Technical information Installation instructions UltraGas (125-1000) Condensing gas heating boilers for natural gas and liquid gas for modulating operation Rated output levels at 40/30ºC and for natural gas 30-UltraGas (125) 28-123 kw 30-UltraGas (150) 28-150 kw 30-UltraGas (200) 44-200 kw 30-UltraGas (250) 49-250 kw 30-UltraGas (300) 57-300 kw 30-UltraGas (350) 58-350 kw 30/31-UltraGas (400) 97-400 kw 30/31-UltraGas (450) 97-450 kw 30/31-UltraGas (500) 97-500 kw 30/31-UltraGas (575) 136-575 kw 30/31-UltraGas (650) 136-650 kw 30/31-UltraGas (720) 142-720 kw 30-UltraGas (850) 166-850 kw 30-UltraGas (1000) 224-1000 kw Hoval products must be installed and commissioned only by appropriately qualified experts. These instructions are intended exclusively for the specialist. Electrical installations may only be carried out by a qualified electrician. The floor standing gas condensing boiler UltraGas (125-1000) are designed and approved for use as heat generators for hot water heating systems with a permissible flow temperature of up to 90 C 1 ), in accordance with EN 483 and EN 677. They are designed for continuously adjustable reduced output operation in heating systems. 1) see technical data Subject to modifi cations 4 210 267 / 04-10/13 EN
1. Safety instructions 1.1 Key to symbols used... 4 2. Important notes 2.1 Acceptance of delivery... 5 2.2 Scope of guarantee... 5 2.3 Instruction manuals... 5 2.4 Regulations, official permits... 5 2.4.1 Germany... 6 2.4.2 Austria... 6 2.4.3 Switzerland... 6 3. Assembly 3.1 Placement... 7 3.2 Mounting of heat insulation... 10 3.3 Mounting the casing... 11 3.4 Mounting of base casing... 14 3.5 Adjusting the length of the ladder types (850,1000)... 15 4. Technical information 4.1 Description of the boiler... 16 4.2 Technical data... 17 4.3 Dimensions / Space requirements... 20 4.3.1 Opening dimension... 21 4.4 Hydraulic resistance... 22 4.5 Brief description of the automatic firing device... 23 5. Installation 5.1 Safety information... 24 5.2 Boiler room requirements... 24 5.2.1 Room air dependent installation... 24 5.2.2 Room air independent installation... 24 5.3 Flue gas connection and flue... 25 5.4 Condensate drainage... 26 5.4.1 Execution variants... 26 5.5 Gas connection... 27 5.6 Hydraulic connection... 27 5.6.1 Customer-side requirements... 28 5.6.2 Hydraulic interconnection... 28 5.6.3 Cascade control... 28 5.7 Electrical connection... 29 6. Commissioning 6.1 Safety information... 30 6.2 Filling with water... 30 6.3 Water quality... 31 6.4 Bleeding the air from the gas line... 32 6.5 Switching on the system... 32 6.6 Gas inlet pressure... 32 6.7 Setting the gas flow rate CO 2 (O 2 ) and measurement of NOx/CO content in the flue gas... 33 6.7.1 Flue gas measurement UltraGas (125-720)... 33 6.7.2 Flue gas measurement UltraGas (850,1000)... 34 6.8 Changing over to a different gas type... 35 6.9 Type (850,1000) Setting for the stabilisation damper (if necessary)... 37 6.10 Handover to the user... 38 6.11 Record - Activation of screed function... 39 2 Table of contents 4 210 267 / 04
7. Maintenance 7.1 Safety information... 41 7.2 Bleeding... 41 7.3 Water refilling... 41 7.4 Information for combustion controller/chimney sweep regarding emission monitor key... 42 7.5 Cleaning... 43 7.5.1 Cleaning the burner cylinder (inside and outside)... 43 7.5.2 Cleaning the exterior of the combustion chamber and burner cylinder... 44 7.5.3 Cleaning/adjusting the ignition and ionisation device... 45 7.6 Setting the gas flow rate CO 2 (O 2 ) and measurement of NOx/CO content in the flue gas... 46 7.7 Clean siphon... 46 7.8 Servicing the neutralisation installation for types 23 and 24 (if fitted)... 47 8. Overview of settings 8.1 Table of parameters... 48 8.2 Fault Reporting overview TopTronic T... 63 8.3 Automatic firing device (Warning, Blocking, Lock-out)... 65 4 210 267 / 04 Table of contents 3
1. Safety instructions i The system shall not be put into operation until all relevant standards and safety regulations are met. For a test run, the following minimum conditions must be satisfied: - Safety valve installed (closed system) - Controls operative (connected to power supply) - Sensor for safety temperature limiter is connected (= boiler temperature sensor) - System filled with water - Siphon filled with water - Expansion tank connected - Flue gas adapter pipe with flue gas pipe connected to flue. - Burner is preset (see point 6.7). 1.1 Key to symbols used Tools: Shows the tools required for the following work. Instruction: Prompts you to carry out an action. Result: Shows the expected reaction to your action. i Note: Provides important information Safety information: Indicates an immediate hazard to persons Warning of dangerous electrical voltage Warning information Indicates danger to machines and Installations Provides important information. Reference to standards and regulations. 4 Safety instructions 4 210 267 / 04
2. Important notes 2.1 Acceptance of delivery i A visual control of the heating boiler should be conducted upon delivery. In the event of damage, the necessary steps should be followed as specified in the delivery contract. The costs for correcting the damage shall be taken over by the individual risk bearer. 2.2 Scope of guarantee i The guarantee does not cover defects caused by: - non-observance of these instructions - non-observance of the operating instructions - incorrect Installation - unauthorised alterations - improper use - contaminated operating media (gas, water, combustion air) - unsuitable chemical additives to the heating water - damage due to the exercise of force - corrosion through halogen compounds - corrosion through nonconforming water quality 2.3 Instruction manuals i A summary of all the instruction manuals relevant to this system can be found in the Hoval System User Guide! In exceptional cases the instructions are kept with the respective components! Additional sources of information: - Hoval catalogue - Standards and regulations 2.4 Regulations, official permits i When installing and operating the system, the standards and regulations specified in sections 2.4.1 to 2.4.3 must be complied with at all times. 4 210 267 / 04 Important information 5
2.4.1 Germany DIN EN 12831 Heating systems in buildings - Methods for calculating the design heat load DIN EN 13384 Flue gas systems - Heat and flow calculation methods DIN EN 12828 Heating systems in buildings - Planning of hot water heating systems. DIN 4755 Oil fired combustion systems. Construction, design, safety requirements. DIN 4756 Gas fired combustion systems. Construction, design, safety requirements, design and execution (for gas burner operation). DIN 18160 Domestic chimneys, requirements, design and construction. TRD 702 Steam boilers with group II hot water generators. TRD 721 Safety equipment against excessive pressure / safety valves for group II steam boilers. VDI 2035 Prevention of damage through corrosion and scale formation in hot water heating systems. DIN 57 116 / VDI 0116 Electrical equipment in combustion systems (VDE regulation). See enclosure N-430 020 for further standards applicable in Germany. 2.4.2 Austria OENORM 12831 12831Heating systems in buildings - Methods for calculating the design heat load OENORM 13384 Flue gas systems - Heat and flow calculation methods OENORM 12828 Heating systems in buildings - Planning of hot water heating systems. ÖNorm B 8130 Open water heating systems; safety equipment. ÖNorm B 8131 Closed water heating systems; requirements to safety, construction and testing. ÖNorm B 8133 Hot water supply systems; safety requirements. ÖNorm B 8136 Heating systems, space and other building requirements. ÖNorm M 7515 Dimensioning of chimneys; definitions and calculation procedure. ÖNorm H 5171 Heating systems - construction requirements for buildings. ÖVGW TR-Gas 2.4.3 Switzerland SN EN 12831 Heating systems in buildings - Methods for calculating the design heat load SN EN 13384 Flue gas systems - Heat and flow calculation methods SN EN 12828 Heating systems in buildings - Planning of hot water heating systems. VKF - Association of Cantonal Fire Insurances. Fire service regulations. SVGW Switzerland. Association of the gas and water trade. SNV 27 10 20 Ventilation requirements for the boiler Installation room. SWKI BT102-01 Quality of water in installations of building technology. Technical tank regulations TTV 1990. and further standards and regulations issued by CEN, CEN ELEC, DIN, VDE, DVGW, TRD and by the legislator. Regulations from the local building authority, insurance companies and chimney sweeps must also be complied with. When using gas as fuel, the regulations of the responsible gas board must also be observed. An official permit may be required. 6 Important information 4 210 267 / 04
3. Assembly 3.1 Placement Space requirements UltraGas (125-1000) Dimensions (mm) Make sure that the cable does not touch any hot locations! For swing out of burner this clearence must be ensured Install gas line straight to the back UltraGas Type A A minimal B C D H H minimum Fig. 01 (125, 150) 180 1 80 2 820 1237 981 1823 1711 3 (200-300) 360 1 160 2 930 1584 1247 1923 1811 3 (350-500) 200 1 100 2 1110 1679 1268 2070 1958 3 (575-720) 200 1 100 2 1290 1843 1438 2086 1984 3 (850, 1000) 420 1 230 2 1550 2154 1703 2139 2037 3 1 If room height is too small: Reduction of measures possible. See A minimum. 2 Attention! With A minimum the burner is no longer swing-out completely! Cleaning makes more difficult! 3 Boiler foot can be shortened, no base casing possible! Details see next page. The 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. 4 210 267 / 04 Assembly 7
UltraGas with shortened boiler feet (All measurements in mm) UltraGas Type a cut off (125, 150) 1723-1783 (200-300) 1823-1883 (350-500) 1970-2030 (575-720) 1986-2046 (850, 1000) 2039-2099 1 Neutralisation box 2 Condensate pump 3 Masonry base 4 Adjustable feed 20-80 mm UltraGas with masonry base and adjustable feet UltraGas Type a UltraGas (575-1000) (125, 150) 1711-1771 (200-300) 1811-1871 (350-500) 1958-2018 (575-720) 1984-2044 (850, 1000) 2037-2097 UltraGas with masonry base without adjustable feet UltraGas Type a UltraGas (575-1000) (125, 150) 1721 (200-300) 1821 (350-500) 1968 (575-720) 1994 (850, 1000) 2047 Base plates and feeds will not be refunded! 8 Assembly 4 210 267 / 04
Procedure: 1. Remove the two upper threaded elements (1) on the boiler base (1a). 2. Take off the front wooden beam. 3. Raise the front of the boiler with a jack (3). 4. Move aside the side beam (4) at the front (see fig. 2) Introduce the front feet and screw in place. 5. Raise the back of the boiler with a jack (3). 6. Move aside the side beam (4) at the back (see fig. 2). Introduce rear feet and screw in place. 7. Remove footboard locking device (5). Remove the locking pin (6) and fold open the footboard carefully. In the case of models 850 and 1000, fold open the 2nd and 3rd footboard and remove the ladder. Hanging up possibilities for crane hooks 5 1b 1 4 3 6 1a Typen (850, 1000) with six feet Typen (575-1000) Fig. 02 Adjustment of the adjustable feet is carried out takes place after installing the neutralisation unit 4 210 267 / 04 Assembly 9
3.2 Mounting of heat insulation 1. Place the insulation blanket (1) around the UltraGas boiler and fix with plastic bands (1a) and clips (1b) -- tension springs (1c) are used for additional fixing -- do not fit the band too tightly (reduces insulation value). 1c 1 1a Fig. 03 1b 10 Assembly 4 210 267 / 04
3.3 Mounting the casing 1. Attach the cable channels (2) left and right to the pins and fix with the hexagon nuts and washers (3a, fig. 4a) already mounted to the boiler. Turn side wall supports (2b, fig. 4b) laterally to the outside. 2. Attach the side walls (4) to the boiler and fix with the hexagon nuts and washers (4a, fig. 4a) already mounted to the boiler. Hook the side wall side onto the screw head on the condensate drip tray at the bottom. Align the side walls centrally. Adjust the free space for electrical box and rear wall. Then tighten the hexagon nuts (4a). 3. Fit the rear wall (terminal plate 5, fig. 4c) of the terminal box using 4 screws (4a). 4. Remove stud (6) on the left or right. Hook the terminal box in at the bottom, on the side where the stud is located. Hold the terminal box in horizontal position and tighten in position with the second stud on the opposite side.fold the terminal box shut towards the top and hook it in. 5. Fit the trim (7) - in order to insert the upper screw (7a). Open the terminal box - in order to insert the lower screw (7b). Close the terminal box 6. Direct the cable for the water pressure sensor (7) downwards, out of the control and plug in at the bottom of the boiler (cable run according to fig. 4). Route all other cables to the left or right of the boiler and establish plug connections. Make sure that the cable does not touch any hot locations! 7. Attach the lower rear wall (8) to the side walls. Mutually attach the rear walls (8a, 8b) and engage together at the side walls. 8. Fit top side walls (9a, 9b). Position the lower edge of the top side walls (longitudinal bore hole) on the special screws of the bottom side walls and slide them in. Attach top side walls using 4 selftapping screws (9c) ø 3.5 x 10. 9. Attach upper rear walls (10, fig. 4) and mount rosette (10a). 10. Put on cover plates (11). Fit top front cover (11a), place pins in slots and slide towards the rear. Then secure with carriage bolt (11b, fig. 4). (When removing, lift first one side, then the other side). 11. Hook in the front cover (8) at the bottom (with rail from type 575) and slide shut at the top (attach with lateral carriage bolt). In the case of a cascade >3, no carriage bolts are fitted on the middle boilers! 12. The remaining 3 casing walls (15, 15a, 16, fig. 6) are attached after mounting the condensate boxes. 4 210 267 / 04 Assembly 11
Secure service platform (7c, fig. 4d) in folded-up position using bolt (1b, fig. 3)! 4a 3a 4a 4 2 2b Illustrated without burner Fig. 4a Fig. 4b 5a 7a 5 6 6a 7b Fig. 4c 7 7c Fig. 4e Fig. 4d 12 Assembly 4 210 267 / 04
Types (850,1000) two-pieces 11 11b Type (125,720) one-piece 10a 11a 10 8b 8a 9b 9c 2 3 Burner wiring Type (125-850); 2 connector plugs Type (1000); 3 connector plugs Boiler temperature sensor Ignition cable 8 9a 3 8 7 Flue gas sensor Line cord Condensate box (if available) Water pressure sensor Fig. 04 4 210 267 / 04 Assembly 13
3.4 Mounting of base casing 1. Mount the siphon (13) delivered loose, incl. double nipple (13a, fig. 5). 2. Position the condensate box (option) under the boiler and make the electrical connection. Create condensate outlet, resp. connection line according to separate instructions. For UltraGas (575,650,720,850,1000): Mount condensate outlet pipe (14, fig. 5) (delivered with boiler). 3. Screw mount the right and left side walls (15, 15a, fig. 6) with the already mounted cap nuts. 4. Attach the front (16) to the side walls (15, 15a). 13a 13 14 Fig. 05 14 Assembly 4 210 267 / 04
15a 15 16 Fig. 06 3.5 Adjusting the length of the ladder types (850,1000) only type UG (850,1000) If the option with shortened boiler feet is being applied or if the boiler is put on a concrete base, the ladder supplied must be shortened (cut away at the notch) resp. lengthened. 4 210 267 / 04 Assembly 15
4. Technical information 4.1 Description of the boiler The Hoval UltraGas is a low emission, energy-saving condensing gas boiler comprising the Ultraclean burner system, a gas fired premix burner with combustion air fan. The Hoval UltraGas has a vertically disposed combustion chamber of stainless steel as a primary heating surface and a secondary heating surface of alufer composite tubes (stainless steel on the water side, aluminium on the waste gas side). The secondary heating surface is designed so that part of the water vapour contained in the flue gas is condensed and the vaporisation heat it contains is utilised for the heating circuit. The gas burner is in the form of a break draught burner, which can easily be swung up for maintenance purposes. The UltraGas is designed to operate with natural and liquid gas. The figure below shows the design principle. Gas safety and control devices Combustion air fan Optional additional controller Flow Heating Electrode for ignition and flame monitoring Double ignition electrode TopTronic T controller Trittbrett zur Service-Erleichterung (ausklappbar) High temperature return alufer heat exchanger Low temperature return Vertical flue gas connection Condensate collection tray 16 Technical information 4 210 267 / 04
4.2 Technical data UltraGas (125-300) Type (125) (150) (200) (250) (300) Nominal output 80/ 60 C with natural gas 1 kw 25-113 25-138 39-185 44-230 51-278 Nominal output 40/ 30 C with natural gas 1 kw 28-123 28-150 44-200 49-250 57-300 Nominal output 80/ 60 C with propane gas kw 31-113 35-138 63-185 78-230 80-278 Nominal output 40/ 30 C with propane gas kw 34-123 39-150 70-200 87-250 91-300 Nominal load with natural gas 1 kw 26-116 26-141 40-188 45-235 52-283 Nominal load with propane gas kw 32-116 36-141 65-190 80-235 84-283 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 90 90 90 90 90 Boiler water content l 206 194 359 341 318 Minimum water flow l/h 0 0 0 0 0 Boiler weight (without water content, incl. casing) kg 383 409 634 672 724 Boiler efficiency at partial load 30% (according to EN 303) % 106,9/96,3 106,9/96,3 106,7/96,1 106,5/95,9 107,0/96,4 (related to net / gross calorific value) 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 480 480 530 530 530 Standard emission rate Nitrogen oxides mg/kwh 26 29 39 38 38 Carbon monoxide mg/kwh 3 4 4 4 9 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 155 155 252 252 252 Gas flow pressure minimum/maximum Natural gas E/LL mbar 18-80 18-80 18-80 18-80 18-80 Propane gas mbar 37-57 37-57 37-57 37-57 37-57 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 Propangas 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 12 12 12 12 12 IP rating (integral protection) IP 20 20 20 20 20 Sound power level - Heating noise (EN 15036 part 1) (room air dependent) db(a) 69 72 65 68 72 - Exhaust noise is radiated from the mouth (DIN 45635 part 47) db(a) 65 67 61 64 66 Sound pressure level (depending on installation conditions) 2 db(a) 59 62 55 58 62 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 Temperature class T120 T120 T120 T120 T120 Flue gas mass flow kg/h 192 234 312 330 470 Flue gas temperature at nominal output 80/ 60 C C 69 71 69 70 71 Flue gas temperature at nominal output 40/ 30 C C 48 49 48 49 49 Volume flow rate combustion air Nm 3 /h 143 175 233 291 350 Feed pressure total at the combustion air/flue gas pipe 3 Pa 100 120 120 130 130 Maximum draught / depression at flue gas outlet Pa - 50-50 - 50-50 - 50 1 Data related to H u. The 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 (a readjustment may be necessary). 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 separate page. 4 210 267 / 04 Technical information 17
Technical data UltraGas (350-575) Type (350) (400) (450) (500) (575) Nominal output 80/ 60 C with natural gas 1 kw 51-320 87-370 87-410 87-460 122-524 Nominal output 40/ 30 C with natural gas 1 kw 58-350 97-400 97-450 97-500 136-575 Nominal output 80/ 60 C with propane gas kw 95-320 139-370 139-410 139-455 169-524 Nominal output 40/ 30 C with propane gas kw 109-350 154-400 154-450 154-500 185-575 Nominal load with natural gas 1 kw 53-330 89-377 89-424 89-471 125-542 Nominal load with propane gas kw 100-330 144-377 144-424 144-471 175-542 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 90 90 90 90 90 Boiler water content l 428 411 387 375 549 Minimum water flow l/h 0 0 0 0 0 Boiler weight (without water content, incl. casing) kg 865 903 955 981 1283 Boiler efficiency at partial load 30% (according to EN 303) (related to net / gross calorific value) % 107,3 / 96,7 107,5 / 96,8 107,5 / 96,8 107,6 / 96,9 107,6 / 96,9 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 750 750 750 750 1000 Standard emission rate Nitrogen oxides mg/kwh 41 43 42 41 48 Carbon monoxide mg/kwh 10 11 12 13 5 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 302 302 302 302 302 Gas flow pressure minimum/maximum Natural gas E/LL mbar 18-80 18-80 18-80 18-80 18-80 Propane gas mbar 37-57 37-57 37-57 37-57 37-57 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 38,0 44 49,5 55,0 63,2 Propangas 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 12 12 12 12 12 IP rating (integral protection) IP 20 20 20 20 20 Sound power level - Heating noise (EN 15036 part 1) (room air dependent) db(a) 74 71 73 75 72 - Exhaust noise is radiated from the mouth (DIN 45635 part 47) db(a) 71 72 73 74 69 Sound pressure level (depending on installation conditions) 2 db(a) 64 61 63 65 62 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 Temperature class T120 T120 T120 T120 T120 Flue gas mass flow kg/h 541 626 704 782 900 Flue gas temperature at nominal output 80/ 60 C C 69 71 71 72 71 Flue gas temperature at nominal output 40/ 30 C C 46 48 47 49 47 Volume flow rate combustion air Nm 3 /h 404 467 525 583 671 Feed pressure total at the combustion air/flue gas pipe 3 Pa 130 130 130 130 130 Maximum draught / depression at flue gas outlet Pa - 50-50 - 50-50 - 50 1 Data related to H u. The 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 (a readjustment may be necessary). 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 separate page. 18 Technical information 4 210 267 / 04
Technical data UltraGas (650-1000) Type (650) (720) (850) (1000) Nominal output 80/60 C with natural gas 1 kw 122-592 127-655 148-776 199-912 Nominal output 40/30 C with natural gas 1 kw 136-650 142-720 166-850 224-1000 Nominal output 80/60 C with liquid gas kw 169-592 169-655 - - Nominal output 40/30 C with liquid gas kw 185-650 185-720 - - Nominal load with natural gas 1 kw 125-613 130-677 152-802 205-943 Nominal load with liquid gas kw 175-613 175-677 - - Working pressure heating max./min. bar 6,0 / 1,0 6,0 / 1,0 6,0 / 1,0 6,0 / 1,0 Working temperature max.. C 90 90 90 90 Boiler water capacity l 529 478 860 793 Min. water circulation l/h 0 0 0 0 Boiler weight (without water content, incl. casing) kg 1328 1438 1743 1893 Boiler efficiency at partial load at 30% (according to EN 303) (related to net / gross calorific value) % 107,5/96,8 107,7/97,0 107,7/97,0 107,7/97,0 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 1000 1000 1200 1200 Standard emission rate Nitrogen oxides mg/kwh 48 48 35 35 Carbon monoxide mg/kwh 5 5 15 15 Co n tent of CO 2 in the exhaust gas max./min. power % 9,0 / 8,8 9,0 / 8,8 9,0 / 8,8 9,0 / 8,8 Dimensions See table of dimensions Connections DN125/ DN125/ DN125 Flow/Return DN PN6 PN6 PN6 DN125 PN6 Gas Inches Rp 2" Rp 2" Rp 2" Rp 2" Flue gas/comb. air Ø mm 302 302 402 402 Gas flow pressure min./ max. Natural gas E/LL mbar 18-80 18-80 18-80 18-80 Liquid gas mbar 37-57 37-57 - - Gas connection value at 0 C / 1013 mbar: Natural gas E - (Wo = 15,0 kwh/m 3 ) Hu = 9,97 h/m 3 m 3 /h 61,3 67,7 80,2 94,3 Natural gas LL- (Wo = 12,4 kwh/m 3 ) Hu = 8,57 h/m 3 m 3 /h 71,5 79,0 93,6 110,0 Propangas 3 (Hu = 25,9 kwh/m 3 ) m 3 /h 23,7 26,1 31,0 - 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 Min./Max. electrical power consumption Watt 62/1030 65/1150 52/1010 212/2730 Standby Watt 12 12 12 12 IP rating (integral protection) IP 20 20 20 20 Acoustic capacity - Heating noise (EN 15036 part 1) (room air-dependent) db(a) 75 77 77 82 - Exhaust noise is radiated from the mouth (DIN 45635 part 47) db(a) 72 74 70 74 Acoustic pressure level (depending on installation) 2 db(a) 65 67 67 72 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 Value for flue calculation Temperature class T120 T120 T120 T120 Flue gas mass flow kg/h 1018 1124 1331 1565 Flue gas temperature at operation 80/60 C C 72 71 69 69 Flue gas temperature at operation 40/30 C C 49 46 49 49 Mass flow combustion air Nm 3 /h 759 838 992 1167 Feed pressure for combustion air/ flue gas system 3 Pa 130 130 130 130 Maximal Draft / negative pressure flue gas outlet Pa - 50-50 -50-50 1 Data reladet to H u. The 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 oefficient of 12,0 up to 15,7 kwh/m 3 is possible (a readjustment may be necessary). 2 See also notes at Engineering. 3 Details for multi-boiler plants (cascade) with common flue gas line: see Hoval UltraGas (250D-2000D). * Data unknown at time of printing Boiler flow resistence see separate page. 4 210 267 / 04 Technical information 19
4.3 Dimensions / Space requirements (All measurements in mm) Note: Minimal space see separate page 1 Flow heating 2 Low temperature-return 3 Gas connection 4 Safety valve 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 joint for plastic tube 11 Air inlet connector (Option) 12 Boiler foot adjustable up to 80 mm 13 Flow fitting pipe (Option) 14 Return fitting pipe (Option) 15 Expansion 1" 16 Pressure limiter ¾ 17 Safety temperature control ½ Type A B C D D1 D2 E F G H I J K L M N O Q R (125,150) 1823 633 1336 981 854 324 820 1565 1378 701 677 143 491 287 199 199 200 242 1633 (200-300) 1923 743 1684 1247 1204 321 930 1667 1428 718 710 155 498 287 280 200 186 368 1696 (350) 2070 923 1775 1268 1294 326 1110 1800 1438 808 630 160 528 284 345 205 205 345 1720 (400-500) 2070 923 1775 1268 1294 326 1110 1800 1438 808 630 160 528 284 345 205 205-12 1829 (575-720) 2086 1103 1928 1438 1480 316 1290 1800 1442 834 608 202 554 284 367 367 110 86 1847 (850,1000) 2139 1363 2243 1703 1790 313 1550 1854 1494 858 636 204 578 294 417 417 218 198 1888 Type S T U V W X Y Z 1,2,5 3 4 8 10 11 (125,150) 351 90 1632 107 207 473 195 138 DN 65 / PN6 / 4 screws* Rp 1" R 1 ½" Ø155/159 DN25 Ø122/125 (200-300) 371 100 1702 108 207 472 217 183 DN 65 / PN6 / 4 screws* Rp 1 ½" R 1 ½" Ø252/256 DN25 Ø197/200 (350) 435 100 1730 100 204 484 267 210 DN 100 / PN6 / 4 screws* Rp 1 ½" R 1 ½" Ø302/306 DN25 Ø197/200 (400-500) 447 100 1812 176 204 484 267 210 DN 100 / PN6 / 4 screws* Rp 2" R 1 ½" Ø302/306 DN25 Ø247/250 (575-720) 513 100 1818 176 204 530 357 218 DN 125 / PN6 / 8 screws* Rp 2" R 2" Ø302/306 DN40 Ø247/250 (850,1000) 624 100 1880 176 214 554 455 243 DN 125 / PN6 / 8 screws* Rp 2" R 2" Ø402/406 DN40 Ø247/250 * DN = nominal diameter, PN = nominal pressure, example DN65 / PN6 / 4 screws 1) Important: An automatic air vent (AAV) must be fitted before any isolation valve. This is not provided by Hoval. 20 Technical information 4 210 267 / 04
4.3.1 Opening dimension Boiler without casings and insulation wrap UltraGas Measurements for installation as individual parts Type A B C D E F G H I J K (125,150) 1520 680 1072 980 1295 1380 1191 1040 140 680 236 (200-300) 1585 790 1422 1330 1355 1445 1260 1390 140 950 316 (350) 1610 970 1530 1420 1380 1450 1272 1480 160 970 377 (400-500) 1810 970 1530 1420 1380 1650 1272 1480 160 970 377 (575-720) 1810 1150 1720 1605 1400 1635 1316 1690 175 1150 408 (850,1000) 1885 1410 2027 1916 1483 1686 1375 2000 199 1410 458 Required min. width of door and corridor to bring in the boiler The following informations are minimal dimensions K L B < 150 K = T = B T B K x L x L B = Boiler width L = max. length of boiler T = Door width K = Corridor width T Calculation example for the necessary corridor width Door width T = 1000 UltraGas (400-500) K = 970 x 1531 = corridor width 1486 1000 4 210 267 / 04 Technical information 21
4.4 Hydraulic resistance UltraGas (125, 150) Flow Druckverlust resistance [mbar] 25 20 15 10 5 0 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Through Volumenstrom put flow rate [m3/h] [m3/h] UltraGas (200-300) Flow resistance [mbar] 60 50 40 30 20 10 0 0 5 10 15 20 25 30 Volumenstrom [m3/h] Through put flow rate [m3/h] UltraGas (350-500) UltraGas (575-720) 30 Flow Druckverlust resistance [mbar] 25 20 15 10 5 0 0 5 10 15 20 25 30 35 40 45 Through Volumenstrom put flow rate [m3/h] Flow resistance [mbar] 25 20 15 10 5 0 0 5 10 15 20 25 30 35 40 45 50 55 60 65 Through Volumenstrom put flow rate [m3/h] UltraGas (850,1000) Flow resistance [mbar] 60 50 40 30 20 10 0 0 10 20 30 40 50 60 70 80 90 100 Through put flow rate [m3/h] 22 Technical information 4 210 267 / 04
4.5 Brief description of the automatic firing device The automatic firing device BIC960 of the UltraGas only operates in conjunction with the heating controller TopTronic T/UG. For this reason, the automatic firing device only needs to take care of the last remaining functions to ensure the correct operation of a modulating gas boiler. The automatic firing device comprises the following functions: -- PWM fan control (230V AC) --Modulating operation -- Common electrode for ignition and flame monitoring (ionisation) --LPG valve and boiler room fan controllable -- Inputs for flow sensor 1 flow sensor 2 flue gas sensor water pressure sensor safety temperature limiter (not used) air pressure switch (not used) gas pressure switch -- Status outputs fault and flame signal -- Allows connection of additional (external) ignition device -- RS 485 connection to TopTronic T/UG -- RS 232 connection to PC -- Start attempts: maximum 4 -- Safety period: 5 sec -- Pre-ignition period: 5 sec -- Pre-purging period: 50 sec -- Follow-on time pump (230V AC): 5 min after heat demand Fuses: The BIC 960 is fitted with 3 fuses: 2AT Mains 4AT Pump 4AT Burner fan Blowing of one of the two 4AT fuses securing the pump or the burner fan, respectively, will prevent the affected device from starting. A failure of the mains fuse of the automatic firing device is displayed on the TopTronic T/UG with the error message DATABUS ERROR 70-6. 4 210 267 / 04 Technical information 23
5. Installation 5.1 Safety information Caution! Sharp edges pose a cutting hazard. Handle the casing parts with care and avoid contact with sharp edges. 5.2 Boiler room requirements The boiler room must satisfy the applicable local building regulations. The boiler room ventilation must satisfy the applicable local regulations in this regard. Boilers may not be installed in rooms containing halogen compounds which can be carried into the combustion air (e.g. wash rooms, drying rooms, DIY rooms, hair dresser rooms). Halogen compunds can originate, for example, from cleaning and degreasing agents, solvents, glue, and bleaching lyes. Ensure that the required combustion air can flow unhindered at all times. This is important for the correct operation of all the boilers installed therein and to protect the users from an oxygen depleted atmosphere. An adequate fresh air supply meeting the local regulations must be provided. 5.2.1 Room air dependent installation The applicable regulations do not normally provide any specific data on the size of air intakes. They only require the pressure in the boiler room not to be below 3 N/m 2. 5.2.2 Room air independent installation i Configuration based on a connection for direct combustion air supply or air intake valve motor (optionally): The following must be observed when laying out the intake pipe: If the intake opening is installed on the house façace near to a noise-sensitive area (e.g. bedroom windows, garden seating area, etc.) we recommed installing a noise damper in the direct fresh air suction line. The intake opening must be easily accessible. No chemicals or poisonous substances may be stored close to the intake opening The intake opening may not be installed beside fume extraction outlets or other venting outlets. Ensure that the intake aperture is free from any obstructions at all times (leaves, snow,...) A safety grid must be installed on the suction opening on the outside wall. 24 Installation 4 210 267 / 04
5.3 Flue gas connection and flue Due to the low flue gas temperatures, condensate forms within the flue. For this reason, HOVAL gas heating boilers can not be connected to conventional house chimneys. i The flue gas extraction system must comply with the following directives: DVGW (TRGI) ÖVGW SVGW/VKF Pursuant to the abovementioned regulations, a flue gas temperature limiter must be installed in the boiler. i i The flue gas system must meet the following requirements: Gastight Watertight Acid-proof Approved for flue gas temperatures of up to 120ºC (T 120) Approved for overpressure Unhindered backflow of condensate into the boiler can only be ensured if: The gradient of the horizontal connection elements is at least 50 mm/m. i Cross sections and maximum lengths are calculated on the basis of graphs or tables. The tables can be obtained from the chimney or flue system manufacturer. The calculation values can be obtained from the table in chapter 4.2. The flue gas conduit cross sections and lengths are calculated following the technical data for the boiler. 4 210 267 / 04 Installation 25
5.4 Condensate drainage i The condensate drainage pipes on the boiler must be made of corrosion resistant material. The following materials are suitable for condensate drainage: PVC PE PP ABS The local regulations regarding condensate drainage must be observed. 5.4.1 Execution variants The siphon needs to be instal-led and filled with water before starting up the system. The siphon is filled with water through the cleaning aperture. Variant 1 (siphon included in the boiler scope of delivery) The siphon needs to be instal-led and filled with water before starting up the system. The siphon is filled with water through the cleaning aperture. Variant 2 with neutralisation (Neutralisation box type KB 23) Variant 3 + 4 (with high-altitude drain) KB 24 Neutralisation box with pump incl. neutralisation KB 22 Neutralisation box with pump without neutralisation 26 Installation 4 210 267 / 04
Variant 5 UltraGas on base without adjustable feet UltraGas (575-1000) The siphon needs to be installed and filled with water before starting up the system. The siphon is filled with water through the cleaning aperture. 1 Neutralisation box 2 Condensate pump: Art. Nr. 6015159 3 Base bricked Condensate pump free standing, with or without high-altitude neutralisation box 5.5 Gas connection Hazard! Explosion hazard due to leaky gas connection. Check the gas connection for gas tightness after completing the boiler installation. Gas connection, see dimension drawings under 4.3. Gas connection, straight to the back! Check for gas tightness after installation! 5.6 Hydraulic connection The boiler comprises the following safety equipment, in accordance with EN 12828:2003: - Minimum pressure limiter DBmin - Safety maximum pressure limiter DBmax - Hydraulic pressure monitor DBmax + 50% - Thermostat - Temperature monitor TBmax + 20% - Safety temperature limiter i To achieve an optimal efficiency, ensure that the return pipe is properly connected. High temperature return (e.g. venting group or calorifier) Low temperature return (e.g. underfloor heating) 4 210 267 / 04 Installation 27
5.6.1 Customer-side requirements A pressure expansion tank adapted to the heating system, water volume and static height. 5.6.2 Hydraulic interconnection When combining a calorifier with floor heating, a mixer needs to be installed. A minimum amount of circulating water is not required. 5.6.3 Cascade control As a basic principle, the Hoval TopTronic should perform cascade control. This ensures an environmentally and product-friendly method of operation. However, if an external cascading strategy is planned and boiler performance control is carried out, frequent cycles should be avoided (at least 12 minutes burner running time is required between cycles). Regarding suitable hydraulic connections, please observe the notes in the planning documentation of the relevant Hoval sales company! Example: UltraGas (125-1000) Gas heating boiler with - water heating, - wall distributor with return separation, - 1 mixed heating circuit and water heating for high temperature return - mixed heating circuit for low temperature return Hydraulic schematic BCST050 Make sure to close off un used connectors tightly Notice: - This hydraulic schematic is a principle schematic. It does not contain all details for installation. The installation must be done 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 unintended closing! - Anti thermal siphon dip has to be installed. - An automatic air vent (AAV) must be fitted on the top boiler connection and before any isolation valve. This is not provided by Hoval. 28 Installation SV AF TopTronic T AAV RS-T P 1 HT NT RS-T Dies ist ein unerlaubter Weg! Gehen Sie einen Schritt zurück oder löschen Sie dieses Shape! UltraGas Sie haben die Möglichkeit (125-1000) (125-650) ein neues Shape zu HT nehmen!!! HT hovhovalh NT hovalhova NT alhovalho RS-T Room station VF1 YK1 M AF Outside sensor VF1 Flow sensor 1 VF2 Flow sensor 2 SF Calorifier sensor B1 Flow temperature monitor (on demand) SV Safety valve AAV Automatic air vent T MK1 T VF2 YK2 M T MK2 B1 MK1 Pump mixing circuit 1 MK2 Pump mixing circuit 2 SLP Calorifier - loading pump YK1 Actuator mixer 1 YK2 Actuator mixer 2 HT NT T SLP KW SF WW High temperature low temperature Dies ist ein unerlaubter Weg! T 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 4 210 267 / 04
5.7 Electrical connection --The electrical connection must be carried out by an approved electrician. i -- The connection diagram is located within the boiler control box. --The electrical circuit diagram is supplied separately. The following applies to Austria and Germany: A connection diagram is provided with the boiler control unit. The power supply must be fitted with an omnipolar isolation switch with a contact gap of at least 3 mm. The following applies to Switzerland: The electrical connections must comply with the system-specific electrical circuit diagram! Safety measures for EMC installation Control units with their own mains connection require the mains, sensor and bus cables to be routed separately. i Cable trunking with dividing partitions should be used. The mains connection for the heating system (boiler-control panel-control unit) must be configured in form of an independent electric circuit. No other electrical loads (light, power outlets,...) may be connected to that electric circuit. The external sensor may not be installed close to transmitters or receivers (garage door openers, amateur radio aerials, radio alarm systems,...). Procedure to remove the front covering panel 1. Remove front cover (1, fig. 23a), after first releasing the lateral locking bolt (1a) (turn approx. ¼ turn to the left and pull out as far as the stop). Lift the front cover (1) straight upwards and remove towards the front. 2. Remove lower front cover (2), after first releasing the lateral locking bolt (2a) (turn approx. ¼ turn to the left and pull out as far as the stop). Slightly raise the lower front cover (2) and remove towards the front. 3. Remove the locking screw (3a) on the right. 4. Lift the switch control box (3) and fold it out. 5. Cable entry refer to the Technical Datasheet (Dimensions, point 4.3, item 6) The electrical connection is to be made in accordance with the diagram supplied. 1 1a 3a 3 2a 2 Fig. 06a Recommended conductor cross sections: Conductor type Cross section Length Mains voltage cables min. 1,0 mm² unlimited m Extra-low voltage cables min. 0,5 mm² (sensors) Data bus cables (screened) 2 x 0,6 mm² max. 50 m max. 100 m 4 210 267 / 04 Installation 29
6. Commissioning After filling the system with water, bleed any air and check for water leaks. Before putting the boiler into operation, the siphon and neutralisation tank needs to be filled with water. When starting up the system for the first time, the correct operation of all the safety and control devices must be verified. The operation and maintenance of the system must be explained to the user in detail. The combustion air needs to be filtered in very dusty environments. The gas flow pressure and the CO 2 value must be checked imperatively and set correctly. 6.1 Safety information Caution! Sharp edges pose a cutting hazard. Handle the casing parts with care and avoid contact with sharp edges. i Caution! Danger of injury for unqualified personnel. Maintenance and cleaning work may only be performed by trained personnel or by the HOVAL Customer Service. Caution! Danger of damaging the system by filling it with incorrect liquids. Water filled into the system must have drinking quality. 6.2 Filling with water Filling of the heating system may only be carried out by qualified personnel. The European Standard EN 14868 and the Directive VDI 2035 must be observed (see chapter 6.3). Open the isolating valves in the flow and return lines. Connect the water hose to the filling tap. Fill the heating system slowly. i Monitor the water level on the manometer. i Use only chemical additives with suppliers confirmation of their safe usage. If frost protection agent is being used, please contact the Hoval company to ask for the separate engineering sheet. 30 Commissioning 4 210 267 / 04
6.3 Water quality Heating Water The European Standard EN 14868 and the directive VDI 2035 must be observed. In particular, attention must be paid to the following stipulations: Hoval boilers and calorifi ers are designed for heating plants without signifi cant 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. Treated fi lling and replacement water must be tested at least 1x yearly. According to the inhibitor manufacturer s instructions, more frequent testing may be necessary. A refi lling is not necessary if the quality of the heating water in existing installations (e.g. exchange of boiler) conforms to VDI 2035. The Directive VDI 2035 applies equally to the replacement water. New and if applicable existing installations need to be adequately cleaned and fl ushed befor being fi lled. The boiler may only be fi lled after the heating system has been fl ushed! Parts of the boiler / calorifi er which have contact with water are made of ferrous materials and stainless steel. On account of the danger of stress cracking corrosion in the stainless steel section of the boiler the chloride, nitrate and sulphate content of the heating water must not exceed 50 mg/l. The 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 drinking water is generally best suited as heating medium, i.e. as fi lling and replacement water. However, as not all drinking water is suitable for use as as fi lling and replacement water the water quality must fulfi l the standard set in VDI 2035. Should the mains water available not be suited for use then it must be desalinated and/ or be treated with inhibitors. The stipulations of EN 14868 must be observed. In order to maintain a high level of boiler effi ciency 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). The total amount of fi lling 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. Maximum filling capacity based on VDI 2035 Total 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 <1 5 10 15 20 25 30 >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 REQUI- 50 l/kw 20 l/kw 20 l/kw 200 to 600 kw RE- 50 l/kw 50 l/kw 20 l/kw always desalinate over 600 kw MENT 1 Sum of alkaline earths 2 If the conductance in µs/cm exceeds the tabular value an analysis of the water is necessary. 4 210 267 / 04 Commissioning 31
6.4 Bleeding the air from the gas line Observe the relevant regulations when bleeding the gas line Open the gas shut-off valve. Bleed the air up to the gas armature. 6.5 Switching on the system Switch on the main switch. 6.6 Gas inlet pressure i The gas flow may only be adjusted and the heating system therefore started up, if the minimum flow pressure values are achieved (see section 6.7 Adjusting the gas flow). The minimum flow pressure in the connector pipe must reach the following values: Natural Gas 18 to 80 mbar Liquid gas 37 to 57 mbar 32 Commissioning 4 210 267 / 04
6.7 Setting the gas flow rate CO 2 (O 2 ) and measurement of NOx/CO content in the flue gas 6.7.1 Flue gas measurement UltraGas (125-720) Screwdriver, allen key 3 mm, TorxT40 The Honeywell multiple actuator allows measuring the inlet pressure on measuring nipple A. A Measuring nipple gas inlet pressure B Impulse pipe connector C Gas choke D Offset screw B D C A i Flow setting operation: To set the flow on the valve, both flue gas values need to be controlled. e.g.: Set upper value - control lower value - value incorrect - set lower value - control upper value -... Press the emission monitoring key. i After 20 min. the controller switches over to normal operation automatically. Position the emission monitor in the flue gas duct. Set the boiler to maximum output (100%). Set the CO 2 (O 2 ) value by turning the choke screw C. i The content in the flue gas must be between CO 2 = 8.5-8.8 (O 2 = 5,9-5,5) vol% (dry). Press the emission monitoring key. Set the CO 2 (O 2 ) value by turning the choke screw D. i The content in the flue gas must be between CO 2 = 8.5-8.8 (O 2 = 5,9-5,5) vol% (dry). Measurement of NOx and CO content. The measured values must meet the limiting values prescribed by the regulations. Values exceeding these reference values are an indication of faulty burner setting, gas burner or heat exchanger contamination or gas burner defect. If the limiting values prescribed by the regulations are exceeded, the boiler must be put out of operation and the corresponding measures for repair work must be initiated. Press the emission monitoring key. 4 210 267 / 04 Commissioning 33
6.7.2 Flue gas measurement UltraGas (850,1000) Screwdriver, allen key 2,5 mm The Dungs multiple actuator allows measuring the inlet pressure on measuring nipple A. A Measuring nipple gas inlet pressure B Impulse pipe connector C Gas choke D Offset screw Use step boards! (see point 7.5.1) B C D A Flow setting operation: i To set the flow on the valve, both flue gas values need to be controlled. e.g.: Set upper value - control lower value - value incorrect - set lower value - control upper value -... Press the emission monitoring key. i After 20 min. the controller switches over to normal operation automatically. Position the emission monitor in the flue gas duct. Set the boiler to maximum output (100%). Set the CO 2 (O 2 ) value by turning the choke screw C. i The content in the flue gas must be between CO 2 = 8.5-8.8 (O 2 = 5,9-5,5) vol% (dry). i Factory setting: Choke screw C 11 mm =^ 4¾ turns from the closed state Ca. 11 mm Set the boiler to minimum output (1%). Set the CO 2 (O 2 ) value by turning the offset screw D. i The content in the flue gas must be between CO 2 = 8.5-8.8 (O 2 = 5,9-5,5) vol% (dry). Measurement of NOx and CO content. The measured values must meet the limiting values prescribed by the regulations. Values exceeding these reference values are an indication of faulty burner setting, gas burner or heat exchanger contamination or gas burner defect. If the limiting values prescribed by the regulations are exceeded, the boiler must be put out of operation and the corresponding measures for repair work must be initiated. Press the emission monitoring key. 34 Commissioning 4 210 267 / 04
6.8 Changing over to a different gas type i This changeover may only be carried out by an authorised specialist or by the HOVAL Customer Service. Changeover from natural gas H to natural gas L An emission check is required when changing to a natural gas of lower calorific value; a correction of the CO 2 (O 2 ) value may be necessary (see section 6.7 Setting the gas flow rate). Changeover from natural gas to liquid gas The applicable local provisions for operating a boiler with liquid gas are to be complied with. VKF DVGW ÖVGW Ensure that the liquid gas line is free of any air. Any air in the liquid gas line can have a negative influence on the flue gas values. For UltraGas (125-350) (850,1000) only approved for propane 1. With boiler already connected: - close the gas valve - place the system switch in the operating panel to 0 2. Remove the boiler hood 3. Set the gas pressure monitor from 10 to 30 mbar (see photo below) 4. On the left of the boiler rating plate, affix the yellow sticker Change made to the set gas type: Liquid gas 5. With boiler already connected: - open gas valve - place the system switch in the operating panel to I 6. Adjust fan speed of rotation according to parameter list to liquid gas 7. Set the CO 2 (O 2 ) content as described under 6.7 at rated output and minimum output to CO 2 = 9,9-10,2 (O 2 = 5,9-5,5) vol-% (dry). For UltraGas (400-720) only approved for propane 4 210 267 / 04 Commissioning 35
For UltraGas (400-720) only approved for propane 1. With boiler already connected: - close the gas shut-off valve - place the system switch in the operating panel to 0 2. Take off the boiler hood Fit the aperture aperture The conversion kit contains: Yellow sticker Aperture with seal 4 scews M5x16 Aperture diameter: UltraGas (400-500) Ø 16,5 mm UltraGas (575-720) Ø 21 mm 3. Set gas pressure monitor from 10 to 30 mbar (see photo page 32) 4. On the left of the boiler rating plate, affix the yellow sticker Change made to the set gas type: Liquid gas 5. With boiler already connected: - open gas valve - place the system switch in the operating panel to I 6. Adjust fan speed of rotation according to parameter list to liquid gas Check for leaks after the installation! 7. Set the CO 2 (O 2 ) content as described under 6.7 at rated output and minimum output to CO 2 = 9,9-10,2 (O 2 = 5,9-5,5) vol-% (dry). 36 Commissioning 4 210 267 / 04
6.9 Type (850,1000) Setting for the stabilisation damper (if necessary) The stabilisation damper reduces the outlet cross-section of the fan during the startup phase. This optimises the start-up characteristics of the boiler! Factory setting for the stroke: 20 mm. This is the optimum setting under normal flue conditions. If even stronger compression is required, the stroke can be set to a maximum of 22.5 mm using the setscrew. If lower compression is required, the stroke can be lowered, e.g. to 18 mm, using the setscrew. Setscrew Stroke 20 mm 4 210 267 / 04 Commissioning 37
6.10 Handover to the user i The manufacturer of the unit is responsible for providing operating instructions for the complete system. The following must be carried out during handover to the user: Provide instructions in the operation and maintenance of the system. Handover of all the instruction manuals and documents. Explain to the user that these instructions must be kept with the system at all times. Written confirmation of receipt of instruction. See last page for handover protocol. 38 Commissioning 4 210 267 / 04
6.11 Record - Activation of screed function Cross where applicable; cut out record and fasten to the control during the active screed function. Minimum requirements for the activation of the screed function: Minimum age cement screed 21 days Minimum age calcium sulphate screed 7 days Flow temperature monitor installed and connected For newly laid screed - see Recommendation of the Federal Association of Radiant Panel Heating. Heating circuit selection for screed function and necessary parameter settings Mixing circuit 1 Mixing circuit 1 Start MC1/MC2 level Parameters 13,16 PRESS Activate Installer level (Code entry) > 3 sec: Access to level Select / Confi rm Set Confi rm End / Exit Required parameter settings: Parameter level Par. No Setting Description MIX.VALVE (1 or 2) 13... C Maximum fl ow temperature to be set MIX.VALVE (1 or 2) 16 Screed program to be set (for description see following page) 1 2 3 1 Function heating (duration: Starting day + 7 days) 2 Surface-ready heating (duration: Starting day + 18 days) 3 Function and surface-ready heating (duration: Starting day + 25 days) Direct heating circuit (possible only with H-Gen without minimum H-Gen temperature - e.g. condensing boiler) Start HC level Parameters 13,16 PRESS H-GEN level Parameter 4 Characteristic heating curve Enable HC Activate Installer level (Code entry) > 3 sec: Access to level Select / Confi rm Set Confi rm End / Exit Required parameter settings: Parameter level Par. No Setting Description - Key DK... Activate heating characteristic curve, above 0 = OFF, e.g. ~ 0.8 for FBH UNMIXED CIRC. 13... C Maximum fl ow temperature to be set UNMIXED CIRC. 16 1 2 3 Screed program to be set (for description see following page) 1 Function heating (duration: Starting day + 7 days) 2 Surface-ready heating (duration: Starting day + 18 days) 3 Function and surface-ready heating (duration: Starting day + 25 days) HEAT GENER. 4... C Max. H-Gen temperature to be set, set as for max. fl ow temperature (after termination of screed function reset max. temperature to the value required). If the screed function is activated for the unmixed circuit, all the other circuits (MC, DHW) are switched off. In alternation with the basic display of the controller, the activated screed heating is displayed giving some information about the remaining term in days screed - 18. Record Screed heating activated by:... Screed heating activated on:... Screed heating ends on:...... Date and signature 4 210 267 / 04 Commissioning 39
Parameter 16 Screed function (Parameter HC, MC1 or MC2) Example: Maximum fl ow temperature 40 C 1 Function heating T [ C] VLSol 55 45 35 25 maximal 55 C maximum 55 C einstellbar! set level! 1=Funktionsheizen Starting day + 7 days 1 = Function heating START 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 DAYS t [TAGE] On the starting day and for the three following days at 25 C constantly Subsequently for 4 days at the set fl ow maximum temp., but limited to a maximum of 55 C 2 Surface-ready heating T [ C] VLSol 55 45 35 25 2=Belegreifheizen Starting day + 18 days 2 = Surface-ready heating START 11 22 33 44 55 66 77 88 9910 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 DAYS t [TAGE] On the starting day and on the 1st day constantly at 25 C, on each further day the demand value rises by 5 C until the maximum fl ow temperature is reached. Subsequently the temperature is lowered again in the same gradations until the low point of 25 C is reached. Example: Set fl ow maximum temp.: 40 C Starting day + 1st day: 25 C 5th - 15th day: constant heating with the max. flow temperature 2nd day: 30 C 16th day: 35 C 3rd day: 35 C 17th day: 30 C 4th day: 40 C 18th day: 25 C 3 Function heating and surface-ready heating Starting day + 25 days T [ C] VLSol 55 45 35 25 3=Funktionsheizen 3 = Function heating and und surface-ready Belegreifheizen heating START 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 [TAGE] t DAYS Combination of 1 function heating and subsequently 2 surface-ready heating 40 Commissioning 4 210 267 / 04
7. Maintenance Caution! Missing or faulty cleaning and maintenance may cause damage to the installation. The heating installation must be surveyed and cleaned once a year. If required, installation maintenance must be carried out. Defects must be remedied immediately in order to prevent damages to the installation! 7.1 Safety information Caution! Sharp edges pose a cutting hazard. Handle the cladding parts with care and avoid contact with sharp edges. Caution! Danger of injury for unqualified personnel. Maintenance and cleaning work may only be performed by trained personnel or by the Hoval Customer Service. Caution! After repair work respectively exchanging boiler parts, a flue gas measurement according to point 6.7 must be carried out imperatively. Caution! If the boiler has several feed-ins: Before accessing the connecting terminals, all electric supply circuits must be disconnected. 7.2 Bleeding Open all radiator valves. Heat up the system for at least half a day with a high flow temperature. Turn off the boiler and wait 5 minutes. Bleed all the air from the system. 7.3 Water refilling The European Standard EN 14868 and the Directive VDI 2035 must be observed (see chapter 6.3). i The systems warns when the water pressure falls below 1 bar and the boiler output is reduced to 50%. If the water pressure falls below 0.5 bar, the boiler is set automatically to a fault state. The system must be refilled with water when the pressure falls below the minimum system pressure: Connect the filling hose to the water supply. Remove the air from the filling hose. Connect the filling hose to the filling and draining cock. Top up with water (see point 6.2). 4 210 267 / 04 Maintenance 41
7.4 Information for combustion controller/chimney sweep regarding emission monitor key All other control elements of the control unit are described in the operating instructions. The emission monitor key can also be used to change over to manual operating mode. Emission monitor key / Manual operation To protect under floor heating systems against invalid overheating during emission monitoring / manual operation it is necessary to implement appropriate safety measures (e.g. safety temperature limiter with pump switch-off). The duration of the emission monitoring is limited to 20 minutes and shall be restarted, if necessary. Scalding hazard due to hot water temperature, since the hot water temperature can exceed the temperature setpoint! Emissions metering PRESS SHORTLY % % Output reference / actual value Modulation display Immediate end REACTIONS for emissions metering Time unit automatically 20 min. thereafter reverts Boiler temperature - > maximum temperature restriction The heating circuits and the calorifi ers regulate to their maximum temperature (at the direct heating circle only, if the warm water mode of operation is adjusted to parallel operation) Manual operation PRESS > 5 seconds Immediate end REACTIONS for manual operation Set reference boiler temperature with button! All heating pumps ON Mixer without current - manual setting necessary! Note the maximum permissible temperature of the fl oor heating! The hot water temperature reaches the set DHW maximum temperature (expert level standard 65 C). 42 Maintenance 4 210 267 / 04
7.5 Cleaning i The boiler may only be cleaned by an authorised technician or by the HOVAL Customer Service. i The HOVAL gas heating boiler should be cleaned and maintained once every year. If the HOVAL gas heating boiler was in operation during the building phase, it will be necessary to carry out a check for cleanliness. If the boiler is dirty, clean it. 7.5.1 Cleaning the burner cylinder (inside and outside) i The burner cylinder must be cleaned if visible contamination exists (such as deposits, e.g. builder s dust). Adjustable spanner, screw driver, vacuum cleaner, compressed air, water. Preparation: 1. Remove front sheet 2. Fold out step board(s) 3. Set the main switch on the boiler control unit to 0. 4. Close the main gas valve. 5. Remove the sound insulation covers. 6. Disconnect all the burner connector plugs. 7. Disconnect the earthing cable (1) from the burner cylinder (fig. 7). 8. Disconnect the gas connection from the gas armatures (use the special open-ended spanner enclosed). 9. Unscrew the fan with the gas mixing unit in place (2, fig. 8).! Removal and cleaning: Fig.: Types (850,1000) Caution, burn hazard 10. Safety gloves must be worn when removing the burner cylinder. 11. Lift the burner cylinder out (3, fig. 9). 12. Clean the premix burner with compressed air inside and out, or rinse thoroughly with water. 13. Remove dust and dirt particles with a vacuum cleaner (4, fig. 10). Reassembly: 14. Replace the gasket on the gas connection. 15. Reassemble the burner in reverse order. 16. Check for leaks. 17. Carry out a flue gas measuring according to point 6.7. 3 1 2 4 Fig. 07 Fig. 08 Fig. 09 Fig. 10 4 210 267 / 04 Maintenance 43
7.5.2 Cleaning the exterior of the combustion chamber and burner cylinder Warning! Chemical burn hazard through cleaning agents. Safety gloves and eye protection must be worn when using cleaning agents. Observe the information on the original packaging. Caution! The system can be damaged when using incorrect cleaning agents. Use only cleaning agents approved for gas boilers with aluminium components. i Spray on the cleaning agent undiluted. Adjustable spanner, screw driver, spray gun Preparation: 1. Set the main switch on the boiler control unit to 0. 2. Close the main gas valve. 3. Remove the sound insulation cover. 4. Disconnect all the burner connector plugs. 5. Remove the front casing. Opening the combustion chamber: 6. Unscrew star knob 7. Burner with the boiler door up swivel (fig. 11) Warning! If a gas pressure spring is weakened, the boiler door is lowered. There is an increased danger of injury when reopening the boiler door. Note! Both gas pressure springs must be replaced.. 8. Remove the cover on the cleaning aperture (9, fig. 12) 9. Remove the neutralisation box and siphon. i (For maintenance of the neutralisation unit see section 7.8 Neutralisation unit) 9 Fig. 11 Fig. 12 44 Maintenance 4 210 267 / 04
Cleaning : Spray the combustion chamber and alufer tubes (3, fig. 13). i The best results are obtained with a spray gun with a suitable wide jet nozzle (fan or conical jet). We recommend, e.g.: Desoxin Leave the applied cleaning agent to react as instructed by the manufacturer. Then remove the contamination on the combustion chamber and alufer tubes by spraying them with clean water using a powerful jet. Repeat the procedure in case of stubborn dirt. Flush clean the bottom tube plate. i Use an angled spray lance. Clean and dry the boiler tray. Clean the siphon. screw it off clean it screw it back on fill it with water Clean the fabric material in the burner cylinder with compressed air. Reconnect the gas and electrical connections. Place the boiler into operation Carry out a flue gas measuring according to point 6.7. Correct the settings, if necessary. Complete a measurement record. 3 Fig. 13 7.5.3 Cleaning/adjusting the ignition and ionisation device Fine sanding paper, long-nosed pliers, blowtorch, compressed air Preparation Set the main system switch of the boiler control to 0. Open the combustion chamber as described in section 7.5.2 (cleaning the exterior of the combustion chamber and burner cylinder). Cleaning Sand the ignition and ionisation device with fine sanding paper. Clear the sanding dust. 4 210 267 / 04 Maintenance 45
Procedure to readjust: Check all electrode distances and reset where necessary (see fig. 14 and 15). Heat the ignition electrode at the kink with the blowtorch until it glows red. Bend the ignition electrode with the long-nosed pliers until the required distance is set. Ignition electrode Ignition and ionisation electrode 4 mm 10 ± 2 mm 4 mm Fig. 14 Fig. 15 Reassembly: ( 214,5 ) Replace the gasket at the gas connection. Reassemble the burner in reverse order. Check for leaks 7.5.4 Cleaning the gas filter HFVR050 (only applicable for UltraGas (450-720)) (if fitted) Gas valve ( 116 ) Gas filter ] ] Die Dichtheit der Verschraubungen ist mittels Leckspray zu prüfen Beim Eindichten aller Gasamaturen darf mit dem Auftragen des Dichtungsmaterials frühstens beim zweiten Gewindegang begonnen werden 46 Maintenance Umbauset Gasventil V434 Gegenstand Werkstoff Bemerkung Aenderungen Werkst.-code Werkstoffnr. Replace the gas filter if it is not possible to clean it perfectly. After assembly, check the gas tightness (e.g. using a leak detection spray). Gezeich. 26.09.13 Umbauset Gasventil V434 Massstab Geprueft 26.09.13 31-UltraGas (575-720) Verwendet in : Pos.10 Faltkarton 655x305x266 Pos.11 Anl. Umbauset Gasventil VR434 Pos.12 Rücksendeformular - Gasventil The gas filter must be cleaned immediately after the initial commissioning and in occasion of the annual maintenance. Clean the removed gas filter with clean running water and reinstall it dry. GASI GASI Masse ohne Toleranzangabe UltraGas (575-720) % siehe Hovalnorm HN 020400 Ersetzt durch: Ersatz fuer: Aktiengesellschaft 3 Art.Nr. 6 034 324K-3 00 4 210 267 / 04