Hoval UltraGas 70 Manual

Subject to modi cations | EN
Technical information
Installation instructions
UltraGas®(70,100)
Condensing gas heating boilers
for natural gas and liquid gas
for modulating operation
The oor-standing gas condensing boilers UltraGas®
(70,100) acc. to EN 15502-1/15502-2-1 are suitable
and licensed for use as heat generators for hot water
heating systems with a permissible ow temperature of
up to 85 °C1). They are designed for continuously cont-
rolled reduced operation in heating systems.
1) See technical data
These instructions apply to the following types:
Rated output levels at 40/30 ºC
and for natural gas
45-UltraGas® (70) 13.6 - 69.9 kW
45-UltraGas® (100) 20.9 - 100.0 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.
4 217 214 / 02 - 11/19

24 217 214 / 02
TABLE OF CONTENTS
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 On delivery...........................................................................................................................................................................5
1.4 Warranty...............................................................................................................................................................................5
1.5 Manuals................................................................................................................................................................................5
1.6 Regulations, official approvals ...........................................................................................................................................6
1.6.1 Germany §........................................................................................................................................................................6
1.6.2 Austria § ...........................................................................................................................................................................6
1.6.3 Switzerland § ....................................................................................................................................................................6
2. Installation
2.1 Set-up...................................................................................................................................................................................7
3. Technical information
3.1 Description of the boiler .....................................................................................................................................................8
3.2 Technical data UltraGas®(70,100).......................................................................................................................................9
3.3 Dimensions........................................................................................................................................................................10
3.4 Space requirement ............................................................................................................................................................11
3.5 Boiler flow resistance........................................................................................................................................................12
3.6 Brief description of the automatic firing device...............................................................................................................12
4. Installation
4.1 Safety instructions ............................................................................................................................................................13
4.2 Requirements on the boilerhouse ....................................................................................................................................13
4.2.1 Room air dependent installation......................................................................................................................................13
4.2.2 Room air independent installation ...................................................................................................................................13
4.3 Flue gas connection and flue gas line..............................................................................................................................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
4.3.4 Design examples for room air independent operation......................................................................................................18
4.4 Condensate drain ..............................................................................................................................................................19
4.4.1 Design variants...............................................................................................................................................................19
4.5 Gas connection..................................................................................................................................................................20
4.6 Hydraulic connection ........................................................................................................................................................21
4.6.1 To be provided on-site.....................................................................................................................................................21
4.6.2 Hydraulic integration .......................................................................................................................................................21
4.7 Electrical connection.........................................................................................................................................................22
4.7.1 Safety measures for EMC according assembly................................................................................................................23
4.7.2 Recommended cable cross sections and permissible maximum length of cable ..............................................................25

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TABLE OF CONTENTS
5. Commissioning
5.1 Safety instructions ............................................................................................................................................................26
5.2 Filling the heating system.................................................................................................................................................26
5.3 Water quality......................................................................................................................................................................27
5.3.1 Heating water..................................................................................................................................................................27
5.4 Venting the gas pipe..........................................................................................................................................................28
5.5 Switching on......................................................................................................................................................................28
5.6 Gas inlet pressure .............................................................................................................................................................28
5.7 Functional check of combustion cylinder pressure monitoring .....................................................................................28
5.7.1 Check pressure in the combustion cylinder (safety check during commissioning) ............................................................29
5.8 Setting the gas quantity, measuring the CO2 (O2) and NOx/CO content in the flue gas (flue gas measurement)..........30
5.9 Changing to a different type of gas ..................................................................................................................................31
5.9.1 Changing from natural gas H to natural gas L..................................................................................................................31
5.9.2 Changing from natural gas to liquid gas ..........................................................................................................................31
5.10 Handover to the operator ..................................................................................................................................................31
5.11 Record - Activation of screed function.............................................................................................................................32
6. Maintenance
6.1 Safety instructions ............................................................................................................................................................34
6.2 Deaeration..........................................................................................................................................................................34
6.3 Top up with water ..............................................................................................................................................................34
6.4 Renewing fuse ...................................................................................................................................................................34
6.5 Information for combustion controller / chimney sweep regarding emission monitor key ...........................................35
6.6 Cleaning.............................................................................................................................................................................36
6.6.1 Cleaning the burner cylinder ...........................................................................................................................................36
6.6.2 Cleaning the combustion chamber and burner cylinder on the outside.............................................................................37
6.6.3 Cleaning/setting ignition ionisation device .......................................................................................................................38
6.7 Setting the gas quantity, measuring the CO2 (O2) and NOx/CO content in the flue gas (according to point 5.8) ..........39
6.8 Maintaining the neutraliser box (if fitted) .........................................................................................................................40
6.9 Cleaning the condensation trap........................................................................................................................................41
6.10 Parameter list - automatic firing device BIC 960..............................................................................................................42

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IMPORTANT NOTES
1. Important notes
1.1 General safety instructions
The system may only be placed in operation
if all the relevant standards and safety regula
-
tions have been complied with.
At least the following conditions must be satised for
a trial operation:
• Safety valve installed (system sealed)
• Control system in operation (connected to the power
supply)
• Sensor for safety temperature limiter connected (= boi-
ler temperature sensor)
• System lled with water
• Condensation trap lled with water
• Expansion tank connected
• Flue gas outlet with ue gas conduit connected to ue
gas system.
• Burner preset (see point 6.6).
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 o󰀨 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 war-
ning 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 e󰀨ect on
skin, eyes and respiratory organs; can cause
irritation.
Handling: Do not inhale vapours and avoid
contact with skin and eyes.

54 217 214 / 02
IMPORTANT NOTES
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 requi
-
red.
§
Provides important information.
Refers to standards and directives.
1.3 On delivery
Carry out a visual inspection immediately on receiving the
boiler. If any damage is found, take the necessary steps
as dened in the delivery contract. The respective risk
carrier bears the cost of repairs.
1.4 Warranty
The warranty does not cover defects attributable to:
• Failure to comply with these instructions
• Failure to comply with the operating instructions
• Incorrect installation
• Impermissible modications
• Incorrect handling
• Contaminated operating materials (gas, water, com-
bustion air)
• Unsuitable chemical additives to the heating water
• Damage caused by the application of force
• Corrosion by halogen compounds (e.g. paints, adhesi-
ves, solvents)
• Corrosion caused by not observing the required water
quality
1.5 Manuals
All instructions relevant to your system can be found
in the Hoval system manual. In exceptional cases, the
instructions can be found with the components.
Further sources of information:
• Hoval catalogue
• Standards, regulations

64 217 214 / 02
IMPORTANT NOTES
1.6.3 Switzerland §
• SN EN 12831 Heating systems in buildings - Procedure
for calculation of the standard heating load
• SN EN 13384 Flue gas systems - Heat and ow
calculation methods
• SN EN 12828 Heating systems in buildings - Design of
hot water heating systems.
• VKF – Association of Cantonal Fire Insurers.
• Fire prevention authority regulations.
• SVGW Swiss Association for Gas and Water.
• SNV 27 10 20 Aeration and ventilation of the boiler
installation room.
• SWKI BT102-01 Water quality for building services
systems.
• Technical tank regulations TTV 1990.
• EKAS - Guidelines for liquid gas Part 2
and further regulations and standards issued by CEN,
CEN ELEC, DIN, VDE, DVGW, TRD and the legislative
body. The regulations of the local building authorities,
insurance companies and chimney sweeps must also be
taken into account. The regulations of the responsible
gas supply company are to be complied with if using gas.
Approval by the authorities may be required.
1.6 Regulations, official approvals
The standards and directives stated under points 1.6.1 to
1.6.3 must be taken into account during installation and
operation of the system.
1.6.1 Germany §
• DIN EN 12831 Heating systems in buildings – Method
for calculation of the design heat load
• DIN EN 13384 Flue gas systems – Calculation methods
in heat and ow engineering
• DIN EN 12828 Heating systems in buildings - Design of
hot water systems.
• DIN 4755 Oil-red systems. Design, construction and
safety engineering requirements.
• DIN 4756 Gas-red combustion systems: design, cons-
truction and safety engineering requirements, design
and construction (for operation with gas burners).
• DIN 18160 House chimneys; requirements, planning
and execution.
• TRD 702 Steam boiler plants with caloriers of the
group II.
• TRD 721 Safety devices against excess pressures / sa-
fety valves / for steam boilers of Group II.
• VDI 2035 Prevention of damage by corrosion and the
formation of scale in hot water heating systems.
• DIN 57 116 / VDI 0116 Electrical equipment for ring
systems (VDE Regulation).
• For further standards applicable in Germany, see
appendix N-430 020.
1.6.2 Austria §
• ÖNORM 12831 Heating systems in buildings -
Procedure for calculation of the standard heating load
• ÖNORM 13384 Waste gas systems – Procedures for
heat and ow calculations
• ÖNORM 12828 Heating systems in buildings - Design
of hot water systems.
• ÖNORM B 8130 Open water heating systems; safety
devices.
• Norm B 8131 Closed water heating systems; safety,
execution and testing requirements.
• ÖNORM B 8133 Hot water production systems; techni-
cal safety requirements.
• ÖNORM B 8136 Heating systems, space requirements
and other building requirements.
• ÖNORM M 7515 Calculations of dimensions of
chimneys; terminology, calculation procedure.
• ÖNORM H 5171 Heating systems – construction
engineering requirements.
• ÖVGW TR-gas (Austrian Gas and Water Confederation
- Technical Guidelines)

74 217 214 / 02
INSTALLATION
45
Fig. 03
4. Using a winch (4, Fig. 03) raise the front of the boiler
and remove the front crossbeam (5).
6
Fig. 04
5. Push the side bar (6, Fig. 04) to the outside in the
front area and lower the boiler.
7 8
Fig. 05
6. Remove screws (3, Fig. 02) at the back. Lift rear
wall and cover and take o󰀨 the rear wall towards the
bottom. Using a winch (7, Fig. 05) raise the boiler at
the back in the centre (8) and remove crossbeam and
side beams. Lower the boiler.
7. A󰀩x the included type label clearly visibly on the boiler.
2. Installation
2.1 Set-up
Hoval recommends setting up the boiler on a
foundation slab.
1
Fig. 01
1. Remove the wooden crate (1, Fig. 01)
CAUTION
Sharp edges (Fig. 02)!
3 2
Fig. 02
2. Remove transportation straps (2, Fig. 02)
3. Remove screws (3) at the front

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TECHNICAL INFORMATION
The secondary heating surface is so designed that part
of the water vapour contained in the ue gas condenses
and the heat of evaporation is utilised for the heating cir-
cuit. 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.
3. Technical information
3.1 Description of the boiler
The Hoval UltraGas®is a low-pollution and energy-saving
condensing gas boiler with the Ultraclean burner system,
a gas-red pre-mix burner with combustion air blow er.
The Hoval UltraGas®has a combustion chamber arran-
ged vertically and fabricated from non-corroding stainless
steel as its primary heating surface and a secondary
heating surface made from corrosion-resistant aluminium
alloy.
Concentric ue gas connection
Connection hose for room
air-independent operation
Flow left and/or right
Internal ue gas conduit
High-temperature
return left and/or right
Low-temperature return
left and/or right
Gas, safety and
control systems
Combustion air blower
Electrode for ignition
and ame monitoring
TopTronic® E control
aluFer®heat exchanger
Condensate drip tray
Horizontal ue gas connec-
tion possible as an option
Fig. 06

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TECHNICAL INFORMATION
3.2 Technical data UltraGas®(70,100)
Type (70) (100)
• Nominal heat output at 80/60 °C, natural gas kW 12.2-64.0 19.0-92.0
• Nominal heat output at 40/30 °C, natural gas kW 13.6-69.9 20.9-100.0
• Nominal heat output at 80/60 °C, propane 2kW 15.4-63.3 23.0-92.0
• Nominal heat output at 40/30 °C, propane 2kW 17.1-69.9 25.3-100.0
• Nominal load with natural gas 1kW 12.5-65.7 19.6-94.1
• Nominal load with propane 2kW 16.0-65.7 23.8-94.1
• Working pressure heating maximum/minimum bar 4.0/1.0 4.0/1.0
• Test pressure bar 6.0 6.0
• Working temperature maximum °C 85 85
• Boiler water content l 157 144
• Flow resistance boiler 3z value 1.5 1.5
•Minimum water ow l/h 0 0
• Boiler weight (without water content, incl. casing) kg 302 331
•Boiler e󰀩ciency at 80/60 °C in full-load operation
(related to net caloric value NCV / gross caloric value GCV) % 98.0/88.3 97.6/87.9
•Boiler e󰀩ciency at 30 % partial load (EN 15502)
(related to net caloric value NCV / gross caloric value GCV) % 108.1/97.4 108.1/97.4
•Standard e󰀩ciency (DIN 4702-8) 40/30 °C % 109.6/98.7 109.1/98.3
(related to net caloric value NCV / gross caloric value GCV) 75/60 °C % 107.1/96.5 107.1/96.5
• Stand-by loss at 70 °C Watt 290 290
• NOx class (EN 15502) 6 6
• Standard emission rate Nitrogen oxides mg/kWh 32 39
• Content of CO2 in the ue gas maximum/minimum output % 9.0/8.8 9.0 / 8.8
• Dimensions
• Connections Flow/return Inches R 1 ½″R 1 ½″
Gas Inches R ¾″ R ¾″
Flue gas/combustion air Ø mm C100/150 C100/150
•Gas ow pressure minimum/maximum
Natural gas E/LL mbar 17.4-50 17.4-50
Propane mbar 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 6.6 9.4
Natural gas LL (Wo = 12.4 kWh/m3) NCV = 8.57 kWh/m3m3/h 7.6 11.0
Propane (NCV = 25.9 kWh/m3) m3/h 2.5 3.6
• Operation voltage V/Hz 230/50 230/50
• Control voltage V/Hz 24/50 24/50
• Electrical power consumption min./max. Watt 25/85 21/148
• Stand-by Watt 12 12
• IP rating (integral protection) IP 20 20
• Lowest ambient temperature during operation °C 5 5
• Highest ambient temperature during operation °C 40 40
• Sound power level
- Heating noise (EN 15036 part 1) (room air dependent) dB(A) 64 67
- Exhaust noise is radiated from the mouth
(DIN 45635 part 47) (room air dependent/room air independent dB(A) 55 59
• Sound pressure level (depending on installation conditions) 4dB(A) 57 59
• Condensate quantity (natural gas) at 40/30 °C l/h 6.2 8.9
• pH value of the condensate approx. 4.2 approx. 4.2
• Flue gas system: requirements, values
Temperature class T120 T120
Type of connection
Flue gas mass ow at nominal heat load kg/h 109.0 157.0
Flue gas mass ow at lowest nominal heat load kg/h 18.8 29.5
Flue gas temperature at nominal output and operation 80/60 °C °C 63 65
Flue gas temperature at nominal output and operation 40/30 °C °C 43 44
Flue gas temperature at lowest nominal heat load and operation 40/30 °C °C 31 32
Maximum permitted temperature of the combustion air °C 50 50
Volume ow rate combustion air Nm3/h 81 117
Feed pressure total at the combustion air/ue gas line Pa 130 130
Maximum draught/depression at ue gas outlet Pa -50 - 50
1Data related to NCV. The boiler series is tested for EE/H-settings. With a factory setting of the Wobbe coe󰀩cient of 15.0 kWh/m3operation
at a Wobbe coe󰀩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 diagrams
4See also notes at “Engineering”.

10 4 217 214 / 02
TECHNICAL INFORMATION
3.3 Dimensions
UltraGas®(70,100) with connection set AS40-S/NT/HT and heating armature group HA40
(All dimensions in mm)
UltraGas®type (70) (100)
1. Heating ow / safety ow R1½″ R1½″
2. Low-temperature return R1½″ R1½″
2a. High-temperature return R1½″ R1½"
3. Feed-through duct for gas line
left or right
R ¾″ R ¾″
4. LAS ue gas supply air connection C100/150 C100/150
4a. Flue gas connection at the back (Option) E 100 E 100
5. Boiler controller
6. Condensate drain (left or right)
(incl. condensate drain (DN25) and 2 m
PVC passage hose inside Ø 19x4 mm
7. Electrical connection on the left or right
hand side
8. Drain
9. Connection set (option)
10. Heating armature group or charging group (option)
Fig. 07

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TECHNICAL INFORMATION
3.4 Space requirement
UltraGas®(70,100)
(All dimensions in mm)
Fig. 08
Boiler door incl. burner swivels upwards
and to the left or to the front.
A = minimum 150 mm *
- Burner service position front
- Boiler cleaning from right
A = optimum 300 mm *
- Burner service position left
- Boiler cleaning from front
* without ttings, 500 mm with ttings

12 4 217 214 / 02
TECHNICAL INFORMATION
3.5 Boiler flow resistance
UltraGas®(70,100)
m3/h = Volumetric current
mbar = Flow resistance
0
10
20
30
40
50
60
70
80
90
100
0
12345678
[mbar]
[m3/h]
3.6 Brief description of the
automatic firing device
The automatic ring device BIC960 of the UltraGas®only
works in connection with the heating regulator
TopTronic® E/UG. As a result, the automatic ring device
only has to take over the last missing functions for correct
operation of a modulating gas boiler.
These are some properties that are integrated in the
auto matic ring device:
• PWM control of the blower (230 VAC)
• Modulating operation
• Common electrode for ignition and ame monitoring
(ionisation)
• LPG valve or boilerhouse fan can be activated
• Inputs for:
- Flow sensor 1
- Flow sensor 2
- Flue gas sensor
- Water pressure sensor
- Safety - limit value thermostat
- (not used)
- Air pressure switch
- Gas pressure switch
• “Fault” and “Flame message” status outputs
• Additional (external) ignition device can be connected
• RS 485 connection to TopTronic®E/UG
• RS 232 connection to the PC
• Number of start attempts: maximum 4
• Safety time: 5 sec
• Pre-ignition: 5 sec
• Pre-ventilation period: 50 sec
• Follow-on time for pump (230 VAC): 5 min after a heat
demand
Fuses:
There are 3 fusible links on the BIC 960:
• 2 A slow-blow Mains
• 4 A slow-blow Pump
• 4 A slow-blow Burner blower
If one of the two 4 A slow-blow fuses, each of which pro-
tects either the pump or burner blower, blows, the device
in question will not start operating.
Failure of the mains fuse of the automatic ring device is
indicated on the display of the TopTronic®E/UG by the
"B:30 Bus interruption to automatic device" error. The er-
ror appears if no communication takes place between the
automatic ring device and TopTronic®E/UG.

134 217 214 / 02
INSTALLATION
4.2.1 Room air dependent installation
Binding values for the size of supply air openings are not
generally specied in the relevant regulations. It is me-
rely required that no partial vacuum in excess of 3 N/m2
occurs.
9
Fig. 09
If the combustion air is extracted from the boi
-
lerhouse, the connection hose (9, Fig. 09) can
be removed - signicant reduction in air intake
noises.
4.2.2 Room air independent installation
Variant using concentric chimney:
The intake air is obtained via a double-walled chimney.
Su󰀩cient ventilation for the boilerhouse is essential.
Variant using separator (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 pos-
sibly 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 ext
-
ractor hood openings or other air extraction
equipment.
4. Installation
4.1 Safety instructions
CAUTION
Cutting injuries as a result of sharp edges.
Handle parts of the casing carefully and
avoid contact with sharp edges.
4.2 Requirements on the boilerhouse
§
Regarding the building specications for boi
-
ler rooms, regulations specic to the state or
country are to be observed.
Regarding the ventilation of boiler rooms, re
-
gulations specic to the state or country are to
be observed.
Gas boilers are not allowed to be installed
in rooms in which halogen compounds oc
-
cur and can get into the combustion air (e.g.
washrooms, drying rooms, hobby rooms,
hairdressers).
Halogen compounds can be created, for ex
-
ample, by cleaning and degreasing agents,
solvents, glue and bleaches.
Always make sure there is an adequate supply of com-
bustion air to the boiler room. This contributes to correct
function of all the ring devices that are operated there,
and provides oxygen for the operating personnel to bre-
athe. Make sure there is an adequate supply of fresh air
to the boiler room, according to local regulations.

14 4 217 214 / 02
INSTALLATION
4.3 Flue gas connection and flue gas line
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
elements 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®(70,100).
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 the following dia-
meter (tolerance of +1/-0.5 %) must be
used:
- E100 or
- C100/150

154 217 214 / 02
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 ob-
served 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. Ho-
wever, 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
chim ney 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.

16 4 217 214 / 02
INSTALLATION
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.
If necessary, insert an
inspection T-piece
Combustion air
UltraGas
(70,100)
Grid to shaft back
ventilation
Example TG K E100 PP
1Air supply grille E100 incl. tube, L = 115 mm, PP
2T-piece with measure opening E100 – 90° PP
3Duct E100 Wall plate 220 x 220 mm with seal ring
and scabbard tube Ø 150 mm, L = 300 mm
4Length element E100 L = 450 mm PP
5Bearing rail E Flue gas tube support in shaft
6Support arch E100 - 90° PP
7Set (2 pieces) distant holder E100 of polypropylene
for tube centering in shaft; 3 sets
8End tube E100 L = 500 mm to top part E100 High grade steel
9Top part E100 for chimney end for back ventilation with
shaft cover 385 x 385 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 ins-
tallation. For the remaining formpieces which have to be
installed, the lengths to be removed must be read o󰀨 from
the table.
Sizing basis
The following diagrams were computed assuming a geo-
graphic altitude of 1000 m above sea level.
UG K E100 PP
UG K E100 Flex PP
0
5
10
15
20
25
30
35
40
0123456
UltraGas®(70)
UltraGas®(100)
Maximum horizontal length connecting pipe (m)
Maximum e󰀨ective height ue gas pipe (m)

174 217 214 / 02
INSTALLATION
4.3.3 Design examples for
room air independent operation
9
6
8
5
7
1
4
3
2
UltraGas
(70)
If necessary, insert an
inspection T-piece
Combustion air
Example UG K C100/150 PP
1Inspection T-piece with measure opening C100/150 PP
222Length adjustment piece C100/150 L = 315-440 mm
3Duct C100/150 Wall plate 220 x 220 mm with connecting
sleeve and scabbard tube Ø 180 mm, L = 300 mm
4Length element E100 L = 450 mm PP
5Bearing rail E Flue gas tube support in shaft
6Support arch E100 - 90° PP
7Set (2 pieces) distant holder E100 of polypropylene
for tube centering in shaft; 3 sets
8End tube E100 L = 500 mm to top part E100 High grade steel
9Top part E100 for chimney end for back ventilation with
shaft cover 385 x 385 mm, clamp tape and seal ring
UltraGas®(70)
Assembly kit UG C100/150 PP
Assembly kit UG C100/150 Flex PP
0
4
8
12
16
20
24
0123456
UltraGas® (70)
Maximum horizontal length connecting pipe (m)
Maximum e󰀨ective height ue gas pipe (m)

18 4 217 214 / 02
INSTALLATION
4.3.4 Design examples for
room air independent 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.
1
3
2
4
5
6
7
9
UltraGas
(70)
8
If necessary, insert an
inspection T-piece
Combustion
air
Min. 1m
Example UG AW C100/150 PP
1Inspection T-piece with measure opening C100/150 PP
2Length adjustment piece C100/150 L = 315-440 mm
3Concentric wall lead-through C100/150 with 2 wall plates
220 mm x 220 mm and wall box 180 mm x 300 mm,
C100/150, white (RAL 9016)
4Outside wall distant holder Ø 150 mm incl. mounting material,
high steel grade
5Arch T-piece C100/150
6Outside wall distant holder Ø 150 mm high grade steel
7Lead pan with bowl C100/150 for roof duct (gradient 25-55°
adjustable), ground plate 500 x 500 mm, black coated
8Rain keep-o󰀨 rail, black coated (RAL 9005)
9LAS-mouth piece C100/150 PP
ue gas tube of high grade steel white coated
Assembly kit
UG AW C100/150 PP
0
2
4
6
8
10
12
14
16
0123456
]
UltraGas®(70)
Maximum horizontal length connecting pipe (m)
Maximum e󰀨ective height ue gas pipe (m)

194 217 214 / 02
INSTALLATION
Option 2
• Design with condensation trap and neutralisation box
• For condensate discharge in lower drain line, incl.
condensate neutralisation.
• Drain on the right.
1.
2.
3.
Fig. 11
Option 3
• Version with condensation trap and condensate delivery
pump
• Without neutralisation, condensate discharge into high-
er drain line.
• Drain optionally on the left or right side.
The condensate delivery pump must be instal-
led in accordance with the enclosed instruc-
tions.
2.
1.
Fig. 12
4.4 Condensate drain
The boiler condensate drain must be made
of corrosion-resistant material. The following
materials are suitable for the condensate
discharge:
• PVC
• PE
• PP
• ABS
Local regulations pertaining to the condensa
-
te discharge must be observed.
4.4.1 Design variants
Before commissioning, the neutraliser box (if
tted) must be lled with neutralisation granu
-
late (gure, point 6.8).
!
WARNING
Before commissioning, the condensate trap
and the neutraliser box must be lled with
water.
The water can be lled into the neutraliser
box and the condensate trap via the cleaning
hole.
Option 1
• Stand version with condensation trap
• With condensate discharge into lower drain line.
• Drain optionally on the left or right side.
3.
1.
2.
Fig. 10

20 4 217 214 / 02
INSTALLATION
Option 4
• Version with condensation trap, neutraliser box and
condensate delivery pump
• With condensate neutralisation - condensate discharge
into higher drain line.
• Drain optionally on the left or right side.
The condensate delivery pump must be instal-
led in accordance with the enclosed instruc-
tions.
3. 4. 2.11.
Fig. 13
4.5 Gas connection
!
DANGER
Danger of explosion due to leaking gas
connection.
• Install a gas counter and gas pressure re-
gulator in the gas supply line.
•
Following installation of the boiler, check
the gas connection for leaks.
The gas connection can be on the left or right
side of the boiler.
The gas line is supplied loose. The connection
cross-section is ¾″.
Fig. 14