assigned. his compa ny must as soon as the adjustment of the cor rect ph value has been completed by inhibitors, which are suitable for aluminum materials also regularly check the inhibitor concentration and the ph value. Space requirements See Dimensions Heating system Heating room Gas boilers cannot be positioned in rooms in which halogen compounds can occur and into which combustion air can enter (e.g. wash-, dryer-, work room, hairdressers and so on). Halogen compounds can be caused by cleaning and degreasing solutions, dissolvents, glue and bleaching lyes. Pay attention to the Procal leaflet, corrosion through Halogen compounds. Combustion air supply he supply of combustion air must be guaranteed. here must be no possibility to close the air supply opening. For a direct combusti on air supply (LAS-system) insert connection C100/150 -> 2xE100PP. able 1: Maximum filling capacity based on VDI 2035 Available for boiler with < 0,3l/kW water capacity otal hardness of the filling water up to... [mol/m 3 ] 1 <0,1 0,5 1 1,5 2 2,5 3 >3,0 f H < >30 d H <0,56 2,8 5,6 8,4 11,2 14,0 16,8 >16,8 e H <0,71 3,6 7,1 10,7 14,2 17,8 21,3 >21,3 ~mg/l <10 50,0 100,0 150,0 200,0 250,0 300,0 >300 Conductance 2 <20 100,0 200,0 300,0 400,0 500,0 600,0 >600 boiler size of the individual boiler maximum filling quantity without desalination 50 to 200 kw 50 l/kw 20 l/kw 20 l/kw always desalinate 1 total of alkaline earths 2 If the conductance in µs/cm exceeds the tabular value an analysis of the water is necessary. he minimum free cross-section for the combustion air can be assumed simplified as follows: Room air-dependent operation: Minimum free cross-section of the opening into the open: 150 cm² or twice 75 cm² and additionally 2 cm² necessary for each kw of output over 50 KW for vent in to the open. Room air-independent operation with separate combustion air pipe to the boiler: 0.8 cm 2 per 1 kw of output. he pressure loss in the combustion air pipe must be considered for the calculation of the ex-haust system. Considering nominal output! 68 Subject to alterations,

70 Hoval opgas (80) Engineering Gas connection Commissioning Start-up is to be carried out only by a speci a list. Burner setting values according to the installation instructions. Shut off valve A shut off valve must be built in in front of every gas boiler. Construction of recommended gas connection Legend: gas ball valve P P gas hose/ compensator gas filter Pressure gauge with test burner and pushbutton valve Manual gas shut-off valve and gas filter Immediately in front of the boiler, a manual gas shut-off device (valve) must be installed according to relevant regulations. Should the local re gulations or conditions demand this, an approved gas filter must be installed in the gas supply pipe between the gas valve (thermal released) and the boiler in order to prevent malfunction due to for eign particles being carried along with the gas. ype of gas he boiler is only to be operated with the type of gas stated on the rating plate. Gas pressure Necessary flow pressure at the boiler inlet: na tural gas min. 18 mbar, max. 50 mbar; propane min. 37 mbar, max. 50 mbar Mud collector he fitting of a mud collector at the gas boiler return is recommendable. Minimum water flow Depending upon type of boiler, different mini mum water flow are de mand ed. See also technical data. During the burner mode the circulation pump must always be in function and the minimum heating water circulating must be guaranteed. Pump after-run time he circulation pump must continue to run for at least 2 minutes each time the bur ner is switched off (the pump after-run time is included in the boiler control with the opronic regulation). Heating boiler in the attic A water pressure guard is built-in in the gas boil er, which automatically turns the gas boiler off in case of water shortage. Note: Mounting of an expansion tank in the boiler flow and pump in the boiler return. See also paragraph expansion tank. Condensate drain he autorisation for the drain of the flue gas condensate in the canalisation must be obtained by the responsible authority. he condensate from the flue gas system cannot be drained over the boiler. he condensate must be conducted away through a siphon before the boiler out of the flue gas pipe. A siphon must be installed at the condensate outlet on the gas boiler (included in the boiler scope of delivery). he condensate must be openly lead into the canalisation. (funnel) Expansion tank An adequately dimensioned expansion tank must be provided. he minimum pressure in the expansion tank and the minimum operating pressure in the boiler has to be 1,5 bar. he expansion tank has to be installed in prin ciple at the boiler return. at the boiler flow. he pump has to be installed in the boi ler return and the expansion tank has to be install ed pump intake side. If the minimum operating pressure in the boil er, specified above, cannot be kept by 1,5 bar (e.g. roof central heating installations), the expansion tank has to be installed in the boiler flow. Starting from 70 C a connecting container is necessary. Noise level he sound power level value is dependent on local and spacial circumstances. he sound pressure level is dependent on the installation conditions and can e.g. be 10 to 15 db(a) lower than the sound power le -vel at a distance of 1 m. DIN 4109 must be observed when installing in domestic living areas. Flue gas system Gas boilers must be connected to a certified and approved flue gas system such as flue gas lines. Flue gas lines must be gas-, condensateand over pressure-tight. he flue gas system must be connected with an angle, so that the resulting condensate of the exhaust system can flow back to the boiler and can be neutralized there before discharging into the canalization. Gas boilers with condensation heat utilisation are to be connected to a flue gas line min. temperature class 120. A flue gas temperature limiter is integrated into the boiler. Subject to alterations,

71 Hoval opgas (80) Examples opgas (80) Gas boiler with main pump, free standing calorifier, wall distributors a direct heating circuit Hydraulic schematic BCO030 BA RS - O 2 x SB-R1K B 1 DHW WW Dies ist ein unerlaubter Weg! Gehen opgas Sie einen Schritt zurück >30 oder löschen Sie dieses Shape! Sie haben die Möglichkeit Pein neues Shape zu nehmen!!! hovhovalhovalhoval hovalhovalhovalhov Gas M5 DKP SLP BW Dies ist ein unerlaubter Weg! Gehen Sie einen Schritt zurück oder löschen Sie dieses Shape! Sie haben die Möglichkeit ein neues Shape zu nehmen!!! hovhovalhoval hovalhovalhov alhovalhovalho valhovalhovalh ovalhovalhoval hovalhovalhov alhovalhovalho valhovalhovalh ovalhovalhoval hovalhovalhov alhovalhovalho valh P CW KW Option / Opzione opgas (80) Gas boiler with main pump, free standing calorifier, wall distributors a direct heating circuit and 1-2 mixed heating circuits Hydraulic schematic BCO040 AF 1 opronic RS- VF1 B1 VF2 B1 DHW WW Notice : his hydraulic schematic is a principle sche matic. It does not contain all details for in stallation. he installation must be do ne according to local conditions, di men - sioning and regulations. For underfloor heating, a flow temperature monitor must be built-in. Shut-off devices to the safety valve (pressurized expansion tank, safety valve, etc.) are to safe against uninten ded closing! Anti thermal siphon dip has to be installed. Dies ist ein unerlaubter Weg! Gehen opgas Sie einen Schritt zurück >30 oder löschen Sie dieses Shape! Sie haben die Möglichkeit Pein neues Shape zu nehmen!!! hovhovalhovalhoval hovalhovalhovalhov Gas M5 DKP YK1 M MK1 MK2 YK2 M P SLP CW KW SF Dies ist ein unerlaubter Weg! Gehen Sie einen Schritt zurück oder löschen Sie dieses Shape! Sie haben die Möglichkeit ein neues Shape zu nehmen!!! hovhovalhoval hovalhovalhov alhovalhovalho valhovalhovalh ovalhovalhoval hovalhovalhov alhovalhovalho valhovalhovalh ovalhovalhoval hovalhovalhov alhovalhovalho valh Option / Opzione RS-O RS- Room station (Openherm) Room station AF, BA Oudoor sensor VF1 Flow sensor 1 VF2 Flow sensor 2 SF, BW Calorifier heater sensor B1 Flow temperature guard (if required) MK1 Pump mixing circuit 1 MK2 Pump mixing circuit 2 DKP Pump for heating circuit without mixing operation SLP Calorifier loading pump M5 Boiler circuit pump YK1 Actuator mixer 1 YK2 Actuator mixer 2 CW DHW Cold Water Domestic Hot Water 70 Subject to alterations,

72 Hoval UltraGas (15-90) Floor standing gas condensing boiler Description Hoval UltraGas (15-90) Floor standing gas condensing boiler Floor standing gas condensing boiler, combustion chamber made of stainless steel Maximal flue gas condensation through downstream heating surface made of alufer stainless steel bounded pipe; flue gas side: aluminium water side: stainless steel hermal insulation with mineral wool mat Water pressure sensor (minimal and maximal limiter integrated) Flue gas temperature sensor with flue gas limiter function Pre-mix burner with blower and venturi Automatic ignition Ionisation guard Gas boiler fully cased with steel plate, red powder-coated Heating connections to left and right for: Flow Return - high temperature Return - low temperature UltraGas (15-50): Flue gas connection backwards to the top UltraGas (70,90): Concentrical flue gas-/combustion air connection, vertically upwards, horizontally to rear as option, see accessories and dimension sheet Control panel opronic /U4.1 Gas firing sequence controller with monitoring unit BIC960 Modulating burner control Connection for external gas solenoid valve and fault indication Regulation function integrated for: 1 mixer circuit 1 heating circuit without mixing operation domestic hot water loading circuit Option to expand the functions by different Key Module and/or UltraGas(70,90) Installation of a supplementary heating regulator opronic /N (see accessories) Main switch I/O Safety temperature limiter 110 C Fuse 6.3 A rouble indication «Burner» Running time meter and count-up Boiler sensor Large LCD-Displays Rotary pushbutton Buttons for daytime room temperature night room temperature hot water temperature operating mode selection (holiday, absent, heating operation prolongation, automatic, summer, continuous - reduced - frost protection) adjusting the heating curves system information emission measurement and manual operation Outdoor sensor AF 200 Flow sensor with plug Calorifier heater sensor with plug Connection available for room station Model range Output range UltraGas at 40/30 C ype kw (15) 3,3-15,5 (20) 4,3-20,3 (27) 5,0-27,2 (35) 5,8-35,7 (50) 8,3-49,9 (70) 13,6-69,9 (90) 16,1-91,5 Optional For propane Free-standing calorifier see Calorifiers Flue gas systems Delivery Floor standing gas condensing boiler fully cased Permissions boilers UltraGas (15-90) CE-Product-ID-No. CE-0085AQ0620 BMS-Modul 0-10 V (Bulding managment system) For boiler control as part of a building management system. External temperature control 0-10 V 0-1,0 V desired value 1,0-10,0 V... 11,5-115 C External temperature control with 0-10 V 0-0,4 V without temperature control (automatic) 0,5-0,9 V... Boiler off 0 % 1,0-10,0 V % By UltraGas (15-50) cannot be installed in the boiler control panel! By UltraGas (70,90) can be installed in the boiler control panel! Subject to alterations,

73 Hoval UltraGas (15-90) Part N Floor standing gas condensing boiler Hoval UltraGas Part N Floor standing gas condensing boiler, combustion chamber made of stainless steel. Down stream heating surface made of alufer stainless steel bounded pipe. Pre-mix burner with blower fan. Modulating burner. With boiler control opronic /U4.1 Delivery Boiler fully cased. UltraGas ype Output range at 40/30 C kw (15) 3,3-15,5 (20) 4,3-20,3 (27) 5,0-27,2 (35) 5,8-35,7 (50) 8,3-49,9 (70) 13,6-69,9 (90) 16,1-91, Accessories Gas filter with measurement nozzle before and behind the filter inset (diameter: 9 mm) Pore width of the filter inset < 50 mm Max. pressure difference 10 mbar Max. inlet pressure 100 mbar ype Connection 70612/6B Rp ¾" 70602/6B Rp 1" Modification set for propane for UltraGas (15-70), opgas comfort (10-22), opgas (30-60) Output range see technical data Modification set for propane for UltraGas (90) Output range see technical data for Hoval UltraGas (15-35) Necessary accessories for ambient air independent operation Connection set for ambient air independent operation without sound absorber for UltraOil (16-35), UltraGas (15-50), MultiJet (20,25) Consisting of: corrugated pipe Ø 50 mm for combustion air supply to burner. Concentric boiler connection piece E80 -> C80/125PP for flue gas and supply air. Necessary if no Hoval LAS flue gas system is used For ambient air independent operation with separate combustion air duct (not concentrical). 72 Subject to alterations,

74 Hoval UltraGas (15-90) Part N Accessories Part N Ø 81 Ø 124 Ø Zuluft Separating piece C80/125 -> 2xE80PP for ambient air independent operation for separate conduction of flue gas and combustion air. Only in combination with connection set for ambient air independent operation Adapter piece C80/125 -> C100/150 PP E 100 C 100/150 Ø Separating piece C100/150 -> 2xE100PP for UltraOil (35,50), opgas (30-60), UltraGas (50-90) for separate conduction of flue gas and combustion air (LAS-system) Recommendation: If the air inlet at the facade is near a noise sensitive place (window of bedroom, terrace etc.), we recommend to use a sound absorber at the direct combustion air inlet for Hoval UltraGas (70,90) Horizontal flue gas connection E100PP for UltraOil (50), UltraGas (70,90) for the conversion of the vertical flue gas connection (series delivery) to a horizontal to rear routed flue gas connection Suction tube for combustion air for UltraGas (70) only necessary with horizontal and concentric flue gas connection (separate ducting of combustion air and flue gas). Connection "Horizontal flue gas connection E 100PP" essential, ø 75 mm he boiler room must be ventilated Subject to alterations,

75 Hoval UltraGas (15-90) Part N Accessories Additional heating regulator set ZN1 for extending functionality and implementing further heating circuits Consisting of: Heating regulator opronic /N for - 1 mixer circuit - 1 heating circuit without mixer - hot water loading Only one key module per regulator is possible! Flow sensor VF202K with 2 m cable and plug. Cable set for connecting the auxiliary heating regulator opronic / N with the boiler controller Mounting on-site Part N Set BMS-Module 0-10 V (Building management system) Consisting of: BMS-Module and rafo Cannot be installed in the boiler control panel! Communication modules/remote connection see Controls Room station RS- for opronic effective on one mixing circuit Remote control RFF- for opronic effective on one mixing circuit Outdoor sensor AF 200 (may be included in the heat generator scope of delivery) for one mixing circuit or for the mean value (per regulator 2 outdoor temperature sensors possible) Cable sensor KV 20/5/6S 5 m cable and plug Contact sensor VF204S can be used as flow or return flow sensor with 4 m cable and plug Subject to alterations,

76 M M M M Hoval UltraGas (15-90) Part N Accessoires for heating regulator system Hoval opronic Part N 1-7 Key-Module for Hoval opronic for further functions additionally to standard functions. Key-Modul consists of: Function key for plugging into opronic opronic incl. accessories Only one Key-Module possible! Standard functions already included in opronic. - 1 mixer circuit - 1 heating circuit without mixing operation - domestic hot water loading circuit Functions of key modules Key- 2. mixing solid fuel- Solar Module circuit storage tank- Bivalent M 1 Key-Module 1 for 2. mixing circuit Function key 1, 1 flow sensor, 2 loose plugs 2 Key-Module 2 for solid fuel/ storage tank/ bivalent installation Function key 2, 3 immersion sensors, 4 loose plugs 3 Key-Modul 3 for solar plants Function key 3, 1 collector sensor, 1 calorifier sensor, 4 loose plugs M M Key-Module 4 for 2. mixing circuit and solid fuel/ storage tank/ bivalent installation Function key 4, 1 flow sensor, 3 immersion sensors, 6 loose plugs Key-Module 5 for 2. mixing circuit and solar plants Function key 5, 1 flow sensor, 1 collector sensor, 1 calorifier sensor, 6 loose plugs Key-Module 6 for solid fuel/ storage tank/ bivalent installation and solar plants Function key 6, 1 collector sensor, 4 immersion sensors, 6 loose plugs M 7 Key-Module 7 for 2. mixing circuit, solid fuel/ storage tank/ bivalent installation and solar plants Function key 7, 1 flow sensor, 1 collector sensor, 4 immersion sensors, 8 loose plugs System approaches and applications see Hoval CD Sensor type Immersion/calorifier sensor: ype KV20/5/6 (L = 5 m) without immersion sleeve flow sensor: ype VF204S with plug collector sensor: ype P1000 (Silicone) Subject to alterations,

77 Hoval UltraGas (15-90) Part N Accessories Part N Flow temperature guard for under floor heating (1 guard per heating circuit) C, differential gap 6K, capillary tube max. 700 mm, setting (visible from the outside) inside the housing cover. Clamp-on thermostat hermostat with strap, enclosed cable and plug RAK-W1000.S Set Clamp-on thermostat hermostat with strap, with cable (4 m) and plug RAK-W1000.S Immersion thermostat RAK-W1000.S SB 150 hermostat with immersion sleeve ½ - depth of immersion150 mm, brass nickel-plated Safety set SG15-1" Suitable up to max. 50 kw complete with safety valve (3 bar) Pressure gauge and automatic air vent with cut off valve Connection: 1" internal thread Safety set SG20-1" Range of application to 100 kw complete with safety valve (3 bar) Pressure gauge and autom. aspirator with shut-off valve. Connection: DN20 1" internal thread Boiler socket for MultiJet (20,25), UltraOil (16-35), UltraGas (15-50) to elevate the condensate drainage made of steel height 150 mm anthracite painted Subject to alterations,

78 Hoval UltraGas (15-90) Part N Condensate drain for Hoval UltraGas (15-90) Condensate pump for transporting condensation water into a higher drainage duct. Including connection line, completely wired, cable and plug for connection to the boiler controller max. transport height: 3.5 m Delivery rate up to 120 l/h combinable with neutralisation box can be mounted in boiler socket Part N Neutralisation box for transporting condensation water into a lower lying drainage duct incl. condensate neutralisation incl. neutralisation granulate 3 kg combinable with condensate pump can be mounted in boiler socket Neutralisation granulate for neutralisation box Refill set volume 3 kg Life time of one filling: approx. 2-4 years; depending on amount of condensate Condensate drain for Hoval UltraGas (70, 90) Condensate pump for UltraGas (70,90), UltraOil (50) for transporting condensation water into a higher drainage duct Including connection line completely wired cable and plug for connection to the boiler controller Max. transport height: 3.5 m combinable with neutralisation box can be mounted in boiler socket Neutralisation box for UltraOil 50, UltraGas (70,90) for transporting condensation water into a lower lying drainage duct incl. neutralisation granulate 6 kg. Combinable with condensate pump; can be mounted in boiler socket Neutralisation granulate for neutralisation box Refill set volume 3 kg Life time of one filling: approx. 2-4 years; depending on amount of condensate Subject to alterations,

79 Hoval UltraGas (15-90) Part N Boiler-Connection set Connection set AS25-S/N/H for mounting a heating armature group HA25 for MultiJet (16), UltraOil (16,20), UltraGas (15-27) Suitable for left or right connection Low/high temperature Connection set, fully thermally insulated Rigid flow pipe and flexible return flow pipe For mounting an armature group HA20 adapter set DN20 - DN25 necessary. Delivery: Connection set in assembly units, complete packet. Part N Connection set AS32-S/N/H for mounting a heating armature group HA32 for UltraGas (35, 50) Suitable for left or right connection Low/high temperature Rigid flow pipe and flexible return flow pipe, thermally insulated with fastening material adapter set DN25 - DN32 necessary. Delivery Connection set in assembly units, complete packet Connection set AS40-S/N/H for mounting a heating armature group HA40 for UltraOil (50), UltraGas (70,90) Connection set fully thermally insulated Rigid flow pipe and flexible return flow pipe with threaded flange R1½" Suitable for left or right connection Low/high temperature Adapter set DN32 - DN40 necessary. Delivery Connection set in assembly units, complete packet Subject to alterations,

80 Hoval UltraGas (15-90) Part N Hoval heating armature groups Part N Heating armature group HA-3BM-R with 3-way engine mixer and heat-insulating box. Installation on the right side (flow on the left). HA group - ype Pump - ype DN20 (¾") Pump with stepless rotation speed control HA20-3BM-R/AX 12-4 AX HA20-3BM-R/AX 13-4 AX DN25 (1") Pump with stepless rotation speed control HA25-3BM-R/AX 12-1 AX HA25-3BM-R/AX 13-1 AX HA25-3BM-R without pump Pumps for HA25-3BM-R for heating armature group HA25-3BM-R without pump. ransition pieces and threaded flanges can be ordered separately if necessary. A V A V DN32 (1¼") Pump with stepless rotation speed control HA32-3BM-R/AX 13-2 AX HA32-3BM-R/A15-2 A HA32-3BM-R without pump Pumps for HA32-3BM-R for heating armature group HA32-3BM-R without pump. ransition pieces and threaded flanges can be ordered separately if necessary. A V A V DN40 (1½") HA40-3M-R without pump Pumps for HA40-3M for heating armature group HA40-3M without pump. ransition pieces and threaded flanges can be ordered separately if necessary. A V ransition piece Z17 hreaded flange Z29 A V ransition piece Z17 hreaded flange Z29 A V ModulA PN V Subject to alterations,

81 Hoval UltraGas (15-90) Part N Hoval heating armature groups Part N Heating armature group HA-3BM-L with 3-way engine mixer and heat-insulating box. Installation on the left side. HA-groupe - ype Pump - ype DN20 (¾") Pump with stepless rotation speed control HA20-3BM-L/AX 12-4 AX HA20-3BM-L/AX 13-4 AX DN25 (1") Pump with stepless rotation speed control HA25-3BM-L/AX 12-1 AX HA25-3BM-L/AX 13-1 AX DN32 (1¼") Pump with stepless rotation speed control HA32-3BM-L/AX 13-2 AX HA32-3BM-L/A 15-2 A Adapter set DN32-DN25 for the installation of the HA group DN32 to a connection set DN Adapter fitting DN32-DN40 for the installation of the HA group DN32 to a wall distributor DN40 or a connection set AS40-S/N/ H Adapter set DN20-DN25 for the installation of the HA group DN20 to a wall distributor DN25 or a connection set DN25. Installation height 120 mm Adapter fitting DN25-DN32 for the installation of the HA group DN25 to a wall distributor DN Subject to alterations,

82 Hoval UltraGas (15-90) Part N Part N Loading group LG-2/ Heating armature group HA-2 For connection of a free standing calorifier, resp. as heating circle without mixing operation, incl. thermal insulation box. Mounting on the right (flow on the left). LG/HA group - type Pump - yp DN20 (¾") Pump with stepless rotation speed control LG/HA20-2/AX12-4 AX DN25 (1") Pump with stepless rotation speed control LG/HA25-2/AX 12-1 AX LG/HA25-2/AX 13-1 AX DN32 (1¼") Pump with stepless rotation speed control LG/HA32-2/AX 13-2 AX Wall brackets for mounting a Hoval Armature group on the wall. axle spacing connection wall clearance ype mm top bottom mm DN Rp 1" R 1" 70,85, DN Rp 1½" R 1" DN Rp 2" R1½" 142, Service Commissioning Commissioning must be made by works service or Hoval trained authorized serviceman/ company is condition for warranty. For commissioning and other services please contact your Hoval sales office. Subject to alterations,

83 Hoval UltraGas (15-90) echnical data UltraGas (15-27) ype (15) (20) (27) Nominal output 80/60 C with natural gas 1 kw 3,0-14,3 3,8-18,7 4,5-25,0 Nominal output 40/30 C with natural gas 1 kw 3,3-15,5 4,3-20,3 5,0-27,2 Nominal output 80/60 C with propane 2 kw 4,5-13,8 4,9-18,6 6,6-24,3 Nominal output 40/30 C with propane 2 kw 5,0-15,3 5,5-20,7 7,3-27,0 Nominal load with natural gas 1 kw 3,1-14,5 4,0-19,0 4,7-25,4 Nominal load with propane 2 kw 4,7-14,3 5,1-19,3 6,8-25,2 Working pressure heating maximum/minimum bar 3,0/1,0 3,0/1,0 3,0/1,0 Working temperature maximum C Boiler water content l Flow resistance boiler 3 z value 3,5 3,5 3,5 Minimum water flow l/h Boiler weight (without water content, incl. casing) kg Boiler efficiency at partial load 30% (according to EN 303) (related to net/gross calorific value) % 107,9/97,2 108,0/97,3 108,0/97,3 Standard efficiency (according to DIN 4702 part 8) 40/30 C % 109,5/98,6 109,5/98,6 109,5/98,6 (related to net/gross calorific value) 75/60 C % 107/96,4 107/96,4 107/96,4 Stand-by loss at 70 C Watt Standard emission rate Nitrogen oxides mg/kwh Carbon monoxide mg/kwh Content of CO 2 in the exhaust gas maximum/minimum output % 9,0/8,8 9,0/8,8 9,0/8,8 Dimensions See table of dimensions Connections Flow/return Inches R1" R1" R1" Gas Inches R¾" R¾" R¾" Flue gas/ combustion air Ø mm E80 E80 E80 Gas flow pressure minimum/maximum Natural gas E/LL mbar Propane mbar Gas connection value at 0 C/1013 mbar: Natural gas E - (Wo = 15,0 kwh/m 3 ) H u = 9,97 kwh/m 3 m 3 /h 1,5 1,9 2,6 Natural gas LL- (Wo = 12,4 kwh/m 3 ) H u = 8,57 kwh/m 3 m 3 /h 1,7 2,2 3,0 Propane (H u = 25,9 kwh/m 3 ) m 3 /h 0,6 0,8 1,0 Operation voltage V/Hz 230/50 230/50 230/50 Control voltage V/Hz 24/50 24/50 24/50 Minimum/maximum electrical power consumption Watt 24/46 24/64 24/58 Stand-by Watt IP rating (integral protection) IP Sound power level - Heating noise (EN part 1) (room air dependent) db(a) Exhaust noise is radiated from the mouth (DIN part 47) (room air dependent/room air independent db(a) Sound pressure level (depending on installation conditions) 4 db(a) Condensate quantity (natural gas ) at 40/30 C l/h 1,3 1,8 2,4 ph value of the condensate ph ca. 4,2 ca. 4,2 ca. 4,2 Flue gas system: requirements, values emperature class Flue gas mass flow kg/h Flue gas temperature at nominal output and operation 80/60 C C Flue gas temperature at nominal output and operation 40/30 C C Volume flow rate combustion air Nm 3 /h Feed pressure total at the combustion air/flue gas pipe Pa Maximum draught/depression at flue gas outlet Pa Data related to H u. he boiler series is tested for EE/H-settings. With a factory setting of the Wobbe coefficient of 15.0 kwh/m 3 operation at a Wobbe coefficient of 12,0 up to 15,7 kwh/m 3 is possible without new settings. (readjustment might be necessary) 2 Data related to H u. 3 Flow resistance boiler in mbar = Volume flow (m 3/ h) 2 x z factor 4 See also notes at Engineering. Boiler flow resistence see diagram. 82 Subject to alterations,

84 Hoval UltraGas (15-90) echnical data UltraGas (35-90) ype (35) (50) (70) (90) Nominal output 80/60 C with natural gas 1 kw 5,2-32,8 7,5-46,1 12,2-64,5 14,4-84,6 Nominal output 40/30 C with natural gas 1 kw 5,8-35,7 8,3-49,9 13,6-69,9 16,1-91,5 Nominal output 80/60 C with propane 3 kw 6,9-32,2 9,9-45,5 15,4-63,3 17,4-83,3 Nominal output 40/30 C with propane 3 kw 7,7-35,7 10,9-49,9 17,1-69,9 19,3-91,5 Nominal load with natural gas 1 kw 5,4-33,3 7,7-46,9 12,5-65,5 14,7-86,0 Nominal load with propane 3 kw 7,2-33,4 10,2-47,2 16,0-65,5 18,0-86,0 Working pressure heating maximum/minimum bar 3,0/1,0 3,0/1,0 4,0/1,0 4,0/1,0 Working temperature maximum C Boiler water content l Flow resistance boiler 4 z value 1,1 1,1 1,5 1,5 Minimum water flow l/h Boiler weight (without water content, incl. casing) kg Boiler efficiency at partial load 30% (according to EN 303) (related to net/gross calorific value) % 108,1/97,4 108,1/97,4 108,0/97,4 108,1/97,4 Standard efficiency (according to DIN 4702 part 8) 40/30 C % 109,5/98,6 109,5/98,6 109,6/98,7 109,6/98,7 (related to net/gross calorific value) 75/60 C % 107,0/96,4 107,0/96,4 107,1/96,5 107,1/96,5 Stand-by loss at 70 C Watt Standard emission rate Nitrogen oxides mg/kwh Carbon monoxide mg/kwh Content of CO 2 in the exhaust gas maximum/minimum output % 9,0/8,8 9,0/8,8 9,0/8,8 9,0/8,8 Dimensions See table of dimensions Connections Flow/return Inches R 1 ¼" R 1 ¼" R 1 ½" R 1 ½" Gas Inches Rp ¾" Rp ¾" R ¾" R ¾" Flue gas/ combustion air Ø mm E80 E80 C100/150 C100/150 Gas flow pressure minimum/maximum Natural gas E/LL mbar Propane mbar Gas connection value at 0 C/1013 mbar: Natural gas E - (Wo = 15,0 kwh/m 3 ) H u = 9,97 kwh/m 3 m 3 /h 3,3 4,7 6,6 8,6 Natural gas LL- (Wo = 12,4 kwh/m 3 ) H u = 8,57 kwh/m 3 m 3 /h 3,9 5,5 7,6 10,0 Propane (H u = 25,9 kwh/m 3 ) m 3 /h 1,3 1,8 2,5 3,3 Operation voltage V/Hz 230/50 230/50 230/50 230/50 Control voltage V/Hz 24/50 24/50 24/50 24/50 Minimum/maximum electrical power consumption Watt 26/59 26/64 27/93 28/138 Stand-by Watt IP rating (integral protection) IP Sound power level - Heating noise (EN part 1) (room air dependent) db(a) Exhaust noise is radiated from the mouth (DIN part 47) (room air dependent/room air independent db(a) Sound pressure level (depending on installation conditions) 2 db(a) Condensate quantity (natural gas ) at 40/30 C l/h 3,1 4,4 6,2 8,1 ph value of the condensate ca. 4,2 ca. 4,2 ca. 4,2 ca. 4,2 Flue gas system: requirements, values emperature class Flue gas mass flow kg/h 55,0 78,0 109,0 143,0 Flue gas temperature at nominal output and operation 80/60 C C Flue gas temperature at nominal output and operation 40/30 C C Volume flow rate combustion air Nm 3 /h Feed pressure total at the combustion air/flue gas pipe Pa Maximum draught/depression at flue gas outlet Pa Data related to H u. he boiler series is tested for EE/H-settings. With a factory setting of the Wobbe coefficient of 15.0 kwh/m 3 operation at a Wobbe coefficient of 12,0 up to 15,7 kwh/m 3 is possible without new settings (readjustment might be necessary) 2 See also notes at Engineering. 3 Data related to H u. 4 Flow resistance boiler in mbar = Volume flow (m 3/ h) 2 x z factor Boiler flow resistence see diagram. Subject to alterations,

85 Hoval UltraGas (15-90) echnical data Boiler flow resistance UltraGas (15-27) Pressure [mbar] loss [mbar] Volume flow [m [m3/h] 3 /h] UltraGas (35,50) Pressure [mbar] loss [mbar] ,5 1 1,5 2 2,5 3 3,5 4 4,5 5 Volume flow [m 3 /h] [m 3 /h] UltraGas (70,90) Pressure loss [mbar] Volume [m3/h] flow [m 3 /h] 84 Subject to alterations,

86 Hoval UltraGas (15-90) Dimensions Hoval UltraGas (15-27) with connection set AS25-S/N/H and armature group HA25 Hoval UltraGas (35,50) with connection set AS32-S/N/H and armature group HA32 (Dimensions in mm) ype UltraGas (15-27) (35,50) ype A B C D E F G H UltraGas (15-27) UltraGas (35,50) Flow heating / Safety flow R 1" R 1¼" 2 Low temperature-return R 1" R 1¼" 2a High temperature-return R 1" R 1¼" 3 Gas connection Rp ¾" Rp ¾" 4 Flue gas outlet DN80 DN80 5 Control panel 6 Condensate drain (left or right) incl. syphon (DN25) and 2 m PVC passage tube Ø-inside 19 x 4 mm 7 Drain 8 Electric cable entry point 9 Absorber hood 10 Heating armature group or loading group (option) Subject to alterations,

87 Hoval UltraGas (15-90) Dimensions Hoval UltraGas (70,90) with connection set AS40-S/N/H and armature group HA40 (Dimensions in mm) ype UltraGas (70) (90) 1. Flow heating / Safety flow R1½" R1½" 2. Low temperature-return R1½" R1½" 2a. High temperature-return R1½" R1½" 3. Duct for the gas pipe left or right R ¾" R ¾" 4. LAS flue gas/supply air connection C100/150 C100/150 4a. Combustion air connection to the back (option) E 100 E Control panel 6. Condensate drain (left or right) incl. syphon (DN25) and 2 m PVC passage tube Ø-inside 19 x 4 mm 7. Electrical connection left or right 8. Drain 9. Connection set (option) 10. Heating armature group or loading group (option) 86 Subject to alterations,

88 Hoval UltraGas (15-90) Dimensions Hoval UltraGas (15-50) (Dimensions in mm) Door of the boiler inclusive burner swivelling to the top and to the left or to the front. A = minimal 150 mm * Burner service position in the front - boiler cleaning from the right A = optimal 300 mm * - Burner service position left - boiler cleaning from the front * without armature group, 500 mm with armature group he cleaning opening must be well accessible. Boiler rear side must be accessible. Hoval UltraGas (70,90) (Dimensions in mm) Door of the boiler inclusive burner swivelling to the top and to the left or to the front. A = minimal 150 mm * Burner service position in the front - boiler cleaning from the right A = optimal 300 mm * - Burner service position left - boiler cleaning from the front * without armature group, 500 mm with armature group Subject to alterations,

89 Hoval UltraGas (15-90) Engineering Standards and guidelines he following standards and guidelines must be complied with: Hoval technical information and installation instructions. Hydraulic and technical control regulations of Hoval. Local building law Fire protection regulations DVGW regulations. DIN EN Safety-relevant requirements. DIN EN Heaters Rules for the calculation of the heat requirements of buildings. VDI 2035 Protection against damage by corrosion and boiler scale formation in heating and service water installations. VDE 0100 Local fire brigade regulations According to local regulations. Water quality Heating water: he European Standard EN and the Directive VDI 2035 must be observed. Hoval boilers and calorifiers are designed for heating plants without significant oxygen intake (plant type I according to EN 14868). Plants with - continuous oxygen intake (e.g. underfloor heating systems without diffusion proof plastic piping) or - intermittent oxygen intake (e.g. where frequent refilling is necessary) must be equipped with separate circuits. reated heating water must be tested at least 1x yearly, according to the inhibitor ma nufacturer s instructions, more frequent testing may be necessary. A refilling is not necessary if the quality of the heating water in existing installations (e.g. exchange of boiler) conforms to VDI he Directive VDI 2035 applies equally to the replacement water. New and if applicable existing installations must be adequately cleaned and flushed before being recharged! he boiler may only be filled after the heating system has been flushed. Parts of the boiler/ the calorifier which have contact with water are made of ferrous materials and stainless steel. On account of the danger of stress cracking corrosion in the parts made of stainless steel the chloride, nitrate and sulfate contents of the heating water must not exceed 50 mg/l in total. he ph value of the heating water should lie between 8,3 and 9,5 after 6-12 weeks of heating operation. Filling and replacement water: For a plant using Hoval boilers untreated drink ing water is generally best suited as filling and replacement water. However, the qua lity of the untreated drinking water must at least fulfil the standard set in VDI 2035 or be desalinated and/or be treated with inhibitors. he stipulations of EN must be observed. In order to maintain a high level of boiler ef ficiency and to avoid overheating of the heat ing surfaces the values given in the table should not be exceeded (dependent on boil er performance ratings - for multi-boiler plants rating of smallest boiler applies - and on the water content of the plant). he total amount of filling and replacement water which is used throughout the total service life of the boiler must not exceed three times the water capacity of the plant. If frost protection agent is being used, please contact the Hoval company to ask for the separate engineering sheet. Frost protection agent see separate engineering sheet «Use of frost protection agent». Heating installation Installation room Gas boilers cannot be positioned in rooms in which halogen compounds can occur and into which combustion air can enter (e.g. laundrettes, hairdressers). Halogen compounds can be caused by clean ing and degreasing solutions, dissolvents, glue and bleaching lyes. Pay attention to the Procal leafl et, corrosion through Halogen compounds. Combustion air he supply of combustion air must be guaranteed. here must be no possibility to close the air supply opening. For direct combustion air to boiler (LAS-System) mount the connection for direct combustion air inlet. he minimum free cross-section for the combustion air can be assumed simplifi ed as follows: Considering nominal output! Room air-dependent operation: Minimum free cross-section of the opening into the open: 150 cm² or twice 75 cm² and additionally 2cm² necessary for each KW of output over 50 KW for vent into the open. Room air-independent operation with separate combustion air pipe to the boiler: 0.8 cm 2 per 1 KW of output. he pressure loss in the combustion air pipe must be considered for the calculation of the exhaust system. able 1: Maximum filling capacity based on VDI 2035 otal hardness of the filling water up to... [mol/m 3 ] 1 <0,1 0,5 1 1,5 2 2,5 3 >3,0 f H < >30 d H <0,56 2,8 5,6 8,4 11,2 14,0 16,8 >16,8 e H <0,71 3,6 7,1 10,7 14,2 17,8 21,3 >21,3 ~mg/l <10 50,0 100,0 150,0 200,0 250,0 300,0 >300 Conductance 2 <20 100,0 200,0 300,0 400,0 500,0 600,0 >600 boiler size of the individual boiler maximum filling quantity without desalination up to 50 kw NO DEMAND 20 l/kw 50 to 200 kw 50 l/kw 20 l/kw 20 l/kw always desalinate 1 total of alkaline earths 2 If the conductance in µs/cm exceeds the tabular value an analysis of the water is necessary. Gas connection Commissioning Start-up is to be carried out only by a specia list of Hoval and the gas supplier. Burner setting values according to the installation instructions. Manual gas shut-off tap and gas filter Immediately in front of the boiler a manual gas shut-off device (tap) must be installed according to relevant regulations. Should the local regu lations or conditions demand this, an approved gas filter must be installed in the gas supply pipe between the gas tap (thermally releasing) and the boiler in order to prevent malfunction due to foreign particles being carried along with the gas. 88 Subject to alterations,

90 Hoval UltraGas (15-90) Engineering ype of gas he boiler is only to be operated with the type of gas stated on the rating plate. A gas pressure controller to reduce the boiler inlet pressure must be installed on-site for propane. Version for Propan ype UltraGas (15-90). Gas pressure natural gas Necessary flow pressure at the boiler inlet: For UltraGas (15-90) min. 18 mbar, max. 50 mbar Gas pressure propane Necessary flow pressure at the boiler inlet: For UltraGas (15-90) min. 37 mbar, max. 50 mbar Space requirements See Dimensions for information Pump after-run time he circulation pump must continue to run for at least 2 minutes each time the burner is switched off (the pump after-run time is inclu ded in the boiler control with the opronic regulation). Heating boiler in the attic If the gas boiler is positioned on the top floor, the installation of a low water protection, which automatically turns the gas burner off in case of water shortage, is recommended. Condensate drain he condensate from the exhaust system can be discharged through the boiler. A condensate trap is not needed anymore with the exhaust system. he condensate drainage without neutralisation is allowed, if you are using for the drain only plastic tubes or stoneware (possibly obtain special exemption from the relevant authority). A siphon must be installed at the condensate outlet on the gas boiler (included in the boiler scope of delivery). he condensate must be openly lead into the canalisation (funnel). Expansion tank An adequately dimensioned expansion tank must be provided. he expansion tank has to be installed in principle at the boiler return. At the heating flow a safety valve must be installed. An automatic exhauster is built in the boiler. Noise level he acoustic power level value is dependent on the local and spacial circumstances. he acoustic pressure level is dependent on the installation conditions and can for instance be 5 to 10 db(a) lower than the acoustic power level at a distance of 1 m. DIN 4109 must be observed when installing in domestic living areas Recommendation: If the air inlet at the facade is near a noise sensitive place (window of bedroom, terrace etc.), we recommend to use a sound absorber at the direct cumbustion air inlet. Chimney dimensions Basic rules: Height over sea level max m. Introduction to a vertical section: 90 Combustion air: In the case of room air-independent operation (accessories optional) the air pipe should be of the same dimension as the flue gas pipe. Flue gas system Gas boilers must be connected to a certified and approved flue gas system such as flue gas lines. Flue gas lines must be gas-, condensateand over pressure-tight. he flue gas system must be connected with an angle, so that the resulting condensate of the exhaust system can flow back to the boiler and can be neutralized there before discharging into the canalization. Gas boilers with condensation heat utilisati on are to be connected to a flue gas line min. temperature class 120. A flue gas temperature limiter is integrated into the boiler. Subject to alterations,

91 Hoval UltraGas (15-90) Examples UltraGas (15-90) Gas boiler with - a direct heating circuit from the boiler Hydraulic schematic BCR010 AF opronic B 1 RS- DKP P SLP Dies ist ein unerlaubter Weg! Gehen Sie einen Schritt zurück oder löschen Sie dieses Shape! UltraGas Sie haben (15-90) die Möglichkeit ein neues Shape zu H nehmen!!! H hovhovalh N hovalhova N alhovalho UltraGas (15-90) Gas boiler with - Free standing-calorifier heating supply from boiler, - a direct heating circuit from wall distributors mixed heating circuits from wall distributors Hydraulic schematic BCR030 AF 1 opronic RS- VF1 B1 VF2 B1 WW DHW DKP MK1 MK2 SLP P Dies ist ein unerlaubter Weg! Gehen Sie einen Schritt zurück oder löschen Sie dieses Shape! UltraGas Sie haben (15-90) die Möglichkeit ein neues Shape zu H nehmen!!! H hovhovalh N hovalhova N alhovalho YK1 M YK2 M SF Dies ist ein unerlaubter Weg! Gehen Sie einen Schritt zurück oder löschen Sie dieses Shape! Sie haben die Möglichkeit ein neues Shape zu nehmen!!! hovhovalhoval hovalhovalhov alhovalhovalho valhovalhovalh ovalhovalhoval hovalhovalhov alhovalhovalho valhovalhovalh ovalhovalhoval hovalhovalhov alhovalhovalho valh CW KW Notice: his hydraulic schematic is a principle schematic. It does not contain all details for installation. he installation must be done according to local conditions, di mensioning and regulations For underfloor heating, a flow temperature monitor must be built-in. Shut-off devices to the safety valve (pressurized expansion tank, safety valve, etc.) are to safe against unintended closing! Anti thermal siphon dip has to be installed. RS- Room station AF Outdoor sensor VF1 Flow sensor 1 VF2 Flow sensor 2 SF Calorifier heater sensor B1 Flow temperature guard (if required) MK1 Pump mixing circuit 1 MK2 Pump mixing circuit 2 DKP Pump for heating circuit without mixing operation SLP Calorifier loading pump YK1 Actuator mixer 1 YK2 Actuator mixer 2 H N High temperature Low temperature CW Cold Water DHW Domestic Hot Water 90 Subject to alterations,

92 Hoval UltraGas (15-90) Examples UltraGas (15-90) Gas boiler with - Solar free standing-calorifier, - a direct heating circuit from wall distributors mixed heating circuits from wall distributors Hydraulic schematic BCR070 AF 5 3 opronic RS- DKP VF1 B1 MK1 VF2 B1 MK2 KVLF S 1 WW DHW P SLP P Dies ist ein unerlaubter Weg! Gehen Sie einen Schritt zurück oder löschen Sie dieses Shape! UltraGas Sie haben die Möglichkeit ein neues Shape zu H nehmen!!! H hovhovalh N hovalhova N alhovalho YK1 M YK2 M SF Dies ist ein unerlaubter Weg! Gehen Sie einen Schritt zurück oder löschen Sie dieses Shape! Sie haben die Möglichkeit ein neues Shape zu nehmen!!! hovhovalhoval hovalhovalhov alhovalhovalho valhovalhovalh ovalhovalhoval hovalhovalhov alhovalhovalho valhovalhovalh ovalhovalhoval hovalhovalhov alhovalhovalho valh SLVF KSPF 2 SOP W KRLF CW KW UltraGas (15-90) Gas boiler with - Free standing-calorifier heating supply from boiler, - Wall distributors with return flow separation, - 1 mixed heating circuit and water heating to the high temperature return - 1 mixed heating circuit and water heating to the low temperature return Hydraulic schematic BCR050 DHW Notice: - his hydraulic schematic is a principle schematic. It does not contain all details for installation. he installation must be done according to local conditions, di mensioning and regulations - For underfloor heating, a flow temperature monitor must be built-in. - Shut-off devices to the safety valve (pressurized expansion tank, safety valve, etc.) are to safe against unintended closing! - Anti thermal siphon dip has to be installed. CW RS- Room station AF Outdoor sensor VF1 Flow sensor 1 VF2 Flow sensor 2 SF Calorifier heater sensor B1 Flow temperature guard (if required) MK1 Pump mixing circuit 1 MK2 Pump mixing circuit 2 DKP Pump for heating circuit without mixing operation SLP Calorifier loading pump SOP Solar circulation pump KSPF Solar tank sensor (calorifier/ buffer) KVLF Solar panel flow sensor (P1000) KRLF Solar panel (return) YK1 Actuator mixer 1 YK2 Actuator mixer 2 H N High temperature Low temperature CW Cold Water DHW Domestic Hot Water Subject to alterations,

93 92

94 Hoval UltraGas Cascades CL/R ( ) Floor standing gas condensing boiler in series Description Hoval UltraGas (70,90) Cascades consisting of the following components 2,3,4 or 5 gas boiler UltraGas (70,90) Hydraulic pipe connection Flue gas over pressure set All components must be ordered separately. (see «page 2 and 3»). On-site Installation of hydraulic connection set Installation of flue gas over pressure set Pressure gauge, automatic air vent, safety valve Data bus connecting cable Hoval UltraGas (70,90) Gas boiler Heating boiler made of steel with condensing systems Combustion chamber made of stainless steel Maximal flue gas condensation through downstream heating surface made of alufer stainless steel bounded pipe; flue gas side: aluminium water side: stainless steel hermal insulation with mineral wool mat Water pressure sensor (built-in water shortage protection) Flue gas temperature sensor with flue gas limiter function Pre-mix burner with blower and venturi Automatic ignition Ionisation guard Gas boiler fully cased with steel plate, red powder-coated Heating connections to left and right for: Flow Return - high temperature Return - low temperature UltraGas (70,90): Combustion air connection, vertically upwards Control panel opronic /U4.1 Gas firing sequence controller with monitoring unit BIC960 Modulating burner control Connection for external gas solenoid valve and fault indication Regulation function integrated for: 1 mixer circuit 1 heating circuit without mixing operation domestic hot water loading circuit Option to expand the functions by different Key Module and/or UltraGas(70,90) Installation of a supplementary heating regulator opronic /N (see accessories) Main switch I/O Safety temperature limiter 110 C Fuse 6.3 A rouble indication «Burner» Running time meter and count-up Boiler sensor Large LCD-Displays Rotary pushbutton Buttons for daytime room temperature night room temperature hot water temperature Model range UltraGas Output range Cascade UltraGas at 40/30 C ype ype kw 2 CL (140) (70) 13, CR (140) (70) 13, CL (180) (90) 16, CR (180) (90) 16, CL (210) (70) 13, CR (210) (70) 13, CL (270) (90) 16, CR (270) (90) 16, CL/R (280) (70) 13, CL/R (360) (90) 16, CL/R (350) (70) 13, CL/R (450) (90) 16,1-458 operating mode selection (holiday, absent, heating operation prolongation, automatic, summer, continuous - reduced - frost protection) adjusting the heating curves system information emission measurement and manual operation Outdoor sensor AF 200 Flow sensor with plug Calorifier heater sensor with plug Connection available for room station Optional For propane Free standing calorifier «Calorifier» Flue gas systems Delivery Floor standing gas condensing boiler fully cased Hydraulic connection set Pipe system consisting of Feed line connection between boilers incl. biral pump M14, check valve and balancing valve Return line connection between boilers wo executions for heating flow connection: top right (cascade CR) or top left (cascade CL) Permissions boilers UltraGas (70,90) CE-Product-ID-No. Delivery Hydraulic connection set packed and delivered separately. Flue gas over pressure set consisting of: Motorized air intake flaps and flue gas collector Delivery flue gas over pressure set supplied in separate packaging BMS-Modul 0-10 V (Bulding managment system) For boiler control as part of a building management system. External temperature control 0-10 V 0-1,0 V desired value 1,0-10,0 V... 11,5-115 C External temperature control with V 0-0,4 V without temperature control (automatic) 0,5-0,9 V... Boiler off 0 % 1,0-10,0 V % Can be installed in the boiler control panel! 1 see engineering instructions CE-0085AQ0620 Subject to alterations,

95 Hoval UltraGas Cascades CL/R ( ) Part N Hoval UltraGas Cascades Part N Hoval UltraGas Standing gas condensing boiler Floor standing gas condensing boiler, combustion chamber made of stainless steel. Down stream heating surface made of alufer stainless steel bounded pipe. Pre-mix burner with blower fan. Modulating burner. With boiler control opronic /U4.1 Delivery Boiler fully cased UltraGas Output range ype kw at 40/30 C (70) 13,6-69,9 (90) 16,1-91, Order the number of boilers necessary for the cascade! Modification propane Output range see technical data for UltraGas (70) for UltraGas (90) Hydraulic connection set Each set is matched to Hoval UltraGas (70,90) Cascade ype Connections number boiler Set of 2 2 C-HS-R right Set of 2 2 C-HS-L left Set of 3 3 C-HS-R right Set of 3 3 C-HS-L left Set of 4 4 C-HS-RL right/ left Set of 5 5 C-HS-RL right/ left One set per cascade necessary! 94 Subject to alterations,

96 Hoval UltraGas Cascades CL/R ( ) Part N Hoval UltraGas Cascades Part N Flue gas over pressure set Each set is matched to Hoval UltraGas (70,90) Cascade ype Connections number boiler Set of 2 2C-AS right/ left Set of 3 3C-AS right/ left Set of 4 4C-AS right/ left Set of 5 5C-AS right/ left One set per cascade necessary! Gas filter with measurement nozzle before and behind the filter inset (diameter: 9 mm) Pore width of the filter inset < 50 mm Max. pressure difference 10 mbar Max. inlet pressure 100 mbar ype Connection 70612/6B Rp ¾" 70602/6B Rp 1" Hydraulic switch with deaerator MH (100) completely insulated and encased, inclusive Victaulic flanges, ½" fitting for the temperature sensor, exhaust automat with automatic shutoff valve, rinsing and emptying device on the soil and the cover Subject to alterations,

97 Hoval UltraGas Cascades CL/R ( ) Part N Accessories Additional heating regulator set ZN1 for extending functionality and implementing further heating circuits Consisting of: Heating regulator opronic /N for - 1 mixer circuit - 1 heating circuit without mixer - hot water loading Only one key module per regulator is possible! Flow sensor VF202K with 2 m cable and plug. Cable set for connecting the auxiliary heating regulator opronic / N with the boiler controller. Mounting on-site Part N ,51 Set BMS-Module 0-10 V (Building management system) Consisting of: BMS-Module and rafo Can be installed in the boiler control panel! Communication modules/remote connection see Controls Room station RS- for opronic effective on one mixing circuit Remote control RFF- for opronic effective on one mixing circuit Outdoor sensor AF 200 (may be included in the heat generator scope of delivery) for one mixing circuit or for the mean value (per regulator 2 outdoor temperature sensors possible) Cable sensor KV 20/5/6S 5 m cable and plug Contact sensor VF204S can be used as flow or return flow sensor with 4 m cable and plug Subject to alterations,

98 M M M M Hoval UltraGas Cascades CL/R ( ) Part N Accessoires for heating regulator system Hoval opronic Part N 1-7 Key-Module for Hoval opronic for further functions additionally to standard functions. Key-Modul consists of: Function key for plugging into opronic opronic incl. accessories Only one Key-Module possible! Standard functions already included in opronic. - 1 mixer circuit - 1 heating circuit without mixing operation - domestic hot water loading circuit Functions of key modules Key- 2. mixing solid fuel- Solar Module circuit storage tank- Bivalent 1 M 1 Key-Module 1 for 2. mixing circuit Function key 1, 1 flow sensor, 2 loose plugs 2 Key-Module 2 for solid fuel/ storage tank/ bivalent installation Function key 2, 3 immersion sensors, 4 loose plugs 3 Key-Modul 3 for solar plants Function key 3, 1 collector sensor, 1 calorifier sensor, 4 loose plugs M M Key-Module 4 for 2. mixing circuit and solid fuel/ storage tank/ bivalent installation Function key 4, 1 flow sensor, 3 immersion sensors, 6 loose plugs Key-Module 5 for 2. mixing circuit and solar plants Function key 5, 1 flow sensor, 1 collector sensor, 1 calorifier sensor, 6 loose plugs Key-Module 6 for solid fuel/ storage tank/ bivalent installation and solar plants Function key 6, 1 collector sensor, 4 immersion sensors, 6 loose plugs M 7 Key-Module 7 for 2. mixing circuit, solid fuel/ storage tank/ bivalent installation and solar plants Function key 7, 1 flow sensor, 1 collector sensor, 4 immersion sensors, 8 loose plugs System approaches and applications see Hoval CD Sensor type Immersion/calorifier sensor: ype KV20/5/6 (L = 5 m) without immersion sleeve flow sensor: ype VF204S with plug collector sensor: ype P1000 (Silicone) Subject to alterations,

99 Hoval UltraGas Cascades CL/R ( ) Part N Accessories Part N Flow temperature guard for under floor heating (1 guard per heating circuit) C, differential gap 6K, capillary tube max. 700 mm, setting (visible from the outside) inside the housing cover. Clamp-on thermostat hermostat with strap, enclosed cable and plug Set Clamp-on thermostat hermostat with strap, with cable (4 m) and plug RAK-W1000.S RAK-W1000.S Immersion thermostat RAK-W1000.S SB 150 hermostat with immersion sleeve ½ - depth of immersion150 mm, brass nickel-plated Safety set SG20-1" Range of application to 100 kw complete with safety valve (3 bar) Pressure gauge and autom. aspirator with shut-off valve. Connection: DN20 1" internal thread Drainage duct Condensate pump for UltraGas (70,90), UltraOil (50) for transporting condensation water into a higher drainage duct Including connection line completely wired cable and plug for connection to the boiler controller Max. transport height: 3.5 m combinable with neutralisation box can be mounted in boiler socket Neutralisation box for UltraOil 50, UltraGas (70,90) for transporting condensation water into a lower lying drainage duct incl. neutralisation granulate 6 kg. Combinable with condensate pump; can be mounted in boiler socket Neutralisation granulate for neutralisation box Refill set volume 3 kg Life time of one filling: approx. 2-4 years; depending on amount of condensate Service Commissioning Commissioning must be made by works service or Hoval trained authorized serviceman/ company is condition for warranty. For commissioning and other services please contact your Hoval sales office. 98 Subject to alterations,

100 Hoval UltraGas Cascades CL/R ( ) echnical data Hoval UltraGas ype (70) (90) (70) (90) set of 2 cascades set of 2 cascades 2 CL (140) 2 CL (180) 3 CL (210) 3 CL (270) 2 CR (140) 2 CR (180) 3 CR (210) 3 CR (270) Nominal output 80/60 C with natural gas 1 kw 12, , , ,4-250 Nominal output 40/30 C with natural gas 1 kw 13, , , ,1-275 Nominal output 80/60 C with propane 3 kw 15, , , ,4-250 Nominal output 40/30 C with propane 3 kw 17, , , ,3-275 Nominal load with natural gas 1 kw 12, , , ,7-258 Nominal load with propane 3 kw 16, , , ,0-268 Working pressure heating maximum/minimum bar 4,0/1,0 4,0/1,0 4,0/1,0 4,0/1,0 Working temperature maximum C Boiler water content (entire cascade) l Minimum water flow l/h Boiler weight (without water content, incl. casing) kg Boiler efficiency at partial load 30% (according to EN 303) (related to net/gross calorific value) % 107,1/96,5 107,2/96,6 107,1/96,5 107,2/96,6 Standard efficiency (according to DIN 4702 part 8) 40/30 C % 109,6/98,7 109,6/98,7 109,6/98,7 109,6/98,7 (related to net/gross calorific value) 75/60 C % 107,1/96,5 107,1/96,5 107,1/96,5 107,1/96,5 Stand-by loss at 70 C (boiler) Watt Standard emission rate Nitrogen oxides mg/kwh Carbon monoxide mg/kwh Content of CO 2 in the exhaust gas maximum/minimum output % 9,0/8,8 9,0/8,8 9,0/8,8 9,0/8,8 Dimensions See table of dimensions Connections Flow/return DN Gas 3/4" Inches to be determined facility-related combustion air mm Gas flow pressure minimum/maximum Natural gas E/LL mbar Propane mbar Gas connection value at 0 C/1013 mbar: Natural gas E - (Wo = 15,0 kwh/m 3 ) Hu = 9,97 kwh/m 3 m 3 /h Natural gas LL- (Wo = 12,4 kwh/m 3 ) Hu = 8,57 kwh/m 3 m 3 /h Propane (Hu = 25,9 kwh/m 3 ) m 3 /h Operation voltage V/Hz 230/50 230/50 230/50 230/50 Control voltage V/Hz 24/50 24/50 24/50 24/50 Minimum/maximum electrical power consumption Watt 54/186 56/276 81/279 84/414 Stand-by Watt IP rating IP Sound power level - Heating noise (EN eil1) (room air depende) db(a) Exhaust noise is radiated from the mouth (DIN part 47) (room air dependent/room air independent) db(a) Sound pressure level (depending on installation conditions) Heating noise 2 db(a) Condensate quantity (natural gas) at 40/30 C l/h 12,4 16,2 18,6 24,3 ph value of the condensate ca. 4,2 ca. 4,2 ca. 4,2 ca. 4,2 Flue gas system: requirements, values emperature class Volume flow rate combustion air Nm 3 /h Flue gas mass flow kg/h Max. flue gas temperature at operation 80/60 C C Max. flue gas temperature at operation 40/30 C C Feed pressure total at the combustion air/flue gas pipe Pa Maximum draught/depression at flue gas outlet Pa Data related to H u. he boiler series is tested for EE/H-settings. With a factory setting of the Wobbe coefficient of 15.0 kwh/m 3 operation at a Wobbe coefficient of 12,0 bis 15,7 kwh/m 3 is possible without new settings. 2 See also notes at Engineering. 3 Data related to H u. UltraGas (70,90) can also be operated with propane. Note: echnical Data Hoval UltraGas (70,90) see Hoval UltraGas (15-90) Subject to alterations,

101 Hoval UltraGas Cascades CL/R ( ) echnical data Hoval UltraGas ype (70) (90) (70) (90) set of 4 cascades set of 5 cascades 4 CL (280) 4 CL (360) 5 CL (350) 5 CL (450) 4 CR (280) 4 CR (360) 5 CR (350) 5 CR (450) Nominal output 80/60 C with natural gas 1 kw 12, , , ,4-417 Nominal output 40/30 C with natural gas 1 kw 13, , , ,1-458 Nominal output 80/60 C with propane 3 kw 15, , , ,4-417 Nominal output 40/30 C with propane 3 kw 17, , , ,3-458 Nominal load with natural gas 1 kw 12, , , ,7-430 Nominal load with propane 3 kw 16, , , ,0-430 Working pressure heating maximum/minimum bar 4,0/1,0 4,0/1,0 4,0/1,0 4,0/1,0 Working temperature maximum C Boiler water content (entire cascade) l Minimum water flow l/h Boiler weight (without water content, incl. casing) kg Boiler efficiency at partial load 30% (according to EN 303) (related to net/gross calorific value) % 107,1/96,5 107,2/96,6 107,1/96,5 107,2/96,6 Standard efficiency (according to DIN 4702 part 8) 40/30 C % 109,6/98,7 109,6/98,7 109,6/98,7 109,6/98,7 (related to net/gross calorific value) 75/60 C % 107,1/96,5 107,1/96,5 107,1/96,5 107,1/96,5 Stand-by loss at 70 C (boiler) Watt Standard emission rate Nitrogen oxides mg/kwh Carbon monoxide mg/kwh Content of CO 2 in the exhaust gas maximum/minimum output % 9,0/8,8 9,0/8,8 9,0/8,8 9,0/8,8 Measurements see dimensions Connections Flow/return DN Gas 3/4" Inches to be determined facility-related combustion air mm Gas flow pressure minimum/maximum Natural gas E/LL mbar Propane mbar Gas connection value at 0 C/1013 mbar: Natural gas E - (Wo = 15,0 kwh/m 3 ) Hu = 9,97 kwh/m 3 m 3 /h Natural gas LL- (Wo = 12,4 kwh/m 3 ) Hu = 8,57 kwh/m 3 m 3 /h Propane (Hu = 25,9 kwh/m 3 ) m 3 /h Operation voltage V/Hz 230/50 230/50 230/50 230/50 Control voltage V/Hz 24/50 24/50 24/50 24/50 Minimum/maximum electrical power consumption Watt 108/ / / /690 Stand-by Watt IP rating IP Sound power level - Heating noise (EN part 1) (room air dependent) db(a) Exhaust noise is radiated from the mouth (DIN part 47) (room air dependent/room air independent db(a) Sound pressure level (depending on installation conditions) Heating noise 2 db(a) Condensate quantity (natural gas ) at 40/30 C l/h 24,8 32,4 31,0 40,5 ph value of the condensate ca. 4,2 ca. 4,2 ca. 4,2 ca. 4,2 Flue gas system: requirements, values emperature class Volume flow rate combustion air Nm 3 /h Flue gas mass flow kg/h Maximale flue gas temperature at operation 80/60 C C Maximale flue gas temperature at operation 40/30 C C Feed pressure total at the combustion air/flue gas pipe Pa Maximum draught/depression at flue gas outlet Pa Data related to H u. he boiler series is tested for EE/H-settings. With a factory setting of the Wobbe coefficient of 15.0 kwh/m 3 operation at a Wobbe coefficient of 12,0 up to 15,7 kwh/m 3 is possible without new settings.. 2 See also notes at Engineering. 3 Data related to H u. UltraGas (70,90) can also be operated with propane. Note: echnical Data Hoval UltraGas (70,90) see Hoval UltraGas (15-90) 100 Subject to alterations,

102 Hoval UltraGas Cascades CL/R ( ) Dimensions Hoval UltraGas (70,90) (Dimensions in mm) Space requirements Legend (70) (90) 1. Flow heating / safety flow R1½" R1½" 2. Low temperature-return R1½" R1½" 2a. High temperature-return R1½" R1½" 3. Duct for the gas pipe left or right R ¾" R ¾" 4. LAS flue gas/supply air connection C100/150 C100/ Control panel C100/150 E Condensate drain (left or right) incl. syphon (DN25) and 2 m PVC passage tube ø-inside19x4 7. Electrical connection left or right 8. Drain (behind the front casing) ½" ½" Subject to alterations,

103 Hoval UltraGas Cascades CL/R ( ) Dimensions Hoval UltraGas Cascade 2 CL (140,180) 1 Flow DN65 2 Return DN65 3 Combustion air connection 200 mountable on both sides 4 Position solar tank sensor 5 Splice for bleeder 1/2" 6 cleaning opening Hoval UltraGas Cascade 2 CR (140,180) 1 Flow DN65 2 Return DN65 3 Combustion air connection 200 mountable on both sides 4 Position solar tank sensor 5 Splice for bleeder 1/2" 6 cleaning opening 102 Subject to alterations,

104 Hoval UltraGas Cascades CL/R ( ) Dimensions Hoval UltraGas Cascade 3CL (210,270) 1 Flow DN65 2 Return DN65 3 Combustion air connection 200 mountable on both sides 4 Position solar tank sensor 5 Splice for bleeder 1/2" 6 cleaning opening Hoval UltraGas Cascade 3CR (210,270) 1 Flow DN65 2 Return DN65 3 Combustion air connection 200 mountable on both sides 4 Position solar tank sensor 5 Splice for bleeder 1/2" 6 cleaning opening Subject to alterations,

105 Hoval UltraGas Cascades CL/R ( ) Dimensions Hoval UltraGas Cascade 4CL (280,360) Hydraulic switch Hydraulic switch 1 Flow DN65 2 Return DN65 3 Combustion air connection 200 mountable on both sides 4 Position solar tank sensor 5 Splice for bleeder 1/2" 5 cleaning opening Hoval UltraGas Cascade 4CR (280,360) 1 Flow DN65 2 Return DN65 3 Combustion air connection 200 mountable on both sides 4 Position solar tank sensor 5 Splice for bleeder 1/2" 5 cleaning opening 104 Subject to alterations,

106 Hoval UltraGas Cascades CL/R ( ) Dimensions Hoval UltraGas Cascade 5CL (350,450) Hydraulic switch 1 Flow DN100 2 Return DN100 3 Combustion air connection 200 mountable on both sides 4 Splice for bleeder 1/2" 5 cleaning opening Hoval UltraGas Cascade 5CR (350,450) Hydraulic switch 1 Flow DN100 2 Return DN100 3 Combustion air connection 200 mountable on both sides 4 Splice for bleeder 1/2" 5 cleaning opening Subject to alterations,

107 Hoval UltraGas Cascades CL/R ( ) Engineering Standards and guidelines he following standards and guidelines must be complied with: Hoval technical information and installation instructions. Hydraulic and technical control regulations of Hoval. Local building law Fire protection regulations DVGW regulations. DIN EN Safety-relevant requirements. DIN EN Heaters Rules for the calculation of the heat requirements of buildings. VDI 2035 Protection against damage by corrosion and boiler scale formation in heating and service water installations. VDE 0100 Local fire brigade regulations According to local regulations. Water quality Heating water: he European Standard EN and the Directive VDI 2035 must be observed. In particular, attention must be paid to the following stipulations: Hoval boilers and calorifiers are designed for heating plants without significant oxygen intake (plant type I according to EN 14868). Plants with - continuous oxygen intake (e.g. underfloor heating systems without diffusion proof plastic piping) or - intermittent oxygen intake (e.g. where frequent refilling is necessary) must be equipped with separate circuits. able 1: Maximum filling capacity based on VDI 2035 reated heating water must be tested at least 1x yearly, according to the inhibitor ma nufacturer s instructions, more frequent testing may be necessary. A refilling is not necessary if the quality of the heating water in existing installations (e.g. exchange of boiler) conforms to VDI he Directive VDI 2035 applies equally to the replacement water. New and if applicable existing installations must be adequately cleaned and flushed before being recharged! he boiler may only be filled after the heating system has been flushed. Parts of the boiler/ the calorifier which have contact with water are made of ferrous materials and stainless steel. On account of the danger of stress cracking corrosion in the parts made of stainless steel the chloride, nitrate and sulfate contents of the heating water must not exceed 50 mg/l in total. he ph value of the heating water should lie between 8,3 and 9,5 after 6-12 weeks of heating operation. Filling and replacement water: For a plant using Hoval boilers untreated drink ing water is generally best suited as filling and replacement water. However, the qua lity of the untreated drinking water must at least fulfil the standard set in VDI 2035 or be desalinated and/or be treated with inhibitors. he stipulations of EN must be observed. In order to maintain a high level of boiler ef ficiency and to avoid overheating of the heat ing surfaces the values given in the ta ble should not be exceeded (dependent on boil er performance ratings - for multi-boiler plants rating of smallest boiler applies - and on the water content of the plant). he total amount of filling and replacement water which is used throughout the total service life of the boiler must not exceed three times the water capacity of the plant. If frost protection agent is being used, please contact the Hoval company to ask for the separate engineering sheet. Heating installation Installation room Gas boilers cannot be positioned in rooms in which halogen compounds can occur and into which combustion air can enter (e.g. laundrettes, hairdressers). Halogen compounds can be caused by clean ing and degreasing solutions, dissolvents, glue and bleaching lyes. Pay attention to the Procal leafl et, corrosion through Halogen compounds. Combustion air For the version with a common exhaust pipe it is imperative that the fresh air flap supplied is in fact installed! he supply of combustion air must be guaranteed. here must be no possibility to close the air supply opening. If the heating rooms are extremely dirty or if there is a high dirt incidence in the combustion air (e.g. operation of the boiler during the construction phase), clean combustion air has to be fed directly from outdoors or from a suitable area. he minimum free cross-section for the combustion air can be assumed simplifi ed as follows: Considering nominal output! - Only room air-dependent operation: Minimum free cross-section of the opening into the open: 150 cm² or twice 75 cm² and additionally 2cm² necessary for each KW of output over 50 KW for vent into the open. Manual gas shut-off tap and gas filter Immediately in front of the boiler a manual gas shut-off device (tap) must be installed according to relevant regulations. Should the local regu lations or conditions demand this, an approved gas filter must be installed in the gas supply pipe between the gas tap (thermally releasing) and the boiler in order to prevent malfunction due to foreign particles being carried along with the gas. otal hardness of the filling water up to... [mol/m 3 ] 1 <0,1 0,5 1 1,5 2 2,5 3 >3,0 f H < >30 d H <0,56 2,8 5,6 8,4 11,2 14,0 16,8 >16,8 e H <0,71 3,6 7,1 10,7 14,2 17,8 21,3 >21,3 ~mg/l <10 50,0 100,0 150,0 200,0 250,0 300,0 >300 Leitwert 2 <20 100,0 200,0 300,0 400,0 500,0 600,0 >600 boiler size of the individual boiler maximum filling quantity without desalination 50 to 200 kw NO DEMAND 50 l/kw 20 l/kw 20 l/kw 200 to 600 kw 50 l/kw 50 l/kw 20 l/kw always desalinate over 600 kw 1 total of alkaline earths 2 If the conductance in µs/cm exceeds the tabular value an analysis of the water is necessary. 106 Subject to alterations,

108 Hoval UltraGas Cascades CL/R ( ) Engineering Gas connection Commissioning Start-up is to be carried out only by a specia list of Hoval and the gas supplier. Burner setting values according to the installation instructions. Shut off valve A shut-off valve must be built-in in front of every gas boiler. ype of gas he boiler is only to be operated with the type of gas stated on the rating plate. A gas pressure controller to reduce the boiler inlet pressure must be installed on-site for propane. Version for Propan ype UltraGas Cascade CL/R ( ). Gas pressure natural gas Necessary flow pressure at the boiler inlet: For UltraGas Cascade CL/R ( ) - min. 18 mbar, max. 50 mbar Gas pressure propane Necessary flow pressure at the boiler inlet: For UltraGas Cascade CL/R ( ) - min. 37 mbar, max. 50 mbar Space requirements See Dimensions for information Heating boiler in the attic If the gas boiler is positioned on the top floor, the installation of a low water protection, which automatically turns the gas burner off in case of water shortage, is recommended. Condensate drain he condensate from the exhaust system can be discharged through the boiler. A condensate trap is not needed anymore with the exhaust system. he condensate drainage without neutralisation is allowed, if you are using for the drain only plastic tubes or stoneware (possibly ob tain special exemption from the relevant authority). A siphon must be installed at the condensate outlet on the gas boiler (included in the boiler scope of delivery). Expansion tank An adequately dimensioned expansion tank must be provided. he expansion tank has to be installed in principle at the boiler return. At the heating flow a safety valve must be installed. An automatic exhauster is built in the boiler. Noise level he acoustic power level value is dependent on the local and spacial circumstances. he acoustic pressure level is dependent on the installation conditions and can for in stance be 5 to 10 db(a) lower than the acoustic power level at a distance of 1 m. Recommendation: If the air inlet at the facade is near a noise sensitive place (window of bedroom, terrace etc.), we recommend to use a sound absorber at the direct cumbustion air inlet. Chimney / flue gas system Gas boilers must be connected to a flue gas system (chimney or flue gas lines). Flue gas lines must be gastight and leaktight against condensate and over pressure and are to be fitted with a safety temperature li miting device. Gas boilers with condensation heat utilisati on are to be connected to a flue gas line min. emperature class 120. A flue gas temperature limiter is built in the boiler. External boiler control In principle the Hoval opronic is intended to assume the cascade control function. his ensures an environmental and product- conserving mode of operation. If, in spite of this, the cascade strategy is planned externally and power control of the boiler takes place, frequent sequencing has to be avoided (a burner running time of at least 12 minutes). Subject to alterations,

109 Hoval UltraGas Cascades CL/R ( ) Engineering Chimney dimensions (Overpressure) to Hoval UltraGas Cascade CL/R ( ) Principles - Height above sea level max m - Introduction to a vertical section 90 - In the case of the Hoval cascades 4CL/R and 5CL/R, immediately after the supplied exhaust pipe a widening of the exhaust pipe s diameter is necessary. Extension for cascades of a set of 4 UltraGas to D250 and cascades of a set of 5 UltraGas to D300 directly after the last exhaust pipe strin gently necessary. Boiler Flue gas line (smooth walled) Number of bow 90 (flue gas + air supply) ype Flue gas-dim. Dimension otal pipe length in m (flue gas + air supply) UltraGas Cascade Hoval internal DN * UltraGas 2 CL/R (140) (70) CL/R (180) (90) CL/R (210) (70) CL/R (270) (90) CL/R (280) (70) CL/R (360) (90) CL/R (350) (70) CL/R (450) (90) Notice: he data contained in the table «chimney dimensions» represent guide values. An exact calculation for the flue gas duct must be made on-site. * With 5 bends or more the residual overpressure of the device is to be reduced by 30% for the calculation. With total pipe lengths exceeding 50 m, a separate calculation is necessary. Chimney dimensions (negative pressure) to Hoval UltraGas Cascade CL/R ( ) he flue gas system is to be dimensioned in such a way that no back circulation is possible in the room. A safe operation of the fl ue gas system has to be proved by approved measuring principles. 108 Subject to alterations,

110 Hoval UltraGas Cascades CL/R ( ) Examples Hoval UltraGas Cascades CL/R ( ) Boiler sequential control by opronic AF opronic opronic opronic VF1 B1 VF2 B1 VF3 B1 WW MK1 MK2 MK3 P Dies ist ein unerlaubter Weg! Gehen Sie einen Schritt zurück oder löschen UltraGas Sie dieses Shape! Sie 70, haben 90 die Möglichkeit 1 ein neues Shape zu nehmen!!! hovhovalh hovalhova alhovalho P Dies ist ein unerlaubter Weg! Gehen Sie einen Schritt zurück oder löschen UltraGas Sie dieses Shape! Sie 70, haben 90 die Möglichkeit 2 ein neues Shape zu nehmen!!! hovhovalh hovalhova alhovalho P Dies ist ein unerlaubter Weg! Gehen Sie einen Schritt zurück oder löschen UltraGas Sie dieses Shape! Sie 70, haben 90 die Möglichkeit 3-5 ein neues Shape zu nehmen!!! hovhovalh hovalhova alhovalho SVLF YK1 M YK2 M YK3 M SLP SF Dies ist ein unerlaubter Weg! Gehen Sie einen Schritt zurück oder löschen Sie dieses Shape! Sie haben die Möglichkeit ein neues Shape zu nehmen!!! hovhovalhoval hovalhovalhova lhovalhovalhov alhovalhovalho valhovalhovalh ovalhovalhoval hovalhovalhova lhovalhovalhov alhovalhovalho valhovalhovalh ovalhovalhoval h M5.1 M5.2 M5.3 KW SVLF Option / Opzione Hoval UltraGas Cascades CL/R ( ) Boiler sequential control by opronic and 1 x GL 0-10V -Module emperature control 0-10V opronic opronic opronic Modul For further information concerning temperature control see Controls P P P SVLF Notice: his hydraulic schematic is a principle schematic. It does not contain all details for installation. he installation must be done according to local conditions, di mensioning and regulations For underfloor heating, a flow temperature monitor must be built-in. Shut-off devices to the safety valve (pressurized expansion tank, safety valve, etc.) are to safe against unintended closing! Anti thermal siphon dip has to be installed. Dies ist ein unerlaubter Weg! Gehen Sie einen Schritt zurück oder löschen UltraGas Sie dieses Shape! Sie 70, haben 90 die Möglichkeit 1 ein neues Shape zu nehmen!!! hovhovalh hovalhova alhovalho M5.1 Dies ist ein unerlaubter Weg! Gehen Sie einen Schritt zurück oder löschen UltraGas Sie dieses Shape! Sie 70, haben 90 die Möglichkeit 2 ein neues Shape zu nehmen!!! hovhovalh hovalhova alhovalho M5.2 Dies ist ein unerlaubter Weg! Gehen Sie einen Schritt zurück oder löschen UltraGas Sie dieses Shape! Sie 70, haben 90 die Möglichkeit 3-5 ein neues Shape zu nehmen!!! hovhovalh hovalhova alhovalho M5.3 Option / Opzione SVLF AF Outdoor sensor VF1 Flow sensor 1 VF2 Flow sensor 2 VF3 Flow sensor 3 SF Calorifier heater sensor B1 Flow temperature guard (if required) SVLF Solar tank sensor MK1 Pump mixing circuit 1 MK2 Pump mixing circuit 2 MK3 Pump mixing circuit 3 Calorifier loading pump YK1 Actuator mixer 1 YK2 Actuator mixer 2 YK3 Actuator mixer 3 M5.1 Boiler circuit pump 1 M5.2 Boiler circuit pump 2 M5.3 Boiler circuit pump 3 KW WW Cold Water Domestic Hot Water Subject to alterations,

111 110

112 Hoval UltraGas ( ) Floor standing gas condensing boiler Description Hoval UltraGas ( ) Floor standing gas condensing boiler Floor standing gas condensing boiler, combustion chamber made of stainless steel Maximal flue gas condensation through tube heat exchanger alufer stainless steel, flue gas side: aluminium water side: stainless steel hermal insulation with mineral wool mat Water pressure sensor (minimal and maximal limiter integrated) Flue gas temperature sensor with flue gas limiter function Pre-mix burner with fan and venturi Automatic ignition Ionisation guard Gas boiler fully cased with steel plates, red powder-coated Heating connections incl. counter flanges, screws and seals backwards for: Flow Return - High temperature Return - Low temperature Control panel opronic /U4.1 (UltraGas ( )) opronic /U4.4 (UltraGas ( )) opronic /U4.3 (UltraGas (1000)) Gas firing sequence controller with monitoring unit BIC960 Modulating burner control Ionisation guard Gas valve Connection for external gas valve and fault indication. Regulation function integrated for: 1 mixer circuit 1 heating circuit without mixing operation domestic hot water loading circuit Option to expand the functions by different key module and/or installation of a supplementary heating regulator opronic /N (see accessories) Main switch I/O Safety temperature limiter 110 C Fuse 6.3 A rouble indication «Burner» Running time meter and count-up Boiler sensor Large LCD-Display Rotary pushbutton Button for daytime room temperature night room temperature hot water temperature operating mode selection (holiday, ab sent, heating operation prolongation, auto matic, summer, continuous - reduced - frost protection) adjusting the heating curves system information emission measurement and manual operation Outdoor sensor AF 200 Flow senosr with plug Calorifier heater sensor with plug Connection available for room station Model range Output range UltraGas at 40/30 C ype kw (125) (150) (200) (250) (300) (350) (400) (450) (500) (575) (650) (720) (850) (1000) Optional Propane With or without neutralization Direct combustion air connection Free-standing calorifier see Calorifiers. Additional control for the 3rd and 4th heating circuits Delivery Boiler, casing and insulation separately packed and delivered On-site Mounting of insulation, casing and control panel Mounting of boiler feet Permissions boilers UltraGas ( ) CE-Produkt-ID-Nr: CE-0085AQ0620 BMS-Module 0-10 V (Building management system) For boiler control as part of a building management system. External temperature control 0-10 V. 0-1,0 V Desired value 1,0-10,0 V... 11,5 C C External temperature control with 0-10 V 0-0,4 V without temperature control (automatic) 0,5-0,9 V... Boiler off 0% 1,0-10,0 V % - 100% Can be installed in the boiler control panel! Subject to alterations,

113 Hoval UltraGas ( ) Part N Floor standing gas condensing boiler Hoval UltraGas Part N Floor standing gas condensing boiler, combustion and flue gas chamber made of stainless steel. ube heat exchanger alufer. Pre-mix burner with fan. Modulating burner. With boiler control opronic /U4.1 (UltraGas ( )) opronic /U4.4 (UltraGas ( )) opronic /U4.3 (UltraGas (1000)) Delivery Boiler, burner and absorber hood are separately packed UltraGas Output range Working pressure ype kw 40/30 C bar (125) (150) (200) (250) (300) (350) (400) (450) (500) (575) (650) (720) (850) (1000) UltraGas PGS (execution for installation on site) Delivery time approx. 6 weeks UltraGas Output range Working pressure ype at 40/30 C kw bar (200) PGS (250) PGS (300) PGS (350) PGS (400) PGS (450) PGS (500) PGS (575) PGS Subject to alterations,

114 Hoval UltraGas ( ) Part N Part N Assembly set for multi-part delivery Boiler and flue gas collector are screwed only, not sealed, in order to enable the boiler to be placed in two sections. Consisting of instruction and special silicone Delivery time approx. 6 weeks Modification set for propane for UltraGas ( ) UltraGas (800D-1000D) Output range see technical data Modification set for propane for UltraGas ( ) UltraGas (1150D-1440D) Output range see technical data No conversion kit is required for boiler types UltraGas ( ) and (850,1000). Conversion must be performed in accordance with the instructions included with the delivery. Gas filter with measurement nozzle before and behind the filter inset (diameter: 9 mm) Pore width of the filter inset < 50 mm Max. pressure difference 10 mbar Max. inlet pressure 100 mbar ype Connection 70612/6B Rp ¾" 70602/6B Rp 1" 70604/6B Rp 1 ¼" 70603/6B Rp 1 ½" 70631/6B Rp 2" Valve testing system for UltraGas ( ), UltraGas (250D-2000D) Automatic, compact testing system for testing the leakage of the gas valve before each burner start with ready-to-connect wiring. Suitable for all gas qualities for which the UltraGas is permitted. UltraGas ( ) UltraGas ( ) UltraGas (850,1000) Subject to alterations,

115 Hoval UltraGas ( ) Part N Accessories Additional heating regulator set ZN1 for extending functionality and implementing further heating circuits Consisting of: Heating regulator opronic /N for - 1 mixer circuit - 1 heating circuit without mixer - hot water loading Only one key module per regulator is possible! Flow sensor VF202K with 2 m cable and plug. Cable set for connecting the auxiliary heating regulator opronic / N with the boiler controller Mounting on-site Part N ,51 Set BMS-Module 0-10 V (Building management system) Consisting of: BMS-Module and rafo Can be installed in the boiler control panel! Communication modules/remote connection see System components Room station RS- for opronic effective on one mixing circuit Remote control RFF- for opronic effective on one mixing circuit Outdoor sensor AF 200 (may be included in the heat generator scope of delivery) for one mixing circuit or for the mean value (per regulator 2 outdoor temperature sensors possible) Cable sensor KV 20/5/6S 5 m cable and plug Contact sensor VF204S can be used as flow or return flow sensor with 4 m cable and plug Subject to alterations,

116 M M M M Hoval UltraGas ( ) Part N Accessoires for heating reglator system Hoval opronic Part N 1-7 Key-Module for Hoval opronic for further functions additionally to standard functions. Key-Modul consists of: Function key for plugging into opronic opronic incl. accessories Only one Key-Module possible! Standard functions already included in opronic. - 1 mixer circuit - 1 heating circuit without mixing operation - domestic hot water loading circuit Functions of key modules Key- 2. mixing solid fuel- Solar Module circuit storage tank- Bivalent M 1 Key-Module 1 for 2. mixing circuit Function key 1, 1 flow sensor, 2 loose plugs Key-Module 2 for solid fuel/ storage tank/ bivalent installation Function key 2, 3 immersion sensors, 4 loose plugs Key-Modul 3 for solar plants Function key 3, 1 collector sensor, 1 calorifier sensor, 4 loose plugs M 4 Key-Module 4 ffor 2. mixing circuit and solid fuel/ storage tank/ bivalent installation Function key 4, 1 flow sensor, 3 immersion sensors, 6 loose plugs M 5 Key-Module 5 for 2. mixing circuit and solar plants Function key 5, 1 flow sensor, 1 collector sensor, 1 calorifier sensor, 6 loose plugs Key-Module 6 for solid fuel/ storage tank/ bivalent installation and solar plants Function key 6, 1 collector sensor, 4 immersion sensors, 6 loose plugs M 7 Key-Module 7 for 2. mixing circuit, solid fuel/ storage tank/ bivalent installation and solar plants Function key 7, 1 flow sensor, 1 collector sensor, 4 immersion sensors, 8 loose plugs System approaches and applications see Hoval CD Sensor type Immersion/calorifier sensor: ype KV20/5/6 (L = 5 m) without immersion sleeve flow sensor: ype VF204S with plug collector sensor: ype P1000 (silicone) Subject to alterations,

117 Hoval UltraGas ( ) Part N Part N Flow temperature switch for under floor heating (1 guard per heating circuit) C, differential gap 6K, capillary tube max. 700 mm, setting (visible from the outside) inside the housing cover. Clamp-on thermostat RAK-W1000.S hermostat with strap, without cable and plug Set Clamp-on thermostat RAK-W1000.S hermostat with strap, with cable (4 m) and plug Immersion thermostat RAK-W1000.S SB 150 hermostat with pocket ½ - depth of immersion150 mm, brass nickel-plated Safety set Complete with safety valve (3 bar), Pressure gauge and autom. aspirator with shut-off valve. Connection inner thread For UltraGas ( ) DN 25-Rp 1" to 200 kw For UltraGas ( ) DN32-Rp 1¼" to 350 kw Automatic quick release air vent with cut-off valve ½" Accessory for sludge separator Assembly tube flow Assembly tube return Assembly tube for flow and return for assembly on flow resp. high and low temperature return of the Hoval UltraGas boiler. With screws and nuts for connection of - an additional safety temperature limiter and a pressure limiter on the flow and - an expansion tank on the return Dimension Suitable for UltraGas Connection DN 65 ( ) flow DN 65 ( ) return DN 100 ( ) flow DN 100 ( ) return DN 125 ( ) flow DN 125 ( ) return Further information see Dimensions Maximum pressure limiter set suitable for assembly tube For boiler nominal output > 300 kw to meet the safety requirements of EN Consisting of: adjustable maximum pressure limiter safety temperature limiter RAK-S.131 and cock Attention Valid for UltraGas double boiler from type 700D; 2 pieces needed Subject to alterations,

118 Hoval UltraGas ( ) Part N Accessories Part N Connection for direct combustion air inlet Cannot be combined with motorised air intake suction flap UltraGas (125, 150) UltraGas ( ) UltraGas (350) UltraGas ( ) UltraGas ( ) UltraGas (850, 1000) Recommendation: If the air inlet at the facade is near a noise sensitive place (window of bedroom, terrace etc.), we recommend to use a sound absorber at the direct combustion air inlet. Motorised air intake suction flap DN 110 for UltraGas ( ) For cascading boiler systems with a common flue gas pipe. Complete with cabling Motorised air intake suction flap DN 180 for UltraGas ( ) For cascading boiler systems with a common flue gas pipe. Complete with cabling Connection for direct combustion air inlet Can only be used in combination with a motorised air intake suction flap (must be ordered separately). Can also be used for cascading boiler systems with a common flue gas pipe. Complete with cabling. UltraGas (125, 150) UltraGas ( ) UltraGas (350) UltraGas ( ) UltraGas ( ) UltraGas (850, 1000) Hydraulic shut off gate PN 16 to be installed directly on flow and or return. As option when no flow/return set has been ordered. Complete with cabling. UltraGas ( ) DN UltraGas ( ) DN 100 also suitable for high pressure version UltraGas ( ) DN 125 also suitable for high pressure version Subject to alterations,

119 Hoval UltraGas ( ) Part N Condensate drainage to UltraGas ( ) Part N Placed under the boiler Condensate box KB 22 for UltraGas ( ), (250D-2000D), UltraOil (65-300), (320D-600D) For condensate drainage into higher situated drain pipe with delivery pump. Max. delivery height 3.5 m, from 1200 kw two delivery pumps necessary. Delivery rate 120 l/h incl. liquid level switch, silicone hose 9/13 mm, 4 m long, electrical cable 1.5 m with plug Neutralisation box KB 23 for UltraGas ( ), (250D-2000D), UltraOil (65-300), (320D-600D) Condensate drainage into lower situated drain pipe without condensate delivery pump with neutralisation 12 kg neutralisation granulate Placed under the boiler Use one box for each boiler Neutralisation box KB 24 for UltraGas ( ), (250D-2000D), UltraOil (65-300), (320D-600D) for transporting condensation water into a higher lying drainage duct, max. delivery height 3.5 m, from 1200 kw two delivery pumps necessary. Delivery rate 120 l/h incl. liquid level switch, silicone hose 9/13 mm, 4 m long, electrical cable 1.5 m with plug 12 kg granulate Neutralisation granulate for neutralisation box Refill set volume 3 kg Life time of one filling: approx. 2-4 years; depending on amount of condensate Condensate pump for transporting condensation water into a higher drainage duct. Including connection line, completely wired, cable and plug for connection to the boiler controller max. transport height: 3.5 m Delivery rate up to 120 l/h combinable with neutralisation box can be mounted in boiler socket Subject to alterations,

120 Hoval UltraGas ( ) Part N Service Part N Commissioning Commissioning must be made by works service or Hoval trained authorized serviceman/ company is condition for warranty. For commissioning and other services please contact your Hoval sales office. Subject to alterations,

121 Hoval UltraGas ( ) echnical data UltraGas ( ) ype (125) (150) (200) (250) (300) Nominal output 80/60 C with natural gas 1 kw Nominal output 40/30 C with natural gas 1 kw Nominal output 80/60 C with propane kw Nominal output 40/30 C with propane kw Nominal load with natural gas 1 kw Nominal load with propane kw Working pressure heating maximum/minimum bar 5,0/1,0 5,0/1,0 5,0/1,0 5,0/1,0 5,0/1,0 Working temperature maximum C Boiler water content l Minimum water flow l/h Boiler weight (without water content, incl. casing) kg Boiler efficiency at partial load 30% (according to EN 303) (related to net/gross calorific value) % 108,1/97,4 108,0/97,3 108,1/97,4 108,1/97,4 108,0/97,3 Standard efficiency (according to DIN 4702 part 8) 40/30 C % 109,6/98,7 109,6/98,7 109,7/98,8 109,7/98,8 109,7/98,8 (related to net/gross calorific value) 75/60 C % 107,1/96,5 107,1/96,5 107,2/96,6 107,2/96,6 107,2/96,6 Heat loss rate at 70 C Watt Standard emission rate Nitrogen oxides mg/kwh Carbon monoxide mg/kwh Content of CO 2 in the exhaust gas maximum/minimum output % 9,0/8,8 9,0/8,8 9,0/8,8 9,0/8,8 9,0/8,8 Dimensions see table of dimensions Connections Flow/return DN DN65/PN6 DN65/PN6 DN65/PN6 DN65/PN6 DN65/PN6 Gas Inches Rp1" Rp1" Rp1½" Rp1½" Rp1½" Flue gas Ø inside mm Gas flow pressure minimum/maximum Natural gas E/LL mbar Propane mbar Gas connection value at 0 C/1013 mbar: Natural gas E - (Wo = 15,0 kwh/m 3 ) H u = 9,97 h/m 3 m 3 /h 11,6 14,1 18,8 23,5 28,3 Natural gas LL- (Wo = 12,4 kwh/m 3 ) H u = 8,57 h/m 3 m 3 /h 13,5 16,5 21,9 27,4 33,0 Propane 3 (H u = 25,9 kwh/m 3 ) m 3 /h 4,5 5,4 7,3 9,1 10,9 Operation voltage V/Hz 230/50 230/50 230/50 230/50 230/50 Control voltage V/Hz 24/50 24/50 24/50 24/50 24/50 Minimum/maximum electrical power consumption Watt 44/168 44/247 44/143 44/224 46/345 Stand-by Watt IP rating (integral protection) IP Sound power level - Heating noise (EN part 1) (room air dependent) db(a) Exhaust noise is radiated from the mouth (DIN part 47) db(a) Sound pressure level heating noise - depending on installation conditions 2 db(a) Condensate quantity (natural gas ) at 40/30 C l/h 10,9 13,3 17,7 22,1 26,6 ph value of the condensate ca. 4,2 ca. 4,2 ca. 4,2 ca. 4,2 ca. 4,2 Flue gas system: requirements, values emperature class Flue gas mass flow kg/h Flue gas temperature at nominal output 80/60 C C Flue gas temperature at nominal output 40/30 C C Volume flow rate combustion air Nm 3 /h Feed pressure total at the combustion air/flue gas pipe 3 Pa Maximum draught/depression at flue gas outlet Pa Data related to H u. he boiler series is tested for EE/H-settings. With a factory setting of the Wobbe coefficient of 15.0 kwh/m 3 operation at a Wobbe coefficient of 12.0 up to 15.7 kwh/m 3 is possible without new settings. 2 See also notes at Engineering. 3 Details for multi-boiler plants (cascade) with common flue gas line: see Hoval UltraGas (250D-2000D). Boiler flow resistence see diagrams. 120 Subject to alterations,

122 Hoval UltraGas ( ) echnical data UltraGas ( ) ype (350) (400) (450) (500) (575) Nominal output 80/60 C with natural gas 1 kw Nominal output 40/30 C with natural gas 1 kw Nominal output 80/60 C with propane kw Nominal output 40/30 C with propane kw Nominal load with natural gas 1 kw Nominal load with propane kw Working pressure heating maximum/minimum bar 6,0/1,0 6,0/1,0 6,0/1,0 6,0/1,0 6,0/1,0 Working temperature maximum C Boiler water content l Minimum water flow l/h Boiler weight (without water content, incl. casing) kg Boiler efficiency at partial load 30% (according to EN 303) (related to net/gross calorific value) % 108,0/97,3 108,1/97,4 108,0/97,3 108,0/97,3 108,1/97,4 Standard efficiency (according to DIN 4702 part 8) 40/30 C % 109,8/98,9 109,8/98,9 109,8/98,9 109,8/98,9 109,9/99,0 (related to net/gross calorific value) 75/60 C % 107,3/96,7 107,3/96,7 107,3/96,7 107,3/96,7 107,4/96,8 Heat loss rate at 70 C Watt Standard emission rate Nitrogen oxides mg/kwh Carbon monoxide mg/kwh Content of CO 2 in the exhaust gas maximum/minimum output % 9,0/8,8 9,0/8,8 9,0/8,8 9,0/8,8 9,0/8,8 Dimensions see table of dimensions Connections Flow/return DN DN100/PN6 DN100/PN6 DN100/PN6 DN100/PN6 DN125/PN6 Gas Inches Rp 1½" Rp 2" Rp 2" Rp 2" Rp 2" Flue gas Ø inside mm Gas flow pressure minimum/maximum Natural gas E/LL mbar Propane mbar Gas connection value at 0 C/1013 mbar: Natural gas E - (Wo = 15,0 kwh/m 3 ) H u = 9,97 h/m 3 m 3 /h 32,6 37,7 42,4 47,1 54,2 Natural gas LL- (Wo = 12,4 kwh/m 3 ) H u = 8,57 h/m 3 m 3 /h 38, ,5 55,0 63,2 Propane 3 (H u = 25,9 kwh/m 3 ) m 3 /h 12,6 14,6 16,4 18,2 20,9 Operation voltage V/Hz 230/50 230/50 230/50 230/50 230/50 Control voltage V/Hz 24/50 24/50 24/50 24/50 24/50 Minimum/maximum electrical power consumption Watt 49/330 60/445 60/582 60/745 62/720 Stand-by Watt IP rating (integral protection) IP Sound power level - Heating noise (EN part 1) (room air dependent) db(a) Exhaust noise is radiated from the mouth (DIN part 47) db(a) Sound pressure level heating noise (depending on installation conditions) 2 db(a) Condensate quantity (natural gas ) at 40/30 C l/h 30,6 35,4 39,9 44,3 50,9 ph value of the condensate ca. 4,2 ca. 4,2 ca. 4,2 ca. 4,2 ca. 4,2 Flue gas system: requirements, values emperature class Flue gas mass flow kg/h Flue gas temperature at nominal output 80/60 C C Flue gas temperature at nominal output 40/30 C C Volume flow rate combustion air Nm 3 /h Feed pressure total at the combustion air/flue gas pipe 3 Pa Maximum draught/depression at flue gas outlet Pa Data related to H u. he boiler series is tested for EE/H-settings. With a factory setting of the Wobbe coefficient of 15.0 kwh/m 3 operation at a Wobbe coefficient of 12.0 up to 15.7 kwh/m 3 is possible without new settings. 2 See also notes at Engineering. 3 Details for multi-boiler plants (cascade) with common flue gas line: see Hoval UltraGas (250D-2000D). Boiler flow resistence see diagrams. Subject to alterations,

123 Hoval UltraGas ( ) echnical data UltraGas ( ) ype (650) (720) (850) (1000) Nominal output 80/60 C with natural gas 1 kw Nominal output 40/30 C with natural gas 1 kw Nominal output 80/60 C with propane kw Nominal output 40/30 C with propane kw Nominal load with natural gas 1 kw Nominal load with propane kw Working pressure heating maximum/minimum bar 6,0/1,0 6,0/1,0 6,0/1,0 6,0/1,0 Working temperature maximum C Boiler water content l Minimum water flow l/h Boiler weight (without water content, incl. casing) kg Boiler efficiency at partial load 30% (according to EN 303) (related to net/gross calorific value) % 108,0/97,3 108,0/97,3 108,1/97,4 108,1/97,4 Standard efficiency (according to DIN 4702 part 8) 40/30 C % 109,9/99,0 109,9/99,0 109,9/99,0 109,9/99,0 (related to net/gross calorific value) 75/60 C % 107,4/96,8 107,4/96,8 107,4/96,8 107,4/96,8 Heat loss rate at 70 C Watt Standard emission rate Nitrogen oxides mg/kwh Carbon monoxide mg/kwh Content of CO 2 in the exhaust gas maximum/minimum output % 9,0/8,8 9,0/8,8 9,0/8,8 9,0/8,8 Dimensions see table of dimensions Connections Flow/return DN DN125/PN6 DN125/PN6 DN125/PN6 DN125/PN6 Gas Inches Rp 2" Rp 2" Rp 2» Rp 2" Flue gas Ø inside mm Gas flow pressure minimum/maximum Natural gas E/LL mbar Propane mbar Gas connection value at 0 C/1013 mbar: Natural gas E - (Wo = 15,0 kwh/m 3 ) H u = 9,97 h/m 3 m 3 /h ,7 80,2 94,3 Natural gas LL- (Wo = 12,4 kwh/m 3 ) H u = 8,57 h/m 3 m 3 /h 71,5 79,0 93,6 110,0 Propane 3 (H u = 25,9 kwh/m 3 ) m 3 /h 23,7 26,1 31,0 36,4 Operation voltage V/Hz 230/50 230/50 230/50 1x230/50 3x400/50 Control voltage V/Hz 24/50 24/50 24/50 24/50 Minimum/maximum electrical power consumption Watt 62/ / / /2730 Stand-by Watt IP rating (integral protection) IP Sound power level - Heating noise (EN part 1) (room air dependent) db(a) Exhaust noise is radiated from the mouth (DIN part 47) db(a) Sound pressure level heating noise (depending on installation conditions) 2 db(a) Condensate quantity (natural gas ) at 40/30 C l/h 57,6 63,6 75,4 88,9 ph value of the condensate ca. 4,2 ca. 4,2 ca. 4,2 ca. 4,2 Flue gas system: requirements, values emperature class Flue gas mass flow kg/h Flue gas temperature at nominal output and operation 80/60 C C Flue gas temperature at nominal output and operation 40/30 C C Volume flow rate combustion air Nm 3 /h Feed pressure total at the combustion air/flue gas pipe 3 Pa Maximum draught/depression at flue gas outlet Pa Data related to H u. he boiler series is tested for EE/H-settings. With a factory setting of the Wobbe coefficient of 15.0 kwh/m 3 operation at a Wobbe coefficient of 12.0 up to 15.7 kwh/m 3 is possible without new settings. 2 See also notes at Engineering. 3 Details for multi-boiler plants (cascade) with common flue gas line: see Hoval UltraGas (250D-2000D). Boiler flow resistence see diagrams. 122 Subject to alterations,

124 Hoval UltraGas ( ) echnical data Boiler flow resistance UltraGas (125, 150) UltraGas ( ) Druckverlust mbar [mbar] Druckverlust mbar [mbar] Volumenstrom m 3 /h [m3/h] m 3 /h UltraGas ( ) UltraGas ( ) Druckverlust mbar [mbar] m 3 /h Volumenstrom [m3/h] Druckverlust mbar [mbar] Volumenstrom m 3 /h [m3/h] UltraGas (850, 1000) m 3 /h = hrough put flow rate mbar = Flow resistance 40 mbar m 3 /h Subject to alterations,

125 Hoval UltraGas ( ) Dimensions UltraGas ( ) (Dimensions in mm) Note: Minimal space see separate page 1 Flow heating 2 Low temperature-return 3 Gas connection 4 Safety flow 5 High temperature-return 6 Electrical connection left or right 7 Draining (behind the front casing) 8 Flue gas connector left or right 9 Boiler control 10 Condensate drain with screw including syphon for plastic tube 11 Air inlet connector (option) 12 Boiler foot adjustable up to 80 mm 13 Safety valve connection flow (option) 14 Safety valve connection return (option) 15 Expansion Rp 1" 16 Pressure limiter Rp ¾" 17 Safety temperature control Rp ½" ype A B C D D1 D2 E F G H I J K L M N O Q R (125,150) ( ) (350) ( ) ( ) (850,1000) ype S U V W X Y Z 1,2, (125,150) DN 65 / PN6 / 4 holes Rp 1" R 1 ½" Ø155/159 DN25 Ø122/125 ( ) DN 65 / PN6 / 4 holes Rp 1 ½" R 1 ½" Ø252/256 DN25 Ø197/200 (350) DN 100 / PN6 / 4 holes Rp 1 ½" R 1 ½" Ø302/306 DN25 Ø197/200 ( ) DN 100 / PN6 / 4 holes Rp 2" R 1 ½" Ø302/306 DN25 Ø247/250 ( ) DN 125 / PN6 / 8 holes Rp 2" R 2" Ø302/306 DN40 Ø247/250 (850,1000) DN 125 / PN6 / 8 holes Rp 2" R 2" Ø402/406 DN40 Ø247/ Subject to alterations,

126 Hoval UltraGas ( ) Dimensions Opening dimension UltraGas Boiler without casing and insulation (Dimensions in mm) UltraGas Measurements for installation as individual parts ype A B C D E F G H I J K (125,150) ( ) (350) ( ) ( ) (850,1000) Weights for partial load insertion UltraGas (all measures in kg) UltraGas Weights for partial load insertion ype 1 base 2 heat exchanger 3 burner (125,150) (200) (250) (300) (350) (400) (450) (500) (575) (650) (720) (850) (1000) Required min. width of door and corridor to bring in the boiler he following informations are minimal dimensions K L B < 150 K = = B B K x L x L B = Boiler width L = max. length of boiler = Door width K = Corridor width Calculation example for the necessary corridor width Door width = 1000 UltraGas ( ) K = 970 x 1531 = corridor width Subject to alterations,

127 Hoval UltraGas ( ) Dimensions Space requirements UltraGas ( ) (Dimensions in mm) For swing out of burner this clearance must be ensured Install gas line straight to the back * * UltraGas ype A A minimal B C D H H minimal (125, 150) ( ) ( ) ( ) (850, 1000) If room height is too small: Reduction of measures possible. See A minimal. 2 Attention! With A the burner is no longer swing-out completely! Cleaning makes more difficult! 3 Feet can be shortened, no base cladding possible. For details, see next page. he boiler may be placed against the wall on one side. For the mounting of the casing yet a wall clearance of 100 mm min. must be provided. 126 Subject to alterations,

128 Hoval UltraGas ( ) Dimensions UltraGas with shortened boiler feet (Dimensions in mm) UltraGas ype A Cut off (125, 150) ( ) ( ) ( ) (850, 1000) Neutralisation box 2 Condensate pump 3 Masonry base 4 Feet adjustable up to mm UltraGas with masonry base and adjustable feet UltraGas ype A UltraGas ( ) (125, 150) ( ) ( ) ( ) (850, 1000) UltraGas with masonry base without adjustable feet UltraGas ype A UltraGas ( ) (125, 150) 1721 ( ) 1821 ( ) 1968 ( ) 1994 (850, 1000) 2047 Base plates and feeds will not be refunded! Subject to alterations,

129 Hoval UltraGas ( ) Dimensions Neutralisation unit for Hoval UltraGas ( ) (Dimensions in mm) Neutralisation box ype KB 23 Application Condensate drainage into lower situated drain pipe. With condensate neutralisation. Placed under or adjacent to the boiler Execution Plastic condensate collector box with neutralisation unit 12 kg neutralisation granulate When installing under to boiler: Fit boiler connection line to neutralisation box. On-site If installing adjacent to the boiler, fit connection pipes between the boiler (siphon) and the neutralisation box. Drain pipe from the neutralisation box 1 Condensate inlet from the boiler 2 Outlet R ¾ 3 Condensate box with 12 kg granulate Neutralisation box with pump ype KB 24 Application Condensate drainage into a higher situated drain pipe With condensate pump, delivery hight 3,5 mm With condensate neutralisation, 12 kg granulate Placed under or adjacent to boiler Execution Collector box with delivery pump and neutralisation unit 12 kg neutralisation granulate Pump delivery height max. 3,5 m (2 dm³/min) Silicon hose Ø 9/13 mm, length 4 m Electro cable length 1,5 m with plug for connection to the boiler control panel if the insatllation is located under the boiler Plastic connection pipe Ø 25, boiler (siphon) to neutralisation box if the installation is location under the boiler. On-site Drain pipe if the silicone hose is to short. In the case of installation adjacent to boiler: Connection pipe between boiler (siphon) and the neutralisation box Electical connection between the delivery pump and the electrical control panel if the supply cable is too short. Condensate box with pump ype KB 22 Application Condensate drainage into a higher situated drain pipe With condensate pump, delivery hight 3,5 mm Placed under or adjacent to boiler Execution ype characteristics as KB 24, but without neutralisation granulate 1 Condensate inlet from the boiler 2 Outlet from pump, silicon hose Ø 9/13 mm, length 4 m 3 Condensate box with 12 kg granulate (KB24) 4 Condensate pump 128 Subject to alterations,

130 Hoval UltraGas ( ) Engineering Standards and guidelines he following standards and guidelines must be complied with: Hoval technical information and installation instructions. Hydraulic and technical control regualtions of Hoval. Local building law Fire protection regulations DVGW regulations. DIN EN Safety-relevant requirements. DIN EN Heaters Rules for the calculation of the heat requirements of buildings. VDI 2035 Protection against damage by corrosion and boiler scale formation in heating and service water installations. VDE 0100 Local fire brigade regulations According to local regulations. Water quality Heating water: he European Standard EN and the Directive VDI 2035 must be observed. Hoval boilers and calorifiers are designed for heating plants without significant oxygen intake (plant type I according to EN 14868). Plants with - continuous oxygen intake (e.g. underfloor heating systems without diffusion proof plastic piping) or - intermittent oxygen intake (e.g. where frequent refilling is necessary) must be equipped with separate circuits. reated heating water must be tested at least 1x yearly, according to the inhibitor manufacturer s instructions, more frequent testing may be necessary. A refilling is not necessary if the quality of the heating water in existing installations (e.g. exchange of boiler) conforms to VDI he Directive VDI 2035 applies equally to the replacement water. New and if applicable existing installations must be adequately cleaned and flushed before being recharged! he boiler may only be filled after the heating system has been flushed. Parts of the boiler/the calorifier which have contact with water are made of ferrous materials and stainless steel. On account of the danger of stress cracking corrosion in the parts made of stainless steel the chloride, nitrate and sulfate contents of the heating water must not exceed 50 mg/l in total. he ph value of the heating water should lie between 8,3 and 9,5 after 6-12 weeks of heating operation. Filling and replacement water: For a plant using Hoval boilers untreated drink ing water is generally best suited as filling and replacement water. However, the qual ity of the untreated drinking water must at least fulfil the standard set in VDI 2035 or be desalinated and/or be treated with inhibitors. he stipulations of EN must be observed. In order to maintain a high level of boiler ef ficiency and to avoid overheating of the heating surfaces the values given in the table should not be exceeded (dependent on boiler performance ratings - for multi-boiler plants rating of smallest boiler applies - and on the water content of the plant). he total amount of filling and replacement water which is used throughout the total service life of the boiler must not exceed three times the water capacity of the plant. If frost protection agent is being used, please contact the Hoval company to ask for the separate engineering sheet. Frost protection agent see separate engineering sheet «Use of frost protection agent». Heating installation Installation room Gas boilers cannot be positioned in rooms in which halogen compounds can occur and into which combustion air can enter (e.g. laundrettes, hairdressers). Halogen compounds can be caused by clean ing and degreasing solutions, dissolvents, glue and bleaching lyes. Pay attention to the Procal leaflet, corrosion through Halogen compounds. Combustion air he supply of combustion air must be guaranteed. here must be no possibility to close the air supply opening. For direct combustion air to boiler (LAS-System) mount the connection for direct combustion air inlet. he minimum free cross-section for the combustion air can be assumed simplified as follows: Considering nominal output! Room air-dependent operation: Minimum free cross-section of the opening into the open: 150 cm² or twice 75 cm² and additionally 2cm² necessary for each KW of output over 50 KW for vent into the open. Room air-independent operation with separate combustion air pipe to the boiler: 0.8 cm 2 per 1 KW of output. he pressure loss in the combustion air pipe must be considered for the calculation of the exhaust system. able 1: Maximum filling capacity based on VDI 2035 otal hardness of the filling water up to... [mol/m 3 ] 1 <0,1 0,5 1 1,5 2 2,5 3 >3,0 f H < >30 d H <0,56 2,8 5,6 8,4 11,2 14,0 16,8 >16,8 e H <0,71 3,6 7,1 10,7 14,2 17,8 21,3 >21,3 ~mg/l <10 50,0 100,0 150,0 200,0 250,0 300,0 >300 Conductance 2 <20 100,0 200,0 300,0 400,0 500,0 600,0 >600 boiler size of the individual boiler maximum filling quantity without desalination 50 to 200 kw NO DEMAND 50 l/kw 20 l/kw 20 l/kw 200 to 600 kw 50 l/kw 50 l/kw 20 l/kw always desalinate over 600 kw 1 total of alkaline earths 2 If the conductance in µs/cm exceeds the tabular value an analysis of the water is necessary. Subject to alterations,

131 Hoval UltraGas ( ) Engineering Gas connection Commissioning Start-up is to be carried out only by a specialist of Hoval and the gas supplier. Burner setting values according to the installation instructions. Manual gas shut-off tap and gas filter Immediately in front of the boiler a manual gas shut-off device (tap) must be installed according to relevant regulations. Should the local re gu la tions or conditions demand this, an approved gas filter must be installed in the gas supply pipe bet ween the gas tap (thermally releasing) and the boil er in order to prevent malfunction due to for eign particles being carried along with the gas. ype of gas he boiler is only to be operated with the type of gas stated on the rating plate. A gas pressure controller to reduce the boiler inlet pressure must be installed on-site for propane. Gas pressure natural gas Necessary flow pressure at the boiler inlet: For UltraGas ( ) min. 18 mbar, max. 80 mbar For UltraGas (850,1000) min. 18 mbar, max. 60 mbar Gas pressure propane Necessary flow pressure at the boiler inlet: For UltraGas ( ) min. 37 mbar, max. 57 mbar Space requirements See Dimensions for information Pump after-run time he circulation pump must continue to run for at least 2 minutes each time the burner is switched off (the pump after-run time is included in the boiler control with the opronic regulation). Heating boiler in the attic If the gas boiler is positioned on the top floor, the installation of a low water protection, which automatically turns the gas burner off in case of water shortage, is recommended. Condensate drain he condensate from the exhaust system can be discharged through the boiler. A condensate trap is not needed anymore with the exhaust system. he condensate drainage without neutralisation is allowed, if you are using for the drain only plastic tubes or stoneware (possibly ob tain special exemption from the relevant authority). A siphon must be installed at the condensate outlet on the gas boiler (included in the boiler scope of delivery). he condensate must be openly lead into the canalisation (funnel). Expansion tank An adequately dimensioned expansion tank must be provided. he expansion tank has to be installed in prin ciple at the boiler return, or at the safety flow. At the safety flow a safety valve and an automatic exhauster must be installed. Noise level he acoustic power level value is dependent on the local and spacial circumstances. he acoustic pressure level is dependent on the installation conditions and can for in stance be 5 to 10 db(a) lower than the acous tic power level at a distance of 1m. DIN 4108 must be observed when installing in domestic living areas Recommendation: If the air inlet at the facade is near a noise sensitive place (window of bedroom, terrace etc.), we recommend to use a sound absorber at the direct cumbustion air inlet. Flue gas system Gas boilers must be connected to a flue gas system (chimney or flue gas lines). Flue gas lines must be gastight and leaktight against condensate and over pressure and are to be fitted with a safety temperature limiting device. Allocation of gas filters for UltraGas ype of boiler Gas throughput m 3 /h Gas filter type Dimension Pressure loss gas filter (with clean filter) mbar UltraGas (125) 11, /6B Rp ¾" 1,1 UltraGas (150) 14, /6B Rp ¾" 1,8 UltraGas (200) 18, /6B Rp ¾" 2,2 UltraGas (250) 23, /6B Rp 1" 0,8 UltraGas (300) 28, /6B Rp 1" 1,3 UltraGas (350) 32, /6B Rp 1" 1,4 UltraGas (400) 37, /6B Rp 1" 2,0 UltraGas (450) 42, /6B Rp 1" 2,5 UltraGas (500) 47, /6B Rp 1 ¼" 1,7 UltraGas (575) 54, /6B Rp 1 ¼" 2,2 UltraGas (650) 61, /6B Rp 1 ¼" 2,8 UltraGas (720) 67, /6B Rp 1 ½" 1,5 UltraGas (850) * 80, /6B Rp 1 ½" 2,2 UltraGas (850) * 80, /6B Rp 2" 1,0 UltraGas (1000) * 94, /6B Rp 1 ½" 3,0 UltraGas (1000) * 94, /6B Rp 2" 1,4 he flue gas system must be connected with an angle, so that the resulting condensate of the exhaust system can flow back to the boiler and can be neutralized there before discharging into the canalization. Gas boilers with condensation heat utilisation are to be connected to a flue gas line min. emperature class 120. A flue gas temperature limiter is built in the boiler. * On the UltraGas (850,1000), installation of a gas filter in front of the gas burner is mandatory! 130 Subject to alterations,

132 Hoval UltraGas ( ) Engineering Dimensions flue gas systems Basic rules: Height over sea level max m. he first 2 m of the flue gas pipe system must have the same dimension as the flue gas connection. Connecting pipes Horizontal connecting pipes must be installed with an inclination of at least 50 mm per metre of their length installed in the direction of the boiler to allow free return flow of condensation water towards the boiler. he whole exhaust system must be installed so that condensate can never collect at any point. Combustion air: In the case of room air-independent opera tion (accessories optional) the air pipe should be of the same dimension as the flue gas pipe. If the flue gas pipe diameter is greater than the combustion air connection an individual calculation must be effected. Boiler Flue gas line (smooth walled) Number of bow 90 (flue gas + air supply) yp Flue gas-dim. mm Dimension otal pipe length in m (flue gas + air supply) UltraGas internal DN * (125) (150) (125) (150) (200) (250) (125) (150) (200) (250) (200) (250) (300) (350) (250) (300) (350) (400) (450) (500) (350) (400) (450) (500) (575) (650) (720) (850) (850) (1000) Notice: he data contained in the table «Dimensions flue gas systems» represent guide values. An exact calculation for the flue gas duct must be made on-site. * With 5 bends or more the feed pressure total at the combustion air/flue gas pipe is to be reduced by 30% for the calculation. With total pipe lengths exceeding 50 m, a separate calculation is necessary. Subject to alterations,

133 Hoval UltraGas ( ) Examples UltraGas ( ) Gas boiler with a direct heating circuit from the boiler Hydraulic schematic BCR010 AF opronic B 1 RS- DKP P SLP Dies ist ein unerlaubter Weg! Gehen Sie einen Schritt zurück oder löschen Sie dieses Shape! UltraGas Sie haben die Möglichkeit ein neues Shape zu H nehmen!!! H hovhovalh N hovalhova N alhovalho UltraGas ( ) Gas boiler with water heating, 1 mixed heating circuit from boiler Hydraulic schematic BCR020 AF opronic VF1 B1 RS- WW DHW MK1 SLP P Dies ist ein unerlaubter Weg! Gehen Sie einen Schritt zurück oder löschen Sie dieses Shape! UltraGas Sie haben die Möglichkeit ein neues Shape zu H nehmen!!! H hovhovalh N hovalhova N alhovalho YK1 M S F Dies ist ein unerlaubter Weg! Gehen Sie einen Schritt zurück oder löschen Sie dieses Shape! Sie haben die Möglichkeit ein neues Shape zu nehmen!!! hovhovalhoval hovalhovalhov alhovalhovalho valhovalhovalh ovalhovalhoval hovalhovalhov alhovalhovalho valhovalhovalh ovalhovalhoval hovalhovalhov alhovalhovalho valh CW KW Notice: - his hydraulic schematic is a principle schematic. It does not contain all details for installation. he installation must be done according to local conditions, di mensioning and regulations - For underfloor heating, a flow temperature monitor must be built-in. - Shut-off devices to the safety valve (pressurized expansion tank, safety valve, etc.) are to safe against unintended closing! - Anti thermal siphon dip has to be installed. RS- Room station AF Outdoor sensor 1 VF1 Flow sensor 1 SF Calorifier heater sensor B1 Flow temperature guard (if required) MK1 Pump mixing circuit 1 DKP Pump for heating circuit without mixing operation SLP Calorifier loading pump YK1 Actuator mixer 1 H High temperature N Low temperature CW Cold Water DHW Domestic Hot Water 132 Subject to alterations,

134 Hoval UltraGas ( ) Examples UltraGas ( ) Gas boiler with Water heating heating supply from boiler, a direct heating circuit from wall distributors 1-2 mixed heating circuits from wall distributors Hydraulic schematic BCR030 AF 1 opronic RS- VF1 B1 VF2 B1 WW DHW DKP MK1 MK2 SLP P Dies ist ein unerlaubter Weg! Gehen Sie einen Schritt zurück oder löschen Sie dieses Shape! UltraGas Sie haben die Möglichkeit ein neues Shape zu H nehmen!!! H hovhovalh N hovalhova N alhovalho YK1 M YK2 M SF Dies ist ein unerlaubter Weg! Gehen Sie einen Schritt zurück oder löschen Sie dieses Shape! Sie haben die Möglichkeit ein neues Shape zu nehmen!!! hovhovalhoval hovalhovalhov alhovalhovalho valhovalhovalh ovalhovalhoval hovalhovalhov alhovalhovalho valhovalhovalh ovalhovalhoval hovalhovalhov alhovalhovalho valh CW KW UltraGas ( ) Gas boiler with Free standing-calorifier heating supply from boiler, Wall distributors with return flow separation, 1 mixed heating circuit and water heating to the high temperature return 1 mixed heating circuit and water heating to the low temperature return Hydraulic schematic BCR050 DHW CW Notice: - his hydraulic schematic is a principle schematic. It does not contain all details for installation. he installation must be done according to local conditions, di mensioning and regulations - For underfloor heating, a flow temperature monitor must be built-in. - Shut-off devices to the safety valve (pressurized expansion tank, safety valve, etc.) are to safe against unintended closing! - Anti thermal siphon dip has to be installed. RS- Room station AF Outdoor sensor VF1 Flow sensor 1 VF2 Flow sensor 2 SF Calorifier heater sensor B1 Flow temperature guard (if required) MK1 Pump mixing circuit 1 MK2 Pump mixing circuit 2 SLP Calorifier loading pump DKP Pump for heating circuit without mixing operation YK1 Actuator mixer 1 YK2 Actuator mixer 2 H N High temperature Low temperature CW Cold Water DHW Domestic Hot Water Subject to alterations,

135 134

136 Hoval UltraGas (250D-2000D) Floor standing gas condensing boiler Description Hoval UltraGas (250D-2000D) Floor standing gas condensing boiler With condensing boiler technology Double boiler made of steel, consisting of 2 indivdual boilers à 125, 150, 200, 250, 300, 350, 400, 450, 575, 650, 720, 850 or 1000 kw hermal insulation with mineral wool combustion chamber made of stainless steel Maximal flue gas condensation through tube heat exchanger alufer stainless steel; flue gas side: aluminium water side: stainless steel Water pressure sensor (minimal and maximal limiter integrated) Flue gas temperature sensor with flue gas limiter function Pre-mix burner with fan and venturi Automatic ignition Ionisation guard Gas boiler fully cased with steel plates, red powder-coated. Flue gas over pressure set consisting of motorised air intake suction flap (connection for direct combustion air supply without accessories possible) and flue gas collector. Heating connections backwards incl. counter flanges, screws and seals Flow Return - High temperature Return - Low temperature Basic boiler control panel opronic /U4.1 (UltraGas (250D-700D) opronic /U4.4 (UltraGas (800D-1700D)) or opronic /U4.3 (UltraGas (2000D)) Gas firing sequence controller with monitoring unit BIC960 Modulating burner control Main switch «I/0» Boiler sensor Ionisation guard Gas valve Connection for external gas valve and fault indication Regulation function per boiler integrated for: 1 mixer circuit 1 heating circuit without mixing operation domestic hot water loading circuit Function extension possibility via different key modules and/or Installation of a supplementary heating regulator opronic /N (see accessoires) Main switch I/O Safety temperature limiter110 C Fuse 6,3 A rouble indication «Burner» Running time meter and count-up Boiler sensor Large LCD-Display Rotary pushbutton Model range Output range UltraGas at 40/30 C ype kw (250D) (300D) (400D) (500D) (600D) (700D) (800D) (900D) (1000D) (1150D) (1300D) (1440D) (1700D) (2000D) Button for daytime room temperature night room temperature hot water temperature operating mode selection (holiday, absent, heating operation prolongation, automatic, summer, continuous - reduced - frost protection) adjusting the heating curves system information emission measurement and manual ope ration Outdoor sensor AF 200 Flow sensor with plug Calorifier heater sensor with plug Connection available for room station Recommendation: If execution of a common flue gas line with over pressure the delivered flue gas over pressure set must be compellingly mounted. Set consists of a flue gas collector and moto rised air intake suction flaps for back flow protection. Permissions boilers ype (250D-2000D) CE-Produkt-ID-Nr: CE-0085AQ0620 Optional For propane Neutralisation unit Free-standing calorifier CombiVal Additional control for more heating circuits Hydraulic connection Delivery Boiler, casing and flue gas over pressure set separately packed and delivered On-site Mounting of boiler foot Mounting of insulation, casing and control panel Mounting of the connection for combustion air connection and flue gas collector (flue gas over pressure set) Bus cable for connecting the two boiler controls of the double boiler on-site (not included in scope of supply). Subject to alterations,

137 Hoval UltraGas (250D-2000D) Part N Floor standing gas condensing boiler Hoval UltraGas Part N Double boiler made of steel, consisting of 2 indivdual boilers à 125, 150, 200, 250, 300, 350, 400, 450, 500, 575, 650, 720, 850 or 1000 kw. hermal insulation with mineral wool. Combus tion and flue gas chambers made of stainless steel. ube heat exchanger alufer. With basic boiler control panel opronic /U4.1 (UltraGas (250D-700D)) opronic /U4.4 (UltraGas ( D)) opronic /U4.3 (UltraGas (2000D)) Delivery 2 boilers, casing with insulation, 2 control panels, combustion air connection and flue gas col lector separately packed and delivered. UltraGas Output range operating at 40/30 C pressure ype kw 1 bar (250D) (300D) (400D) (500D) (600D) (700D) (800D) (900D) (1000D) (1150D) (1300D) (1440D) (1700D) (2000D) Gas filter with measurement nozzle before and behind the filter inset (diameter: 9 mm) Pore width of the filter inset < 50 mm Max. pressure difference 10 mbar Max. inlet pressure 100 mbar ype Connection 70612/6B Rp ¾" 70602/6B Rp 1" 70604/6B Rp 1 ¼" 70603/6B Rp 1 ½" 70631/6B Rp 2" Valve testing system for UltraGas ( ), UltraGas (250D-2000D) Automatic, compact testing system for testing the leakage of the gas valve before each burner start with ready-to-connect wiring. Suitable for all gas qualities for which the UltraGas is permitted. UltraGas (250D-700D) UltraGas (800D-1440D) UltraGas (1700D-2000D) For an UltraGas double boiler, two valve testing systems must be ordered. 136 Subject to alterations,

138 Hoval UltraGas (250D-2000D) Part N Accessories Assembly set for multi-part delivery Boiler and flue gas collector are screwed only, not sealed, in order to enable the boiler to be placed in two sections. Consisting of instruction and special silicone. Part N Delivery time approx. 6 weeks Modification set for propane for UltraGas ( ) UltraGas (800D-1000D) Output range see technical data Modification set for propane for UltraGas ( ) UltraGas (1150D-1440D) Output range see technical data No conversion kit is required for boiler types UltraGas (250D-700D) and (1700D-2000D). Conversion must be performed in accordance with the instructions included with the delivery. Additional heating regulator set ZN1 for extending functionality and implementing further heating circuits Consisting of: Heating regulator opronic /N for - 1 mixer circuit - 1 heating circuit without mixer - hot water loading Only one key module per regulator is possible! Flow sensor VF202K with 2 m cable and plug. Cable set for connecting the auxiliary heating regulator opronic /N with the boiler controller. Mounting on-site ,51 Set BMS-module 0-10V Communication modules/remote connection see Controls Subject to alterations,

139 M M M M Hoval UltraGas (250D-2000D) Part N Accessoires for heating reglator system Hoval opronic Part N 1-7 Key-Module for Hoval opronic for further functions additionally to standard functions. Key-Modul consists of: Function key for plugging into opronic opronic incl. accessories Only one Key-Module possible! Standard functions already included in opronic. - 1 mixer circuit - 1 heating circuit without mixing operation - domestic hot water loading circuit Functions of key modules solid fuel- Key- 2. mixing storage tank- Module circuit Bivalent Solar M 1 Key-Module 1 for 2. mixing circuit Function key 1, 1 flow sensor, 2 loose plugs Key-Module 2 for solid fuel/ storage tank/ bivalent installation Function key 2, 3 immersion sensors, 4 loose plugs Key-Modul 3 for solar plants Function key 3, 1 collector sensor, 1 calorifier sensor, 4 loose plugs M 4 Key-Module 4 for 2. mixing circuit and solid fuel/ storage tank/ bivalent installation Function key 4, 1 flow sensor, 3 immersion sensors, 6 loose plugs M 5 Key-Module 5 for 2. mixing circuit and solar plants Function key 5, 1 flow sensor, 1 collector sensor, 1 calorifier sensor, 6 loose plugs Key-Module 6 for solid fuel/ storage tank/ bivalent installation and solar plants Function key 6, 1 collector sensor, 4 immersion sensors, 6 loose plugs M System approaches and applications see Hoval CD 7 Key-Module 7 for 2. mixing circuit, solid fuel/ storage tank/ bivalent installation and solar plants Function key 7, 1 flow sensor, 1 collector sensor, 4 immersion sensors, 8 loose plugs Sensor type Immersion/calorifier sensor: ype KV20/5/6 (L = 5 m) without immersion sleeve flow sensor: ype VF204S with plug collector sensor: ype P1000 (silicone) Subject to alterations,

140 Hoval UltraGas (250D-2000D) Part N Part N Room station RS- for opronic effective on one mixing circuit Remote control RFF- for opronic effective on one mixing circuit Outdoor sensor AF 200 (may be included in the heat generator scope of delivery) for one mixing circuit or for the mean value (per regulator 2 outdoor temperature sensors possible) Cable sensor KV 20/5/6S 5 m cable and plug Contact sensor VF204S can be used as flow or return flow sensor with 4 m cable and plug Flow temperature guard for underfloor heating system (1 guard per heating circuit) C, differential gap 6K, capillary tube max. 700 mm setting (visible from the outside) under the housing cover Clamp-on thermostat RAK-W1000.S hermostat with strap, without cable and plug Kit clamp-on thermostat RAK-W1000.S hermostat with strap, enclosed cable (4 m) and plug Immersion thermostat RAK-W1000.S SB 150 hermostat with pocket ½" - depth of immersion 150 mm, brass nickel-plated Safety set Complete with safety valve (3 bar), Pressure gauge and autom. aspirator with shut-off valve. Connection inner thread For UltraGas ( ) DN 25-Rp 1" to 200 kw For UltraGas ( ) DN32-Rp 1¼" to 350 kw Subject to alterations,

141 Hoval UltraGas (250D-2000D) Part N Condensate drainage to UltraGas (250D-2000D) Part N Placed under the boiler Condensate box KB 22 for UltraGas ( ), (250D-2000D), UltraOil (65-300), (320D-600D) For condensate drainage into higher situated drain pipe with delivery pump. Max. delivery height 3.5 m, from 1200 kw two delivery pumps necessary. Delivery rate 120 l/h incl. liquid level switch, silicone hose 9/13 mm, 4 m long, electrical cable 1.5 m with plug Neutralisation box KB 23 for UltraGas ( ), (250D-2000D), UltraOil (65-300), (320D-600D) Condensate drainage into lower situated drain pipe without condensate delivery pump with neutralisation 12 kg neutralisation granulate Placed under the boiler Use one box for each boiler Neutralisation box KB 24 for UltraGas ( ), (250D-2000D), UltraOil (65-300), (320D-600D) for transporting condensation water into a higher lying drainage duct, max. delivery height 3.5 m, from 1200 kw two delivery pumps necessary. Delivery rate 120 l/h incl. liquid level switch, silicone hose 9/13 mm, 4 m long, electrical cable 1.5 m with plug 12 kg granulate Condensate pump for transporting condensation water into a higher drainage duct. Including connection line, completely wired, cable and plug for connection to the boiler controller max. transport height: 3.5 m Delivery rate up to 120 l/h combinable with neutralisation box can be mounted in boiler socket Subject to alterations,

142 Hoval UltraGas (250D-2000D) Part N Accessories Part N Connection for a direct combustion air supply In combination with the motor-driven air intake dampers included in the scope of delivery of the double boiler system. Pro installation two pieces must be ordered. UltraGas (250D, 300D) UltraGas (400D-600D) UltraGas (700D) UltraGas (800D-1000D) UltraGas (1150D-1440D) UltraGas (1700D, 2000D) Pipe connection double boiler Flow/ Return PN6 Flow/Return PN6 Pipe connection set for double boiler including motorised air shut off valve. for UltraGas (250D-600D) for UltraGas (700D-1000D) for UltraGas (1150D-1440D) for UltraGas (1700D,2000D) Hydraulic shut off gate PN 16 to be installed directly on flow and or return. As option when no flow/return set has been ordered. Complete with plugs and cabling. wo pieces required per double boiler! Suitable for high pressure version (8bar)! UltraGas (250D-600D) 1 piece DN UltraGas (700D-1000D) 1 piece DN UltraGas (1150D-2000D) 1 piece DN High temperature-return High temperature-return Pipe connection set for double boiler (e.g. for return calorifier charge) for UltraGas (250D-600D) for UltraGas (700D-1000D) for UltraGas (1150D-1440D) for UltraGas (1700D, 2000D) Subject to alterations,

143 Hoval UltraGas (250D-2000D) Part N Part N Assembly tube flow Assembly tube return Assembly tube for flow and return for assembly on flow resp. high and low temperature return of the Hoval UltraGas boiler. For connection of - an additional safety temperature limiter and a pressure limiter on the flow and - an expansion tank on the return Dimension Suitable to UltraGas Connection DN 65* (250D-600D) flow DN 65* (250D-600D) return DN 100* (700D-1000D) flow DN 100* (700D-1000D) return DN 125* (1250D-2000D) flow DN 125* (1250D-2000D) return * 2 pieces are necessary Further information see Dimensions Hoval UltraGas ( ) Maximum pressure limiter set suitable for assembly tube For boiler nominal output > 300 kw to meet the safety requirements of EN Consisting of: adjustable maximum pressure limiter safety temperature limiter RAK-S.131 and cock Attention Valid for UltraGas double boiler from type 700D; 2 pieces needed Services Commissioning Commissioning must be made by works service or Hoval trained authorized serviceman/ company is condition for warranty. For commissioning and other services please contact your Hoval sales office. 142 Subject to alterations,

144 Hoval UltraGas (250D-2000D) echnical data UltraGas (250D-700D) ype (250D) (300D) (400D) (500D) (600D) (700D) Nominal output 80/60 C with natural gas 1 kw Nominal output 40/30 C with natural gas 1 kw Nominal output 80/60 C with propane 3 kw Nominal output 40/30 C with propane 3 kw Nominal load with natural gas 1 kw Nominal load with propane 3 kw Working pressure heating maximum/minimum bar 5,0/1,0 5,0/1,0 5,0/1,0 5,0/1,0 5,0/1,0 6,0/1,0 Working temperature maximum C Boiler water content l Minimum water flow l/h Boiler weight (without water content, incl. casing) kg Boiler efficiency at partial load 30% (according to EN 303) (related to net/gross calorific value) % 108,1/97,4 108,0/97,3 108,1/97,4 108,1/97,4 108,0/97,3 108,0/97,3 Standard efficiency (according to DIN 4702 part 8) 40/30 C % 109,6/98,7 109,6/98,7 109,7/98,8 109,7/98,8 109,7/98,8 109,8/98,9 (related to net/gross calorific value) 75/60 C % 107,1/96,5 107,1/96,5 107,2/96,6 107,2/96,6 107,2/96,6 107,3/96,7 Stand-by loss at 70 C Watt Standard emission rate Nitrogen oxides mg/kwh Carbon monoxide mg/kwh Content of CO 2 in the exhaust gas maximum/minimum output % 9,0/8,8 9,0/8,8 9,0/8,8 9,0/8,8 9,0/8,8 9,0/8,8 Dimensions See table of dimensions Connections DN80/ DN80/ DN80/ DN80/ DN80/ DN125/ Flow/return DN PN6 PN6 PN6 PN6 PN6 PN6 Gas Inches 1 1 1½ 1½ 1½ 1½ Flue gas Ø inside mm Gas flow pressure minimum/maximum Natural gas E/LL mbar Propane mbar Gas connection value at 0 C/1013 mbar: Natural gas E - (Wo = 15,0 kwh/m 3 ) H u = 9,97 kwh/m 3 m 3 /h 23,1 28,2 37,6 47,0 56,6 65,2 Natural gas LL- (Wo = 12,4 kwh/m 3 ) H u = 8,57 kwh/m 3 m 3 /h 27,0 32,9 43,9 54, ,1 Propane (H u = 32,7 kwh/m 3 ) m 3 /h 8,9 10,9 14,5 18,1 21,9 25,2 Operation voltage V/Hz 230/50 230/50 230/50 230/50 230/50 230/50 Control voltage V/Hz 24/50 24/50 24/50 24/50 24/50 24/50 Minimum/maximum electrical power consumption Watt 44/336 44/494 44/286 44/448 46/690 49/660 Stand-by Watt IP rating (integral protection) IP Sound power level - Heating noise (EN part 1) (room air dependent) db(a) Exhaust noise is radiated from the mouth (DIN part 47) db(a) (room air dependent/room air independent Sound pressure level heating noise (depending on installation conditions) 2 db(a) Condensate quantity (natural gas ) at 40/30 C l/h 21,7 26,5 35,3 44,2 53,2 61,3 ph value of the condensate ph ca. 4,2 ca. 4,2 ca. 4,2 ca. 4,2 ca. 4,2 ca. 4,2 Flue gas system: requirements, values emperature class Flue gas mass flow kg/h Flue gas temperature at nominal output and operation 80/60 C C Flue gas temperature at nominal output and operation 40/30 C C Volume flow rate combustion air Nm 3 /h Feed pressure total at the combustion air/flue gas pipe Pa Maximum draught/ depression at flue gas outlet Pa Data related to H u. he boiler series is tested for EE/H-settings. With a factory setting of the Wobbe coefficient of 15.0 kwh/m 3 operation at a Wobbe coefficient of 12,0 up to 15,7 kwh/m 3 is possible without new settings. 2 See also notes at Engineering. 3 Data related to H u. UltraGas (250D-700D) can also be operated with propane. Boiler flow resistence see diagrams. Subject to alterations,

145 Hoval UltraGas (250D-2000D) echnical data UltraGas (800D-1300D) ype (800D) (900D) (1000D) (1150D) (1300D) Nominal output 80/60 C with natural gas 1 kw Nominal output 40/30 C with natural gas 1 kw Nominal output 80/60 C with propane 3 kw Nominal output 40/30 C with propane 3 kw Nominal load with natural gas 1 kw Nominal load with propane 3 kw Working pressure heating maximum/minimum bar 6,0/ 1,0 6,0/ 1,0 6,0/ 1,0 6,0/ 1,0 6,0/ 1,0 Working temperature maximum C Boiler water content l Minimum water flow l/h Boiler weight (without water content, incl. casing) kg Boiler efficiency at partial load 30% (according to EN 303) (related to net/gross calorific value) % 108,1/97,4 108,0/97,3 108,0/97,3 108,1/97,4 108,0/97,3 Standard efficiency (according to DIN 4702 part 8) 40/30 C % 109,8/98,9 109,8/98,9 109,8/98,9 109,9/99,0 109,9/99,0 (related to net/gross calorific value) 75/60 C % 107,3/96,7 107,3/96,7 107,3/96,7 107,4/96,8 107,4/96,8 Stand-by loss at 70 C Watt Standard emission rate Nitrogen oxides mg/kwh Carbon monoxide mg/kwh Content of CO 2 in the exhaust gas maximum/minimum output % 9,0/8,8 9,0/8,8 9,0/8,8 9,0/8,8 9,0/8,8 Dimensions See table of dimensions Connections Flow/return DN DN125/ PN6 DN125/ PN6 DN125/ PN6 DN150/ PN6 DN150/ PN6 Gas Inches Flue gas Ø inside mm Gas flow pressure minimum/maximum Natural gas E/LL mbar Propane mbar Gas connection value at 0 C/1013 mbar: Natural gas E - (Wo = 15,0 kwh/m 3 ) H u = 9,97 kwh/m 3 m 3 /h 75,4 84,9 94,3 108,5 122,7 Natural gas LL- (Wo = 12,4 kwh/m 3 ) H u = 8,57 kwh/m 3 m 3 /h 88 98,9 109,9 126,5 143,1 Propane (H u = 32,7 kwh/m 3 ) m 3 /h 29,1 32,7 36,4 41,9 47,3 Operation voltage V/Hz 230/50 230/50 230/50 230/50 230/50 Control voltage V/Hz 24/50 24/50 24/50 24/50 24/50 Minimum/maximum electrical power consumption Watt 60/890 60/ / / /2060 Stand-by Watt IP rating (integral protection) IP Sound power level - Heating noise (EN part 1) (room air dependent) db(a) Exhaust noise is radiated from the mouth (DIN part 47) db(a) Sound pressure level heating noise (depending on installation conditions) 2 db(a) Condensate quantity (natural gas ) at 40/30 C l/h 70,9 79,7 88,5 101,9 115,2 ph value of the condensate ph ca. 4,2 ca. 4,2 ca. 4,2 ca. 4,2 ca. 4,2 Flue gas system: requirements, values emperature class Flue gas mass flow kg/h Flue gas temperature at nominal output and operation 80/60 C C Flue gas temperature at nominal output and operation 40/30 C C Volume flow rate combustion air Nm 3 /h Feed pressure total at the combustion air/flue gas pipe Pa Maximum draught/depression at flue gas outlet Pa Data related to H u. he boiler series is tested for EE/H-settings. With a factory setting of the Wobbe coefficient of 15.0 kwh/m 3 operation at a Wobbe coefficient of 12,0 up to 15,7 kwh/m 3 is possible without new settings. 2 See also notes at Engineering. 3 Data related to H u. UltraGas (250D-700D) can also be operated with propane. Boiler flow resistence see diagrams. 144 Subject to alterations,

146 Hoval UltraGas (250D-2000D) echnical data UltraGas (1440D-2000D) ype (1440D) (1700D) (2000D) Nominal output 80/60 C with natural gas 1 kw Nominal output 40/30 C with natural gas 1 kw Nominal output 80/60 C with propane 3 kw Nominal output 40/30 C with propane 3 kw Nominal load with natural gas 1 kw Nominal load with propane 3 kw Working pressure heating maximum/minimum bar 6,0/1,0 6,0/1,0 6,0/1,0 Working temperature maximum C Boiler water content l Minimum water flow l/h Boiler weight (without water content, incl. casing) kg Boiler efficiency at partial load 30% (according to EN 303) (related to net/gross calorific value) % 108,0/97,3 108,1/97,4 108,1/97,4 Standard efficiency (according to DIN 4702 part 8) 40/30 C % 109,9/99,0 109,9/99,0 109,9/99,0 (related to net/gross calorific value) 75/60 C % 107,4/96,8 107,4/96,8 107,4/96,8 Stand-by loss at 70 C Watt Standard emission rate Nitrogen oxides mg/kwh Carbon monoxide mg/kwh Content of CO 2 in the exhaust gas maximum/minimum output % 9,0/8,8 9,0/8,8 9,0/8,8 Dimensions See table of dimensions Connections Flow/return DN DN150/PN6 DN150/PN6 DN150/PN6 Gas Inches 2 2 2" Flue gas Ø inside mm Gas flow pressure minimum/maximum Natural gas E/LL mbar Propane mbar Gas connection value at 0 C/1013 mbar: Natural gas E - (Wo = 15,0 kwh/m 3 ) H u = 9,97 kwh/m 3 m 3 /h 135,5 160,5 188,6 Natural gas LL- (Wo = 12,4 kwh/m 3 ) H u = 8,57 kwh/m 3 m 3 /h 158,0 187,2 220,0 Propane (H u = 32,7 kwh/m 3 ) m 3 /h 52,3 62,0 72,8 Operation voltage 1x 230/50 V/Hz 230/50 230/50 3x400/50 Control voltage V/Hz 24/50 24/50 24/50 Minimum/maximum electrical power consumption Watt 65/ / /5460 Stand-by Watt IP rating (integral protection) IP Sound power level - Heating noise (EN part 1) (room air dependent) db(a) Exhaust noise is radiated from the mouth (DIN part 47) db(a) Sound pressure level heating noise (depending on installation conditions) 2 db(a) Condensate quantity (natural gas) at 40/30 C l/h 127,3 150,8 177,8 ph value of the condensate ph ca. 4,2 ca. 4,2 ca. 4,2 Flue gas system: requirements, values emperature class Volume flow rate combustion air Nm 3 /h Flue gas mass flow kg/h Flue gas temperature at nominal output and operation 80/60 C C Flue gas temperature at nominal output and operation 40/30 C C Feed pressure total at the combustion air/flue gas pipe Pa Maximum draught/ depression at flue gas outlet Pa Data related to H u. he boiler series is tested for EE/H-settings. With a factory setting of the Wobbe coefficient of 15.0 kwh/m 3 operation at a Wobbe coefficient of 12,0 up to 15,7 kwh/m 3 is possible without new settings. 2 See also notes at Engineering. 3 Data related to Hu. UltraGas (250D-700D) can also be operated with propane. Boiler flow resistence see diagrams. Subject to alterations,

147 Hoval UltraGas (250D-2000D) echnical data Boiler flow resistence UltraGas (250D,300D) [mbar] one boiler flowing both boiler flowing [m 3 /h] UltraGas (400D-600D) [mbar] one boiler flowing [m 3 /h] both boiler flowing UltraGas (700D-1000D) UltraGas (1150D-1440D) [mbar] [mbar] Druckverlust [mbar] one boiler flowing both boiler flowing one boiler flowing both boiler flowing Volumenstrom [m 3 /h] [m3/h] [m 3 /h] UltraGas (2000D) [mbar] m 3 /h = hrough put flow rate mbar = Flow resistance 60 one boiler flowing both boiler flowing [m 3 /h] 146 Subject to alterations,

148 Hoval UltraGas (250D-2000D) Dimensions UltraGas (250D-2000D) (Dimensions in mm) UltraGas ype A B C C1 D E F G H I J K L M N O P Q (250D, 300D) (400D-600D) (700D) (800D-1000D) (1150D-1440D) (1700D, 2000D) UltraGas ype (250D,300D) (400D-600D) (700D) (800D-1000D) (1150D-1440D) (1700D,2000D) 1 Flow heating... DN65/PN6/4S* DN65/PN6/4S* DN100/PN6/4S* DN100/PN6/4S* DN125/PN6/8S* DN125/PN6/8S* 1a Flow pipe connection (option) 1... DN80/PN6/4S* DN80/PN6/4S* DN125/PN6/8S* DN125/PN6/8S* DN150/PN6/8S* DN150/PN6/8S* 2 Low temperature-return... DN65/PN6/4S* DN65/PN6/4S* DN100/PN6/4S* DN100/PN6/4S* DN125/PN6/8S* DN125/PN6/8S* 2a Return pipe connection (option) 1... DN80/PN6/4S* DN80/PN6/4S* DN125/PN6/8S* DN125/PN6/8S* DN150/PN6/8S* DN150/PN6/8S* 3 Gas connection... Rp 1" Rp 1½" Rp 1½" Rp 2" Rp 2" Rp 2 4 Safety flow and flow calorifier... R 1½" R 1½" R 1½" R 1½" R 2" R 2 5 High temperature-return... DN65/PN6/4S* DN65/PN6/4S* DN100/PN6/4S* DN100/PN6/4S* DN100/PN6/8S* DN125/PN6/8S* 5a High temperature-return Pipe connection (option) Motorised air shut off valve... DN80/PN6/4S* DN80/PN6/4S* DN125/PN6/8S* DN125/PN6/8S* DN150/PN6/8S* DN150/PN6/8S* 7 Induction combustion air... Ø104/110 Ø104/110 Ø104/110 Ø180/182 Ø180/182 Ø180/182 8 Flue gas outlet connection left or right possible... 9 Flue gas collector Condensate drain with screw including syphon for plastic tube Boiler foot adjustable up to mm... Ø254/256 Ø306/308 Ø356/358 Ø356/358 Ø356/358 Ø504/506 DN25 DN25 DN25 DN25 DN40 DN40 1 Data for pipe connection (option) to Hoval UltraGas (250D-2000D) * DN = nominal diameter, PN = nominal pressure, S = number of screw, example DN80/PN6/4S Notes Detailed measurements see UltraGas ( ) Minimal space - see separate page Subject to alterations,

149 Hoval UltraGas (250D-2000D) Dimensions Minimal spaces UltraGas (250D-2000D) (Dimensions in mm) For swing out of burner this clearance must be ensured Install gas line straight to the back * * with hydraulic connection set UltraGas ype A A minimal B C D H H minimal (250D, 300D) (400D-600D) (700D-1000D) (1150D-1440D) (1700D, 2000D) If room height is too small: Reduction of measures possible. See A minimal. 2 Attention! With A the burner is no longer swing-out completely! Cleaning makes more difficult! 3 Feet can be shortened, no base cladding possible. For details, see next page. he boiler may be placed against the wall on one side. For the mounting of the casing yet a wall clearance of 100 mm min. must be provided. 148 Subject to alterations,

150 Hoval UltraGas (250D-2000D) Dimensions UltraGas with shortened boiler feet (Dimensions in mm) UltraGas ype A Cut off (250D, 300D) (400D - 600D) (700D D) (1150D D) (1700D, 2000D) Neutralisation box 2 Condensate pump 3 Masonry base 4 Feet adjustable up to mm UltraGas with masonry base and adjustable feet UltraGas (1150D-2000D) UltraGas ype (250D, 300D) (400D - 600D) (700D D) (1150D D) (1700D, 2000D) A UltraGas with masonry base without adjustable feet UltraGas (1150D-2000D) UltraGas ype A (250D, 300D) 1721 (400D - 600D) 1821 (700D D) 1968 (1150D D) 1994 (1700D, 2000D) 2047 Base plates and feeds will not be refunded! Subject to alterations,

151 Hoval UltraGas (250D-2000D) Dimensions Neutralisation unit for UltraGas (250D-1440D) (Dimensions in mm) Neutralisation box ype KB 23 Application Condensate drainage into lower situated drain pipe. With condensate neutralisation. Placed under or adjacent to the boiler Version Plastic condensate collector tank with neutralisation unit 12 kg neutralisation granulate When installing under to boiler: Fit boiler connection line to neutralisation box. On-site: If installing adjacent to the boiler, fit connection pipes between the boiler (siphon) and the neutralisation box. Drain line from the neutralisation box 1 Condensate inlet from the boiler 2 Outlet R ¾ 3 Condensate box with 12 kg granulate Neutralisationsbox with pump ype KB 24 Application Condensate drainage into a higher situated drain pipe With condensate pump, delivery height 3,5 mm With condensate neutralisation, 12 kg granulate Installation under or adjacent to boiler Execution Collector tank with delivery pump and neutralisation unit 12 kg neutralisation-granulate Pump delivery height max. 3,5 m (2 dm³/min) at boiler performance above 1200 kw two neutralisation boxes/pumps are necessary Silicon hose Ø 9/13 mm, length 4 m Electro cable length 1,5 m with plug for connection to the boiler control panel if the insatllation is located under the boiler Plastic connection pipe Ø 25, boiler (siphon) to neutralisation box if the installation location is under the boiler. On-site Drain pipe if the silicone hose is to short. In the case of installation adjacent to boiler: Connection pipe between boiler (siphon) and the neutralisation box Electical connection between the delivery pump and the electrical control panel if the supply cable is too short. Condensat box with pump ype KB 22 Execution: Condensate drainage into a higher situated drain pipe With condensate pump, delivery hight 3,5 mm Installation under or adjacent to boiler 1 Condensate inlet from the boiler 2 Outlet from pump, silicon hose Ø 9/13 mm, length 4 m 3 Condensate tank with 12 kg granulate (KB24) 4 Condensate pump Execution ype characteristics as KB 24, but without neutralisation granulate. 150 Subject to alterations,

152 Hoval UltraGas (250D-2000D) Engineering Standards and guidelines he following standards and guidelines must be complied with: Hoval technical information and installation instructions. Hydraulic and technical control regualtions of Hoval. Local building law Fire protection regulations DVGW regulations. EN Heating systems in buildings. DIN EN Heaters Rules for the calculation of the heat requirements of buildings. VDI 2035 Protection against damage by corrosion and boiler scale formation in heating and service water installations. VDE 0100 Local fire brigade regulations According to local regulations. Water quality Heating water: he European Standard EN and the Directive VDI 2035 must be observed. Hoval boilers and calorifiers are designed for heating plants without significant oxygen intake (plant type I according to EN 14868). Plants with continuous oxygen intake (e.g. underfloor heating systems without diffusion proof plastic piping) or intermittent oxygen intake (e.g. where fre quent refilling is necessary) must be equipped with separate circuits. able 1: Maximum filling capacity based on VDI 2035 reated heating water must be tested at least 1x yearly, according to the inhibitor ma nu facturer s instructions, more frequent test ing may be necessary. A refilling is not necessary if the quality of the heating water in existing installations (e.g. exchange of boiler) conforms to VDI he Directive VDI 2035 applies equally to the replacement water. New and if applicable existing installations must be adequately cleaned and flushed be fore being recharged! he boiler may only be filled after the heating system has been flushed. Parts of the boiler/ the calorifier which have contact with water are made of ferrous materials and stainless steel. On account of the danger of stress cracking corrosion in the parts made of stainless steel the chloride, nitrate and sulfatge contents of the heating water must not exceed 50 mg/l in total. he ph value of the heating water should lie between 8,3 and 9,5 after 6-12 weeks of heating operation. Filling and replacement water: For a plant using Hoval boilers untreated drink ing water is generally best suited as filling and replacement water. However, the qual ity of the untreated drinking water must at least fulfil the standard set in VDI 2035 or be desalinated and/or be treated with inhibi tors. he stipulations of EN must be observed. In order to maintain a high level of boiler ef ficiency and to avoid overheating of the heat ing surfaces the values given in the ta ble should not be exceeded (dependent on boil er performance ratings - for multi-boiler plants rating of smallest boiler applies - and on the water content of the plant). otal hardness of the filling water up to... [mol/m 3 ] 1 <0,1 0,5 1 1,5 2 2,5 3 >3,0 f H < >30 d H <0,56 2,8 5,6 8,4 11,2 14,0 16,8 >16,8 e H <0,71 3,6 7,1 10,7 14,2 17,8 21,3 >21,3 ~mg/l <10 50,0 100,0 150,0 200,0 250,0 300,0 >300 Conductance 2 <20 100,0 200,0 300,0 400,0 500,0 600,0 >600 boiler size of the individual boiler maximum filling quantity without desalination 200 to 600 kw NO 50 l/kw 50 l/kw 20 l/kw always desalinate over 600 kw DEMAND he total amount of filling and replacement water which is used throughout the total service life of the boiler must not exceed three times the water capacity of the plant. If frost protection agent is being used, please contact the Hoval company to ask for the separate engineering sheet. Frost protection agent see separate engineering sheet «Use of frost protection agent». Heating installation Installation room Gas boilers cannot be positioned in rooms in which halogen compounds can occur and in to which combustion air can enter (e.g. laundrettes, hairdressers). Halogen compounds can be caused by clean ing and degreasing solutions, dissolvents, glue and bleaching lyes. Pay attention to the Procal leafl et, corrosion through Halogen compounds. Combustion air he supply of combustion air must be guaranteed. here must be no possibility to close the air supply opening. For direct combustion air to boiler (LAS-System) mount the connection for direct combustion air inlet. he minimum free cross-section for the combustion air can be assumed simplifi ed as follows: Considering nominal output! Room air-dependent operation: Minimum free cross-section of the opening into the open: 150 cm² or twice 75 cm² and additionally 2cm² necessary for each KW of output over 50 KW for vent into the open. Room air-independent operation with separa te combustion air pipe to the boiler: 0.8 cm 2 per 1 KW of output. he pressure loss in the combustion air pipe must be consi dered for the calculation of the exhaust system. 1 total of alkaline earths 2 If the conductance in µs/cm exceeds the tabular value an analysis of the water is necessary. Subject to alterations,

153 Hoval UltraGas (250D-2000D) Engineering Gas connection Manual gas shut-off tap and gas filter Immediately in front of the boiler a manual gas shut-off device (tap) must be installed ac cording to relevant regulations. Should the local regulations or conditions demand this, an approved gas filter must be installed in the gas supply pipe between the gas tap (thermally releasing) and the boil er in order to prevent malfunction due to for eign particles being carried along with the gas. Commissioning Start-up is to be carried out only by a specialist of Hoval and the gas supplier. Burner setting values according to the installation instructions. Shut off valve A shut off valve must be built in in front of every gas boiler. ype of gas he boiler is only to be operated with the type of gas stated on the rating plate. Pump after-run time he circulation pump must continue to run for at least 2 minutes each time the burner is switched off (the pump after-run time is included in the boiler control with the opronic regulation). Heating boiler in the attic If the gas boiler is positioned on the top floor, the installation of a low water protecti on, which automatically turns the gas burner off in case of water shortage, is recommen ded. Condensate drain he condensate from the exhaust system can be discharged through the boiler. A condensate trap is not needed anymore with the exhaust system. he condensate drainage without neutralisation is allowed, if you are using for the drain only plastic tubes or stoneware. (possibly obtain special exemption from the relevant authority). Noise level he acoustic power level value is dependent on the local and spacial circumstances. he acoustic pressure level is dependent on the installation conditions and can for instance be 5 to 10 db(a) lower than the acoustic power level at a distance of 1m. DIN 4109 must be observed when installing in domestic living areas Recommendation: If the air inlet at the facade is near a noise sensitive place (window of bedroom, terrace etc.), we recommend to use a sound absorber at the direct cumbustion air inlet. Connecting pipes Horizontal connecting pipes must be installed with an inclination of at least 50 mm per metre of their length installed in the direction of the boiler to allow free return flow of condensation water towards the boiler. he whole exhaust system must be installed so that condensate can never collect at any point. A gas pressure controller to reduce the boiler inlet pressure must be installed on-site for propane. Gas pressure natural gas Necessary flow pressure at the boiler inlet: For UltraGas (250D-2000D) min. 18 mbar, max. 80 mbar Gas pressure propane Necessary flow pressure at the boiler inlet: For UltraGas (250D-1440D) min. 37 mbar, max. 57 mbar Space requirements See Dimensions for information Allocation of gas filters for UltraGas Boiler type A siphon must be installed at the condensate outlet on the gas boiler (included in the boiler scope of delivery). he condensate must be openly lead into the canalisation. (funnel) Expansion tank An adequately dimensioned expansion tank must be provided. he expansion tank has to be installed in prin ciple at the boiler return, or at the safety flow. At the safety flow a safety valve and an auto matic exhauster must be installed. Gas throughput m 3 /h Gas filter type Dimensions Pressure loss gas filter (with clean filter) mbar UltraGas (125) 11, /6B Rp ¾" 1,1 UltraGas (150) 14, /6B Rp ¾" 1,8 UltraGas (200) 18, /6B Rp ¾" 2,2 UltraGas (250) 23, /6B Rp 1" 0,8 UltraGas (300) 28, /6B Rp 1" 1,3 UltraGas (350) 32, /6B Rp 1" 1,4 UltraGas (400) 37, /6B Rp 1" 2,0 UltraGas (450) 42, /6B Rp 1" 2,5 UltraGas (500) 47, /6B Rp 1 ¼" 1,7 UltraGas (575) 54, /6B Rp 1 ¼" 2,2 UltraGas (650) 61, /6B Rp 1 ¼" 2,8 UltraGas (720) 67, /6B Rp 1 ½" 1,5 UltraGas (850) * 80, /6B Rp 1 ½" 2,2 UltraGas (850) * 80, /6B Rp 2" 1,0 UltraGas (1000) * 94, /6B Rp 1 ½" 3,0 UltraGas (1000) * 94, /6B Rp 2" 1,4 Flue gas system Gas boilers must be connected to a certified and approved flue gas system such as flue gas lines. Flue gas lines must be gas-, condensateand over pressure-tight. he flue gas system must be connected with an angle, so that the resulting condensate of the exhaust system can flow back to the boiler and can be neutralized there before discharging into the canalization. Gas boilers with condensation heat utilisation are to be connected to a flue gas line min. temperature class 120. A flue gas temperature limiter is integrated into the boiler. * On the UltraGas (850,1000), installation of a gas filter in front of the gas burner is mandatory! 152 Subject to alterations,

154 Hoval UltraGas (250D-2000D) Engineering Chimney dimensions (Overpressure) to UltraGas (250D-2000D) Principles - Height above sea level max m he first two metres of the flue pipe must ha ve the same dimension as the flue gas outlet. - Combustion air: In the case of room air-dependent operation (accessories optional) the air pipe must be at least the same dimension as the flue gas pipe. If the flue gas pipe diameter is greater than the combustion air connection the combustion air pipe must be extended adequately. - Flue gas overpressure set: Compellingly necessary, included in the scope of delivery! Boiler Flue gas line (smooth walled) Number of bow 90 (flue gas + air supply) ype Flue gas-dim. Dimension otal pipe length in m (flue gas + air supply) UltraGas internal DN * (250D) (300D) (250D) (300D) (400D) (500D) (400D) (500D) (600D) (700D) (800D) (900D) (1000D) (700D) (800D) (900D) (1000D) (1150D) (1300D) (1150D) (1300D) (1440D) (1700D) (2000D) Notice: he data contained in the table «Dimensions flue gas systems» represent guide values. An exact calculation for the flue gas duct must be made on-site. * With 5 bends or more the feed pressure total at the combustion air/flue gas pipe is to be reduced by 30% for the calculation. With total pipe lengths exceeding 50 m, a separate calculation is necessary. Subject to alterations,

155 Hoval UltraGas (250D-2000D) Examples UltraGas (250D-2000D) Gas boiler with Water heating, 4 mixed heating circuits from wall distributors Hydraulic schematic BC010 AF 1 1 opronic opronic VF1 B1 VF2 B1 VF2 VF3 B1 VF4 B1 WW DHW MK1 MK2 MK2 MK3 MK4 Y10.1 P Dies ist ein unerlaubter Weg! Gehen Sie einen Schritt zurück oder löschen Sie dieses Shape! UltraGas Sie haben die Möglichkeit ein neues Shape zu nehmen!!! hovhovalh hovalhova alhovalho Y10.2 Dies ist ein unerlaubter Weg! Gehen Sie einen Schritt zurück oder löschen Sie dieses Shape! UltraGas Sie haben die Möglichkeit ein neues Shape zu nehmen!!! hovhovalh hovalhova alhovalho P YK1 M YK2 M YK2 YK3 M YK4 M SLP SF Dies ist ein unerlaubter Weg! Gehen Sie einen Schritt zurück oder löschen Sie dieses Shape! Sie haben die Möglichkeit ein neues Shape zu nehmen!!! hovhovalhoval hovalhovalhov alhovalhovalho valhovalhovalh ovalhovalhoval hovalhovalhov alhovalhovalho valhovalhovalh ovalhovalhoval hovalhovalhov alhovalhovalho valh CW KW UltraGas (250D-2000D) Gas boiler with Water heating, main pump, Hydraulic switches, 4 mixed heating circuits from wall distributors Hydraulic schematic BC020 AF 1 1 opronic opronic VF1 B1 VF2 B1 VF2 VF3 B1 VF4 B1 DHW WW MK1 MK2 MK2 MK3 MK4 Y10.1 M5.1 P Dies ist ein unerlaubter Weg! Gehen Sie einen Schritt zurück oder löschen Sie dieses Shape! Sie UltraGas haben die Möglichkeit ein neues Shape zu nehmen!!! hovhovalh hovalhova alhovalho Y10.2 M5.2 P Dies ist ein unerlaubter Weg! Gehen Sie einen Schritt zurück oder löschen Sie dieses Shape! Sie UltraGas haben die Möglichkeit ein neues Shape zu nehmen!!! hovhovalh hovalhova alhovalho SVLF YK1 M YK2 M YK2 YK3 M YK4 M SLP SF Dies ist ein unerlaubter Weg! Gehen Sie einen Schritt zurück oder löschen Sie dieses Shape! Sie haben die Möglichkeit ein neues Shape zu nehmen!!! hovhovalhoval hovalhovalhov alhovalhovalho valhovalhovalh ovalhovalhoval hovalhovalhov alhovalhovalho valhovalhovalh ovalhovalhoval hovalhovalhov alhovalhovalho valh CW KW AF Outdoor sensor VF1 Flow sensor 1 VF2 Flow sensor 2 VF3 Flow sensor 3 VF4 Flow sensor 4 SF Calorifier heater sensor B1 Flow temperature guard (if required) SVLF Solar tank sensor MK1 Pump mixing circuit 1 MK2 Pump mixing circuit 2 MK3 Pump mixing circuit 3 MK4 Pump mixing circuit 4 M5.1 Boiler circuit pump 1 M5.2 Boiler circuit pump 2 SLP Calorifier loading pump YK1 Actuator mixer 1 YK2 Actuator mixer 2 YK3 Actuator mixer 3 YK4 Actuator mixer 4 Y10.1 Valve 1 or zone valve (Single wire system) Y10.2 Valve 2 or zone valve (Single wire system) CW DHW Cold Water Domestic Hot Water Notice: his hydraulic schematic is a principle schematic. It does not contain all details for installation. he installation must be done according to local conditions, di mensioning and regulations For underfloor heating, a flow temperature monitor must be built-in. Shut-off devices to the safety valve (pressurized expansion tank, safety valve, etc.) are to safe against unintended closing! Anti thermal siphon dip has to be installed. Notes Primary pump on-site 154 Subject to alterations,

156 Hoval UltraGas (250D-2000D) Examples UltraGas (250D-2000D) Gas boiler with Water heating, main pump, Bypass distributor, 4 mixed heating circuits from wall distributors Hydraulic schematic BC030 AF 1 1 opronic opronic VF1 B1 VF2 B1 VF2 VF3 B1 VF4 B1 WW DHW MK1 MK2 MK2 MK3 MK4 Y10.1 P Dies ist ein unerlaubter Weg! Gehen Sie einen Schritt zurück oder löschen Sie dieses Shape! Sie UltraGas haben die Möglichkeit ein neues Shape zu nehmen!!! hovhovalh hovalhova alhovalho Y10.2 M5.1 M5.2 SVLF P Dies ist ein unerlaubter Weg! Gehen Sie einen Schritt zurück oder löschen Sie dieses Shape! Sie UltraGas haben die Möglichkeit ein neues Shape zu nehmen!!! hovhovalh hovalhova alhovalho YK1 M YK2 M YK2 YK3 M YK4 M SLP SF Dies ist ein unerlaubter Weg! Gehen Sie einen Schritt zurück oder löschen Sie dieses Shape! Sie haben die Möglichkeit ein neues Shape zu nehmen!!! hovhovalhoval hovalhovalhov alhovalhovalho valhovalhovalh ovalhovalhoval hovalhovalhov alhovalhovalho valhovalhovalh ovalhovalhoval hovalhovalhov alhovalhovalho valh CW KW AF Outdoor sensor VF1 Flow sensor 1 VF2 Flow sensor 2 VF3 Flow sensor 3 VF4 Flow sensor 4 SF Calorifier heater sensor B1 Flow temperature guard (if required) SVLF Solar tank sensor MK1 Pump mixing circuit 1 MK2 Pump mixing circuit 2 MK3 Pump mixing circuit 3 MK4 Pump mixing circuit 4 M5.1 Primary pump 1 M5.2 Primary pump 2 SLP Calorifier loading pump YK1 Actuator mixer 1 YK2 Actuator mixer 2 YK3 Actuator mixer 3 YK4 Actuator mixer 4 Y10.1 Valve 1 or zone valve (Single wire system) Y10.2 Valve 2 or zone valve (Single wire system) CW Cold Water DHW Domestic Hot Water Notice: his hydraulic schematic is a principle schematic. It does not contain all details for installation. he installation must be done according to local conditions, di mensioning and regulations For underfloor heating, a flow temperature monitor must be built-in. Shut-off devices to the safety valve (pressurized expansion tank, safety valve, etc.) are to safe against unintended closing! Anti thermal siphon dip has to be installed. Notes Primary pump on-site Subject to alterations,

157 156

158 Hoval CompactGas ( ) Gas boiler Description Hoval CompactGas Gas boiler Boiler High efficiency boiler to EN for firing of gas Downstream heating surface made of alufer bounded pipe Boiler completely welded Also suitable for LowNOx-burner with extremely low pollutant emissions Insulation at the boiler body 80 mm mineral wool mat and special fabric Boiler completely cased with steel plate, red powder coated Accessible cover from checkered sheet. Flue gas outlet, heating flow- and heating return connections to the top incl. counter flanges, screws and seals Condensate trap Optional Control panel with boiler control and regulators in different designs Free standing calorifier see Calorifiers Boiler door swivells to the left Delivery Gas boiler, insulation and casing are delivered separately packed On site Installation of the casing and insulation, boiler control and condensate trap Model series CompactGas type Output kw (1000) (1400) (1800) (2200) (2800) Permissions boilers CE-Product-ID-Number CE 0085 B0376 according to Directive on appliances burning gaseous fuels 90/396/EG he boiler complies with the PED Pressure Equipment Directive 97/23EG. Boiler control opronic /U3.2 For operating temperature to 105 C For mounting on top of boiler CompactGas ( ) mounting sideways left or right Integrated control for 1 mixing circuit 1 heating circuit without mixer domestic hot water loading circuit Possibility of further functions using various key modules and/or installation of separate control unit opronic /N (see accessories) Main switch I/O Safety temperature limiter 120 C, Fine fuse 6,3 A Fault display «burner» Running time meter and count-up counter Boiler sensor Large LCD display Rotary push button Buttons for day time room temperature night room temperature hot water temperature operating mode selection (holiday, absent, heating operation prolongation, automatic, summer, continuous - reduced - frost protection) adjusting the heating curves system information emission measurement and manual operation Outdoor sensor AF 200 Flow sensor with plug Calorifier sensor with plug Plug connection for burner Connection available for room stations Delivery Boiler control separately delivered At place Mounting of the control panel at the boiler Installation of the boiler control for mounting sideways Control panel with thermostat 2.2 For systems without opronic regulator For direct 2-stage burner control, requirement starting from external calorifieror heater instruction is possible. Main switch I/O Safety temperature limiter 110 C Selector switch burner load Switch summer/winter 3 boiler temperatur regulators C temperatur regulator for base load heating temperatur regulator for full load heating temperatur regulator for calorifier Boiler and burner breakdown lamp Plug connection for burner Optional 2 Running time meter integrated 2 Burner running time meter and count-upcounter integrated Flue gas thermometer, 4,5 m capillary tube Delivery Control panel separately delivered At place Mounting of the control panel at the boiler Control panel with thermostat 0.2 For external control For systems without opronic regulator For special control function Main switch I/O Safety temperature limiter 120 C, 3 boiler temperatur regulators C temperatur regulator for base load heating temperatur regulator for full load heating temperatur regulator for calorifier without burner plug connection Optional 2 Running time meter integrated 2 Burner running time meter and count-upcounter integrated Flue gas thermometer, 4,5 m capillary tube Safety temperature limiter 130 C Delivery Control panel separately delivered At place Mounting of the control panel at the boiler Subject to alterations,

159 Hoval CompactGas ( ) Part N CompactGas Gas boiler ( ) Part N Boiler High efficiency boiler made of steel for gas firing, without control panel Design: delivery complete Boiler, insulation and casing separately packed and delivered working CompactGas Output pressure ype kw bar (1000) (1400) (1800) (2200) (2800) he minimum boiler operating temperature and the minimum boiler return temperature must imperatively be observed (see technical data) A return temperature control must be provided! he condensate trap must imperatively be mounted on the flue gas outlet of the boiler! Blind flange made of steel incl. setscrews and gasket for CompactGas (1000) for CompactGas ( ) Intermediate flange drilled D480x20 for CompactGas (1000) Intermediate flange drilled D520x20 for CompactGas ( ) Subject to alterations,

160 Hoval CompactGas ( ) Part N Control panels with heating regulator opronic for Hoval CompactGas Boiler controller opronic /U3.1 Max. operating temperature 90 C Operating pressure 4 bar - Uno-3 (50-160,360), Max-3 ( ) Operating pressure 5 bar - Uno-3 ( ) For mounting on top of boiler (sideways, change on site). Integrated control function for - 1 mixing circuit - 1 heating circuit without mixer - domestic hot water loading circuit incl. outdoor sensor, flow sensor and calorifier sensor with plug Option to expand the functions by - different key modules and/or - mounting of an additional heating regulator opronic /N (see accessories) Part N Boiler controller opronic /U3.2 Max. operating temperature 105 C Operating pressure 3 bar - Uno-3 (50-160) Operating pressure 4 bar - Uno-3 ( ) Max-3 ( ) he boiler complies with the Pressure Equipment Directive (PED) 97/23/EC. Request for corresponding boiler plate required. Functions like boiler controller opronic /U3.1 Delivery: Boiler controller separately delivered Contact sensor VF204 can be used as flow or return flow sensor with 4 m cable Subject to alterations,

161 Hoval CompactGas ( ) Part N Control panels with heating regulator opronic to Hoval CompactGas Control panel 2.2 For systems without opronic regulator. For direct 2-stage burner control, requirement starting from external calorifieror heater instruction is possible. - without burner running time meter and count-up-counter - incl. 2 burner running time meter integrated - incl. 2 burner running time meter and count-up-counter integrated For mounting sideways left or right on the boiler Part N Control panel 0.2 For external switching command For systems without opronic regulator For special control function - without burner running time meter and count-up-counter - incl. 2 burner running time meter integrated - incl. 2 burner running time meter and count-up-counter integrated For mounting sideways left or right on the boiler Accessories to control panel with thermostat Flue gas thermometer 4 m, capillary tube Accessories to heat regulation system opronic 1 1 Key module 1 for Hoval opronic for 2. mixing circuit Key module consists of: Function key 1, 1 flow sensor VF204S with plug, 2 loose plugs Only one key module is possible! System approaches and applications see Hoval CD Additional heating regulator set ZN1 for extending functionality and implementing further heating circuits Consisting of: Heating regulator opronic /N for - 1 mixer circuit - 1 heating circuit without mixer - hot water loading Only one key module per regulator is possible! Flow sensor VF202K with 2 m cable and plug. Cable set for connecting the auxiliary heating regulator opronic / N with the boiler controller. Mounting on-site , Subject to alterations,

162 Hoval CompactGas ( ) Part N Part N Set BMS-Modul 1-10 V (Building management system) Control 0-10 V ^= 11,5-115 C Consing of: BMS-Module and rafo Can be installed! Communication modules/remote connection see Controls Room station RS- for opronic effective on one mixing circuit Remote control RFF- for opronic effective on one mixing circuit Outdoor sensor AF 200 (may be included in the heat generator scope of delivery) for one mixing circuit or for the mean value (per regulator 2 outdoor temperature sensors possible) Flue gas temperature sensor P 1000/4 L = 2.5 m including fixing screws (installation on site) Cable sensor KV 20/5/6S 5 m cable and plug Contact sensor VF204S can be used as flow or return flow sensor with 4 m cable and plug Subject to alterations,

163 Hoval CompactGas ( ) Part N Part N Flow temperature guard for under floor heating (per heating circuit 1 guard) C, differential gap 6K, capillary tube max. 700 mm, setting (from the outside visibly) inside the housing cover. Clamp-on thermostat RAK-W1000.S hermostat with strap, without cable and plug Immersion thermostat RAK-W1000.S SB 150 hermostat with pocket ½ - depth of immersion 150 mm brass nickel-plated Vibration elements for boiler socket For sound and vibration absorbation. Made of rubber. Cross-section 80/50 mm. Delivery Set of 4 vibration elements per boiler, mounted under the boiler socket to CompactGas Length ype Size mm (1000) (4 pcs.) 400 (1400) (4 pcs.) 500 (1800) (4 pcs.) 800 (2200) (4 pcs.) 800 (2800) (4 pcs.) Service Commissioning Commissioning must be made by works service or Hoval trained authorized serviceman/ company is condition for warranty. For commissioning and other services please contact your Hoval sales office. 162 Subject to alterations,