Hoval UltraGas 15 Manual

Subject to modi cations | EN
Technical information
Installation instructions
4 217 213 / 01 - 05/18
UltraGas®(15-50)
Condensing gas heating boilers
for natural gas and liquid gas
for modulating operation
These instructions apply to the following types:
Rated output levels at 40/30 ºC
and for natural gas
45-UltraGas®(15) 3.1 - 15.5 kW
45-UltraGas®(20) 4.0 - 20.2 kW
45-UltraGas®(27) 5.0 - 27.2 kW
45-UltraGas®(35) 5.8 - 35.7 kW
45-UltraGas®(50) 8.3 - 50.1 kW
Hoval products may only be installed and commissioned
by appropriately qualied experts. These instructions
are intended exclusively for the specialist. Electrical
in stal lations may only be carried out by a qualied
electrician.
The oor-standing gas condensing boilers UltraGas®
(15-50) acc. to EN 15502-1/15502-2-1 are suitable and
licensed for use as heat generators for hot water heat-
ing systems with a permissible ow temperature of up
to 85 °C1). They are designed for continuously control-
led reduced operation in heating systems.
1) See technical data

1. Important notes
1.1 General safety instructions.................................................................................................................................................4
1.2 Explanation of the symbols ................................................................................................................................................4
1.2.1 Warnings ..........................................................................................................................................................................4
1.2.2 Warning symbols...............................................................................................................................................................4
1.2.3 Information........................................................................................................................................................................5
1.3 Acceptance of delivery........................................................................................................................................................5
1.4 Scope of guarantee .............................................................................................................................................................5
1.5 Instruction manuals.............................................................................................................................................................5
1.6 Regulations, official permits...............................................................................................................................................6
1.6.1 Germany §........................................................................................................................................................................6
1.6.2 Austria § ...........................................................................................................................................................................6
1.6.3 Switzerland § ....................................................................................................................................................................6
2. Assembly
2.1 Set-up, levelling...................................................................................................................................................................7
3. Technical data
3.1 Description of the boiler .....................................................................................................................................................8
3.2 Technical data UltraGas®(15-50)...................................................................................................................... 9
3.3 Dimensions........................................................................................................................................................................10
3.4 Space requirements .......................................................................................................................................................... 11
3.5 Boiler-Flow resistance ......................................................................................................................................................12
3.6 Brief description of the automatic firing device...............................................................................................................12
4. Installation
4.1 Safety information .............................................................................................................................................................13
4.2 Boiler room requirements .................................................................................................................................................13
4.2.1 Room air dependent installation......................................................................................................................................13
4.2.2 Room sealed installation.................................................................................................................................................13
4.3 Flue gas connection and flue............................................................................................................................................14
4.3.1 Project planning instructions, flue gas systems ...............................................................................................................15
4.3.2 Design examples for room air dependent operation.........................................................................................................16
4.3.3 Design examples for room air independent operation......................................................................................................17
4.4 Condensate drain ..............................................................................................................................................................20
4.4.1 Design variants...............................................................................................................................................................20
4.4.2 Fitting the condensate drain (standard design with siphon) .............................................................................................21
4.4.3 Fitting the neutralisation box ...........................................................................................................................................22
4.4.4 Fitting the condensate delivery pump ..............................................................................................................................23
4.4.5 Fitting the neutralisation box and the condensate delivery pump .....................................................................................24
4.5 Gas connection..................................................................................................................................................................25
4.6 Hydraulic connection ........................................................................................................................................................26
4.6.1 Customer-side requirements ...........................................................................................................................................26
4.6.2 Hydraulic interconnection................................................................................................................................................26
4.7 Electrical connection.........................................................................................................................................................27
4.7.1 Safety measures for EMC according assembly................................................................................................................28
4.7.2 Recommended cable cross sections and permissible maximum length of cable ..............................................................30
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TABLE OF CONTENTS

5. Commissioning
5.1 Safety information .............................................................................................................................................................31
5.2 Filling with water ...............................................................................................................................................................31
5.3 Water quality......................................................................................................................................................................32
5.3.1 Heating water..................................................................................................................................................................32
5.4 Bleeding the air from the gas line.....................................................................................................................................33
5.5 Switching on the system...................................................................................................................................................33
5.6 Gas inlet pressure .............................................................................................................................................................33
5.7 Functional check of combustion cylinder pressure monitoring .....................................................................................33
5.7.1 Check pressure in the combustion cylinder (safety check during commissioning) ............................................................34
5.8 Setting the gas quantity, measuring the CO2(O2) and NOx/CO content in the flue gas (flue gas measurement) .........35
5.9 Changing to a different type of gas ..................................................................................................................................36
5.9.1 Changing from natural gas H to natural gas L..................................................................................................................36
5.9.2 Changing from natural gas to liquid gas ..........................................................................................................................36
5.10 Handover to the operator ..................................................................................................................................................36
5.11 Record - Activation of screed function.............................................................................................................................37
6. Maintenance
6.1 Safety information .............................................................................................................................................................39
6.2 Bleeding.............................................................................................................................................................................39
6.3 Water refilling ....................................................................................................................................................................39
6.4 Renewing fuse ...................................................................................................................................................................39
6.5 Information for combustion controller/chimney sweep regarding emission monitor key .............................................40
6.6 Cleaning.............................................................................................................................................................................41
6.6.1 Cleaning the burner cylinder ...........................................................................................................................................41
6.6.2 Cleaning the exterior of the combustion chamber and burner cylinder .............................................................................42
6.6.3 Leakage testing ..............................................................................................................................................................43
6.6.4 Cleaning/adjusting the ignition and ionisation device.......................................................................................................43
6.7 Setting the gas flow rate CO2(O2) and measurement of NOx/CO content in the flue gas ...............................................43
6.8 Clean siphon or neutralisation box ..................................................................................................................................44
6.9 Maintenance of the Neutralisation equipment (if available) ............................................................................................45
6.9.1 Procedure for servicing the neutralisation installation......................................................................................................45
6.10 Parameter list - automatic firing device BIC 960..............................................................................................................46
3
4 217 213 / 01
TABLE OF CONTENTS

1. Important notes
1.1 General safety instructions
The system shall not be put into operation
until all relevant standards and safety regula
-
tions are met.
For a test run, the following minimum conditions must be
satised:
• Safety valve installed (closed system)
• Controls operative (connected to power supply)
• Sensor for safety temperature limiter is connected
• (= boiler temperature sensor)
• System lled with water
• Siphon lled with water
• Expansion tank connected
• Flue gas adapter pipe with ue gas pipe connected to
ue.
• Burner is preset (see point 6.7).
WARNING
The heat generator can only be de-energised
by disconnection from the mains (e.g. all-
pole switch).
WARNING
All electric power supply circuits must be
switched off before accessing the terminals.
1.2 Explanation of the symbols
1.2.1 Warnings
!
DANGER
... indicates a situation of immediate danger
which will lead to serious or fatal injuries if
not avoided.
!
WARNING
... indicates a situation of possible danger
which can lead to serious or fatal injuries if
not avoided.
!
CAUTION
... indicates a situation of possible danger
which can lead to minor or slight injuries if
not avoided.
NOTICE
... indicates a situation of possible danger
which can lead to damage to property if not
avoided.
1.2.2 Warning symbols
The following warning signs are combined for the warn-
ing notes with signal words CAUTION, WARNING and
DANGER.
!
General warning of a danger zone.
«Warning: dangerous electrical voltage» as a
warning for accident prevention.
Ensures that people do not come into contact
with electrical voltage. The danger sign with
the black lighting symbol warns against the
danger of electrical voltage.
«Warning of hot surface» sign for indicating
safety.
Indicates dangers of injury and burns on hot
surfaces.
Incorrect handling of potentially explosive
substances can lead to serious damage, po
-
tentially fatal injuries and incalculable costs.
Danger: Substances with a corrosive effect on
skin, eyes and respiratory organs; can cause
irritation.
Handling: Do not inhale vapours and avoid
contact with skin and eyes.
44 217 213 / 01
IMPORTANT INFORMATION

Warning of cutting injuries:
Avoid cutting injuries. Clearly indicate the dan
-
ger of cutting on sharp-edged parts to avoid
serious and costly injuries.
1.2.3 Information
Information:
Provides important information.
Follow the instructions for use.
Requirements to comply with the instructions.
Tool:
Which tools and other equipment are required.
§
Provides important information.
Refers to standards and directives.
1.3 Acceptance of delivery
A visual control of the heating boiler should be conducted
upon delivery.
In the event of damage, the necessary steps should be
followed as specied in the delivery contract. The costs
for correcting the damage shall be taken over by the indi-
vidual risk bearer.
1.4 Scope of guarantee
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
1.5 Instruction manuals
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 re-
spective components!
Additional sources of information:
• Hoval catalogue
• Standards and regulations
5
4 217 213 / 01
IMPORTANT INFORMATION

1.6 Regulations, official permits
When installing and operating the system, the standards
and regulations spec i ed in point 1.6.1 to 1.6.3 must be
complied with at all times.
1.6.1 Germany §
• DIN EN 12831 Heating systems in buildings - Methods
for calculating the design heat load
• DIN EN 13384 Flue gas systems - Heat and ow calcu-
lation methods
• DIN EN 12828 Heating systems in buildings - Planning
of hot water heating systems.
• DIN 4755 Oil red combustion systems.
• Construction, design, safety requirements.
• DIN 4756 Gas red 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 genera-
tors.
• 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 combus-
tion systems (VDE regulation).
• See enclosure N-430 020 for further standards applica-
ble in Germany.
1.6.2 Austria §
• ÖNORM 12831 Heating systems in buildings - Methods
for calculating the design heat load
• ÖNORM 13384 Flue gas systems -
• Heat and ow calculation methods
• ÖNORM 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; re-
quirements to safety, construction and testing.
• ÖNORM B 8133 Hot water supply systems; safety re-
quirements.
• ÖNORM B 8136 Heating systems, space and other
building requirements.
• ÖNORM M 7515 Dimensioning of chimneys; denitions
and calculation procedure.
• ÖNORM H 5171 Heating systems - construction re-
quirements for buildings.
• ÖVGW TR-Gas
1.6.3 Switzerland §
• SN EN 12831 Heating systems in buildings - Methods
for calculating the design heat load
• SN EN 13384 Flue gas systems - Heat and ow calcu-
lation 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 buil-
ding 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 re-
sponsible gas board must also be observed. An ofcial
permit may be required.
64 217 213 / 01
IMPORTANT INFORMATION

2. Assembly
2.1 Set-up, levelling
The boiler is xed to wooden transport chocks. For trans-
port up and down stairs, it is wise to leave these timbers
in place under the boiler.
A special foundation plate for the boiler is not an essen-
tial, but it is recommended.
Space requirement
For further information on space requirements, see chap-
ter 3.4.
The cleaning apertures must be easily acces
-
sible.
Installing and levelling the boiler
Remove transport chocks. Store nuts and washers. Lift
the boiler on one side and put grub screws of boiler base
from the bottom through the slot of the boiler sockets. Fix
boiler feet using hexagonal nuts (Fig. 01).
Using a spirit level, set the boiler in longitudinal and trans-
verse direction and position it with a slight forward tilt.
This is done by adjusting the nuts on the boiler feet. After
this adjustment, the upper (locking) nuts on the boiler feet
must be tightened.
Fig. 01
7
4 217 213 / 01
ASSEMBLY

3. Technical data
3.1 Description of the boiler
The Hoval UltraGas®is a low emission, energy-saving
condensing gas boiler comprising the Ultraclean burner
sys tem, a gas red premix burner with combustion air
fan. The Hoval UltraGas®has a vertically disposed com-
bustion chamber of stainless steel as a primary heating
surface and a secondary heating surface of a corrosion
resistant aluminium alloy.
The secondary heating surface is designed so that part of
the water vapour contained in the ue gas is condensed
and the vaporisation heat it contains is utilised for the
heating circuit. The gas burner is congured as a vertical
burner that can be swivelled up easily for maintenance
work. The UltraGas®is provided for operation with natural
gas and liqueed gas. The design principle is shown in
the following drawing.
Fig. 02
Feed tube on left and/or right side
High temperature return
on left and/or right side
Low temperature return
on left and/or right side
Gas safety and control devices
Combustion air fan
Electrode for ignition
and ame monitoring
TopTronic®E controller
aluFer®heat exchanger
Condensate collection tray
Flue gas connection
84 217 213 / 01
TECHNICAL INFORMATION

3.2 Technical data UltraGas®(15-50)
Type (15) (20) (27) (35) (50)
• Nominal heat output at 80/60 °C, natural gas kW 3.0-14.3 3.8-18.7 4.5-25.0 (50) 5.2-32.8
•Nominal heat output at 40/30 °C, natural gas kW 3.3-15.5 4.3-20.3 5.0-27.2 5.8-35.7 5.8-35.7
• Nominal heat output at 80/60 °C, propane 2kW 4.5-13.8 4.9-18.6 6.6-24.3 6.9-32.2 6.9-32.2
•Nominal heat output at 40/30 °C, propane 2kW 5.0-15.3 5.5-20.7 7.3-27.0 7.7-35.7 7.7-35.7
• Nominal load with natural gas 1kW 3.1-14.5 4.0-19.0 4.7-25.4 5.4-33.3 5.4-33.3
• Nominal load with propane 2kW 4.7-14.3 5.1-19.3 6.8-25.2 7.2-33.4 7.2-33.4
• Working pressure heating maximum/minimum bar 3.0/1.0 3.0/1.0 3.0/1.0 3.0/1.0 3.0/1.0
• Test pressure bar 4.5 4.5 4.5 4.5 4.5
• Working temperature maximum °C 85 85 85 85 85
• Boiler water content l 57 55 51 81 81
Flow resistance boiler 3z value 3.5 3.5 3.5 1.1 1.1
•Minimum water ow l/h 0 0 0 0 0
• Boiler weight (without water content, incl. casing) kg 176 179 186 205 205
•Boiler efciency at 80/60 °C in full-load operation
(related to net caloric value NCV / gross caloric value GCV) % 97.5/87.8 97/88.1 97.9/88.2 97.9/88.2 97.9/88.2
•Boiler efciency at 30 % partial load (EN 15502)
(related to net caloric value NCV / gross caloric value GCV) % 107.9/97.2 108.0/97.3 108.0/97.3 108.1/97.4 108.1/97.4
•Standard efciency (DIN 4702-8) 40/30 °C % 109.5/98.6 109.5/98.6 109.5/98.6 109.5/98.6 109.5/98.6
(related to net caloric value NCV/gross caloric value GCV) 75/60 °C % 107/96.4 107/96.4 107/96.4 107.0/96.4 107.0/96.4
• Stand-by loss at 70 °C Watt 160 160 160 220 220
• NOx class (EN 15502) 6 6 6 6 6
• Standard emission rate Nitrogen oxides mg/kWh 25 26 28 31 31
• Content of CO2 in the ue 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 Inches R 1″R 1″R 1″ R 1 ¼″ R 1 ¼″
Gas Inches R ¾″ R ¾″ R ¾″ Rp ¾″ Rp ¾″
Flue gas/
combustion air Ø mm E80 E80 E80 E80 E80
•Gas ow pressure minimum/maximum
Natural gas E/LL mbar 17.4-50 17.4-50 17.4-50 17.4-50 17.4-50
Propane mbar 37-50 37-50 37-50 37-50 37-50
•Gas connection value at 15 °C/1013 mbar:
Natural gas E (Wo = 15.0 kWh/m3) NCV = 9.97 kWh/m3m3/h 1.5 1.9 2.6 3.3 3.3
Natural gas LL (Wo = 12.4 kWh/m3) NCV = 8.57 kWh/m3m3/h 1.7 2.2 3.0 3.9 3.9
Propane (NCV = 25.9 kWh/m3) m3/h 0.6 0.8 1.0 1.3 1.3
• 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
• Electrical power consumption min./max. Watt 20/41 22/58 20/54 24/96 24/96
• Stand-by Watt 12 12 12 12 12
• IP rating (integral protection) IP 20 20 20 20 20
• Lowest ambient temperature during operation °C 5 5 5 5 5
• Highest ambient temperature during operation °C 40 40 40 40 40
• Sound power level
- Heating noise (EN 15036 part 1) (room air dependent) dB(A) 57 61 66 62 62
- Exhaust noise is radiated from the mouth
(DIN 45635 part 47) (room air dependent/room air independent dB(A) 43 49 55 55 55
• Sound pressure level (depending on installation conditions) 4dB(A) 50 56 59 55 55
•Condensate quantity (natural gas) at 40/30 °C l/h 1.3 1.8 2.4 3.1 3.1
• pH value of the condensate pH approx. 4.2 approx. 4.2 approx. 4.2 approx. 4.2 approx. 4.2
•Flue gas system: requirements, values
Temperature class T120 T120 T120 T120 T120
Type of connection B23P, C53, C63
Flue gas mass ow at nominal heat load kg/h 23 31 42 55.0 55.0
Flue gas mass ow at lowest nominal heat load kg/h 4.7 6.0 7.1 8.1 8.1
Flue gas temperature at nominal output and operation 80/60 °C °C 62 63 64 65 65
Flue gas temperature at nominal output and operation 40/30 °C °C 45 45 45 46 46
Flue gas temperature at lowest nominal heat load and operation 40/30 °C °C 31 31 31 31 31
Maximum permitted temperature of the combustion air °C 50 50 50 50 50
Volume ow rate combustion air Nm3/h 17 23 31 41 41
Feed pressure total at the combustion air/ue gas line Pa 100 100 100 120 120
Maximum draught/depression at ue gas outlet Pa -50 -50 -50 -50 -50
1Data related to NCV. The boiler series is tested for EE/H-settings. With a factory setting of the Wobbe coefcient of 15.0 kWh/m3operation at a
Wobbe coefcient of 12.0 up to 15.7 kWh/m3is possible without new settings (readjustment might be necessary).
2Data related to NCV.
3Flow resistance boiler in mbar = Volume ow (m3/h)2x z factor; or see diagram
4See also notes at “Engineering”.
94 217 213 / 01
TECHNICAL INFORMATION

3.3 Dimensions
(Dimensions in mm)
Fig. 03
Type UltraGas®(15-27) (35,50)
1Heating ow / safety ow R 1" R 1¼"
2 Low temperature-return R 1" R 1¼"
2a High temperature-return R 1" R 1¼"
3Gas connection Rp ¾" Rp ¾"
4Flue gas outlet DN80 DN80
5 Boiler control
6 Condensate drain (left or right) incl.
siphon DN25 and 2 m PVC continu-
ous-ow tube inner Ø 19 x 4 mm
7 Draining
8 Electric cable entry point
9 Sound absorber hood
10 Heating armature group
or loading group (Option)
Type A B C D E F G H
UltraGas®(15-27) 1400 655 333 1320 1220 852 1184 144
UltraGas® (35,50) 1640 895 573 1560 1460 930 1340 222
10 4 217 213 / 01
TECHNICAL INFORMATION

3.4 Space requirements
(Dimensions in mm)
Fig. 04
Boiler door incl. burner swings upward and to the left or
outward.
A = minimum 150 mm *
- Burner service position front - boiler cleaning from
the right
A = optimum 300 mm *
- Burner service position left - boiler cleaning from
the front
- Boiler can be placed with the right side directly
against the wall
- however, a minimum gap of 160 mm is required.
* without armature group, 500 mm with armature group
• The cleaning aperture must be easily accessible.
• Ensure access to the area beh
11
4 217 213 / 01
TECHNICAL INFORMATION

3.5 Boiler-Flow resistance
UltraGas®(15-27)
UltraGas®(35,50)
0
5
10
15
20
25
30
0 0,5 1 1,5 2 2,5 3 3,5 4 4,5 5
[m
3
/h]
[mbar]
0
5
10
15
20
25
30
35
0123
[m3/h]
[mbar]
3.6 Brief description of the
automatic firing device
The automatic ring device BIC960 of the UltraGas®only
operates in conjunction with the heating controller Top-
Tronic® E/UG. For this reason, the automatic ring device
only needs to take care of the last remaining functions to
ensure the correct operation of a modulating gas boiler.
The automatic ring device comprises the following func-
tions:
• PWM fan control (230V AC)
• Modulating operation
• Common electrode for ignition and ame monitoring
(ionisation)
• LPG valve and boiler room fan controllable
• Inputs for
- ow sensor 1
- ow sensor 2
- ue gas sensor
- water pressure sensor
- safety temperature limiter (not used)
- air pressure switch
- gas pressure switch
• Status outputs «fault» and «ame signal»
• Allows connection of additional (external) ignition device
• RS 485 connection to TopTronic®E/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
Sicherungen:
The BIC 960 is tted 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 ring device is
displayed on the TopTronic®E/UG by the failure message
„B:30 Bus interruption to automatic device“. The failure
appears when there is no communication between auto-
matic ring device and TopTronic®E/UG.
m3/h = Volume ow
mbar = Flow resistance
12 4 217 213 / 01
TECHNICAL INFORMATION

4. Installation
4.1 Safety information
CAUTION
Sharp edges pose a cutting hazard.
Handle the cladding parts with care
and avoid contact with sharp edges.
4.2 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 con-
taining halogen compounds which can be
carried into the combustion air (e.g. wash
rooms, drying rooms, DIY rooms, hair dres-
ser rooms).
•
Halogen compounds can originate, for
example, from cleaning and degreasing
agents, solvents, glue, and bleaching lyes.
Ensure that the required combustion air can ow unhin-
dered at all times. This is important for the correct opera-
tion 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.
4.2.1 Room air dependent installation
- The applicable regulations do not normally provide any
specic data on the size of air intakes. They only re-
quire the pressure in the boiler room not to be below
3 N/m2.
- This means that for a rated thermal output of up to
50 kW an air intake with a cross section of at least
300 cm2must be available.
- For rectangular apertures the aspect ratio should not
exceed 1.5:1. If a grid is tted on the air intake, a suit-
able allowance must be made to obtain an air intake
cross section of 300 cm2.
4.2.2 Room sealed installation
Conguration based on a concentric ue system:
- The suction air is supplied through a double-wall ue
system.
- Ensure the boiler room is sufciently ventilated.
Conguration using a separating piece (optional):
When conguring the intake tube, comply with
the following:
-
If the air inlet at the facade is near a noise
sensitive place (window of bedroom, terrace
etc.), we recommend to use a sound absor-
ber at the direct combustion air inlet.
-
The air intake opening must be freely acces-
sible and have a protective grating or possi
-
bly wind protection equipment.
-
Always keep the air inlet clear (leaves,
snow, ...)
-
Do not store any chemicals or poisonous
substances in the vicinity of the air inlet
- Do not install the air inlet adjacent to extrac
-
tor hood openings or other air extraction
equipment.
13
4 217 213 / 01
INSTALLATION

4.3 Flue gas connection and flue
Due to the low ue gas temperature, condensate forms in
the ue gas line and wind protection equipment.
§
The ue gas extraction system must comply
with the following directives:
• DVGW (TRGI)
• ÖVGW
• SVGW/VKF
Pursuant to the abovementioned regulations,
a ue gas temperature limiter must be instal-
led in the boiler.
The ue gas system must meet the following
requirements:
• Gastight
• Watertight
• Acid-proof
•
Approved for ue gas temperatures of up to
120 ºC (T 120)
• Approved for overpressure
!
WARNING
The ue gas lines must be secured against
unwanted loosening of the plug connections.
• Unhindered back ow of condensate into
the boiler can only be ensured if:
• The gradient of the horizontal connection el
-
ements is at least 50 mm/m.
§
Only one heat generator may be connected
to the same chimney. If two heat generators
are to be connected to the same chimney, the
relevant regulations must be complied with.
•
Cross sections and maximum lengths are
calculated on the basis of graphs or tables.
The tables can be obtained from the chim
-
ney or ue system manufacturer. The calcu
-
lation values can be obtained from the table
under point 3.2.
• The ue gas conduit cross sections and
lengths are calculated following the techni
-
cal data for the boiler.
•
The concentric supply air/exhaust system of
the boiler can also be conducted horizon
-
tally backwards. The Hoval remodelling set
allows a remodelling on site.
The following only applies for countries in
which the wall duct is allowed.
For C53 construction boilers, the air intake
opening for the combustion air must not be on
the opposing wall of the exhaust opening of
the ue gas line.
When designing and installing ue gas conduits, manu-
facturer’s instructions for design and routing and the re-
quirements of building law must be observed. We recom-
mend that you consult the regional chimney inspector in
good time.
Your Hoval dealer can supply an approved ue gas sys-
tem suitable for your UltraGas® (15,20,27,35,50).
Please observe the technical information supplied
with your ue gas conduit.
!
WARNING
Flue gas outlet for oversized ue gas lines.
- For ue gas systems from third-party sup-
pliers (air/ue gas line of versions C63/
C63x), a connector with DN 80 (tolerance
of +1/-0.5 %) must be used.
14 4 217 213 / 01
INSTALLATION

4.3.1 Project planning instructions, flue gas systems
All applicable regional and country-specic regulations
and laws pertaining to the routing of ue gas must be
observed and complied with.
Measure opening
Each supply and exhaust pipe must be equipped with a
testing vent (already included in the construction sets).
These should be placed in such a way that they can con-
veniently be reached to perform a measurement.
Length adjustment
The concentric length elements should not be shortened.
Insert the length compensators or reducing lengths to ad-
just to the required lengths.
The basic ue pipes can be reduced in length to t. How-
ever, the cut ends must be carefully smoothed to avoid
damage to the gasket of the connecting piece.
Distance holder
When installing the pipes in a shaft a spacer must be
used at least every 2 metres. To provide support for the
chimney stack the lowest element must be xed (bearing
rail or pipe clip).
Flue gas temperature
The Hoval ue duct systems E80 PP, E100 PP, E80 Flex
PP, E100 Flex PP, C80/125 PP, C100/150 PP and E130
PP are long-term temperature resistant to 120 °C.
Connecting pipes
Horizontal connection lines must be routed with a down-
ward slope of at least 5 cm per running metre of their
length in the direction of the boiler to ensure that conden-
sate can ow back to the boiler unhindered. The whole
exhaust system must be installed so that condensate can
never collect at any point.
!
WARNING
The ue gas lines must be secured against
unwanted loosening of the plug connections.
Condensate drain
Condensation water accumulating in the ue
gas pipe can be drained via the boiler.
15
4 217 213 / 01
ASSEMBLY

4.3.2 Design examples for
room air dependent operation
Use the suitable ue gas system from Hoval or a ue gas
system certied in accordance with DIN EN 14471. Stain-
less steel ue gas systems in accordance with EN 483
can also be used.
UltraGas
If necessary, insert an
inspection T-piece
Grid to shaft back
ventilation
Example UG K1 E80
Assembly kit UG K1 E80 PP to UltraGas®(15-50)
1Length element E80 L = 200 mm PP
2T-piece with measure opening E80 - 90° PP
3Duct E80 Wall plate 220 x 220 mm with seal ring
and casing tube D = 150 mm, L = 300 mm
4Length element E80 L = 450 mm PP
5Bearing rail E Flue gas tube support in shaft
6Support arch E80 - 90° PP
7Set (2 pieces) distant holder E80 of polypropylene
for tube centering in shaft 3 sets
8End tube E80 L = 500 mm to top part 80; high grade steel
9Top part 80 for chimney end for back ventilation with shaft
cover 400 x 400 mm, clamp tape and seal ring
To determine the total length of ue gas pipe and com-
bustion air duct, the total lengths can be obtained from
the diagrams and calculated for the simple chimney in-
stallation. For the remaining formpieces which have to be
installed, the lengths to be removed must be read off from
the table.
Sizing basis
The following diagrams were computed assuming a geo-
graphic altitude of 1000 m above sea level.
UG K E80 PP
UG K E80 Flex PP
0
4
8
12
16
20
24
28
32
36
40
012345
UltraGas®(50)
UltraGas® (35)
UltraGas®(15-27)
Maximum horizontal length connecting pipe (m)
Maximum effective height ue gas pipe (m)
Assembly kit UG K E100 PP
Assembly kit UG K E100 Flex PP
0
5
10
15
20
25
30
35
40
0123456
Anbindeleitung [m]
Höhe [m]
UltraGas®(35)
UltraGas®(50)
Maximum horizontal length connecting pipe (m)
Maximum effective height ue gas pipe (m)
16 4 217 213 / 01
ASSEMBLY

4.3.3 Design examples for
room air independent operation
UltraGas
9
6
8
5
7
4
3
2
1
If necessary, insert an
inspection T-piece
Combustion air
Example UG K3 C80/125 PP
1Connecting assembly kit LAS to UltraGas®(15-50) and
Boiler connection piece E80 ->C80/125 PP, L = 200 mm
2Inspection T-piece C80/125 PP with measure opening
3Duct C80/125 Wall plate with splice 220 x 220 mm
Scabbard tube D = 150 mm, L = 300 mm
4Length element E80 L = 450 mm PP
5Bearing rail E Flue gas tube support in shaft
6Support arch E80 - 90° PP
7Set (2 pieces) distant holder E80 of polypropylene
for tube centering in shaft; 3 sets
8End tube E80 L = 500 mm to top part 80 high grade steel
9Top part 80 for chimney end for back ventilation with
shaft cover 400 x 400 mm, clamp tape and seal ring
Assembly kit
UG K C80/125 PP
UG K C80/125 Flex PP
0
2
4
6
8
10
12
14
16
18
20
22
24
26
0123456
UltraGas® (35)
UltraGas®(50)
UltraGas®(15)
UltraGas®(20)
UltraGas®(27)
Maximum horizontal length connecting pipe (m)
Maximum effective height ue gas pipe (m)
UltraGas®(35-50)
Assembly kit UG K3 C100/150 PP
Assembly kit UG K3 C100/150 Flex PP
0
4
8
12
16
20
24
0123456
UltraGas® (50)
UltraGas® (35)
Maximum horizontal length connecting pipe (m)
Maximum effective height ue gas pipe (m)
174 217 213 / 01
ASSEMBLY

Ambient air independent operation
Approval
VKF-No. Z 14603
CE 0432BPR220556
4
5
6
7
9
8
10
UltraGas
3
2
1
If necessary, insert an
inspection T-piece
Grid to shaft back
ventilation
Combustion air
Example UG K-LAS C80/125 PP
1Connection assembly kit LAS to UltraGas®and
Boiler connection piece E80 ->C80/125 PP, L = 200 mm
2Inspection T-piece C80/125 PP with measure opening
3Wall plate to wall duct C80/125; 220 x 220 mm
4Wall socket D = 150 mm L = 300 mm to wall duct
5Bearing rail E Flue gas tube support in shaft
6Support arch C80/125 - 90° PP
7Set (2 pieces) distant holder E130 of spring steel;
a distant holder must be used at least every 2 metres
8Top part E130 for chimney end for back ventilation
with shaft cover
9Rain keep-off rail D=125 grey
10 LAS-mouth piece C80/125 PP Flue gas tube
of high grade steel white coated
Assembly kit
UG K-LAS C80/125 PP
0
2
4
6
8
10
12
14
16
18
20
22
24
0123456
UltraGas® (35)
UltraGas®(15)
UltraGas®(20)
UltraGas®(27)
Maximum horizontal length connecting pipe (m)
Maximum effective height ue gas pipe (m)
18 4 217 213 / 01
ASSEMBLY

5
6
7
8
10
UltraGas
3, 4
2
1
9
If necessary, insert an
inspection T-piece
Combustion
air
Min. 1m
Example UG AW C100/150 PP
1Connection assembly kit LAS to UltraGas® (35,50)
and boiler connection piece E80 -> C80/ 125 PP, L= 200
2Adapter piece C80/125 -> C100/150
3Inspection T-piece with measure opening C100/ 150 PP
4Concentric wall duct with wall plate 220 x 220 mm C100/150
white coated (RAL 9016)
5Outside wall distant holder Ø 150 mm
incl. mounting material, high grade steel
6Arch T-piece C100/150
7Outside wall distant holder Ø 150 mm stainless steel
8Lead pan with bowl C100/150 for roof execution
(gradient 25-55° adjustable), ground plate 500 x 500 mm
9Rain keep-off rail, steel anthracite
10 LAS-mouth piece C100/ 150 PP
Flue gas tube of high grade steel white coated
Assembly kit
UG AW C80/125 PP
0
2
4
6
8
10
12
0123456
UltraGas® (35)
UltraGas®(15)
UltraGas®(20)
UltraGas®(27)
Maximum horizontal length connecting pipe (m)
Maximum effective height ue gas pipe (m)
Assembly kit
UG AW C100/150 PP
0
2
4
6
8
10
12
14
16
0123456
Anbindeleitung [m]
Höhe [m]
UltraGas®(35)
UltraGas®(50)
UltraGas®(70)
Maximum horizontal length connecting pipe (m)
Maximum effective height ue gas pipe (m)
194 217 213 / 01
ASSEMBLY

4.4 Condensate drain
The boiler condensate drain must be made
of corrosion-resistant material. The following
materials are suitable for the condensate dis
-
charge:
• PVC
• PE
• PP
• ABS
Local regulations pertaining to the conden
-
sate discharge must be observed.
4.4.1 Design variants
Possibility 1 - see chapter 4.4.2
• Execution with siphon
• Condensate discharge into lower drain line.
Fig. 05
Possibility 2 - see chapter 4.4.3
• Execution with neutralisation box
• For condensate discharge in lower drain line, incl.con-
densate neutralisation.
Fig. 06
Possibility 3 - see chapter 4.4.4
• Siphon and condensate delivery pump
• Without neutralisation, condensate discharge into high-
er drain line.
Fig. 07
Possibility 4 - see chapter 4.4.5
• Neutralisation box and condensate delivery pump
• With condensate neutralisation - condensate discharge
into higher drain line.
Fig. 08
20 4 217 213 / 01
INSTALLATION