Hoval UltraGas AM condens (50-350) User manual

Important telephone numbers
Heating installer
Plumbing system installer
Electrical installer
Fuel supplier
Chimney sweep
To be completed by the heating specialist:
Order No.:
Boiler type:
Neutralisation system: yes no
Condensate lifting pump: yes no
Set to:
Natural gas H Natural gas L Liquid gas
Heating pump type:
Heating controller type:
Mixer type:
Separate calorifier type:
Calorifier sensor Thermostat
Outside temperature sensor
Room temperatur sensor
Combustion air supply Room Outside
Heating calculation principles
Lowest outside temperature: °C
Heat requirement: kW
Max. feed temperature: °C
Operating instructions
UltraGas AM condens (50-350)
4 200 191 / 01 Subject to changes
Hoval LTD
Northgate
Newark
Nottinghamshire NG24 1JN
Phone: [phone]
Fax: [phone]

4 200 191 / 01
2
Safety instructions
In the case of danger:
• Cut off the fuel immediately (gas) and electrical
supply!
If you smell gas
(Operation with a gas blower burner)
Do not smoke
Prevent the occurrence of open fire and
sparks (e.g. do not on lights or electrical
appliances)
Open windows and doors
Close the gas cock
Notify the heating specialist/installer
Comply with the safety regulations of the
gas supply authority (see gas meter) and
the heating firm!
If you smell flue gas:
• Shut down the system
• Open windows and doors
• Notify the heating specialist
Maintain an air supply in the
boiler installation room
(windows):
Openings for air inlet and outlet
must not be closed, or there will
be no combustion air (see page
1). Closed air inlets can lead to
incomplete combustion and
possible poisoning.
General information
Dear Hoval Customer
With your Hoval UltraGas AM condens you have
acquired a product manufactured according to the
state-of-the-art and to the very highest quality
standards.
For the correct installation and operation of your Hoval
UltraGas AM condens, all applicable laws, regulations
and standards must be complied with; in particular the
regulations of the responsible energy supply
authorities. In the case of queries, please contact your
installation specialist or your nearest Hoval after-
sales service agent.
Assembly and installation of the boiler is only to be
carried out by the trained staff of an approved installer.
An installation check is to be carried out before
commissioning and the system is to be cleared for
operation by the specialist.
To guarantee safe and trouble-free use, operate your
Hoval UltraGas AM condens only according to these
operating instructions.
The Hoval UltraGas AM condens is to be used only for
the purpose and with the fuels for which it is suitable
on the basis of its design and construction and for
which Hoval has given its approval.
Do not carry out any modifications to the appliance, as
this will result in Hoval waiving all its legal obligations.
Conversion kits are to be installed and the work
accepted by approved installers or the Hoval after-
sales service.
Providing it is handled correctly, your Hoval appliance
will ensure you enjoy comfortable living conditions for
many years.

4 200 191 / 01
3General information
Intended purpose:
The UltraGas AM condens boiler is
only to be operated with the fuels
detailed in the technical information/
installation instructions. The heat
produced must be carried away only
by means of the heating water. All
orifices and openings on the boiler
must be closed during operation!
Precautionary instructions:
Corrosion protection
Do not use any sprays, solvents, chlorine-containing
cleaning agents, paints, adhesives etc. in the vicinity
of the appliance. These substances can lead to
corrosion in the boiler and the flue gas system.
Filling the heating system
Mains water can normally be used for filling the
heating system. In exceptional cases, where the water
quality renders it unsuitable for filling the heating
system (highly corrosive water or water with a high
lime content), contact your approved specialist.
Checking the water level
Check the system water level at regular intervals
(page 8).
General
Hoval UltraGas AM condens gas boilers are equipped
with automatic control and safety devices. They are
normally in operation from the beginning to the end of
the heating period. During this time the necessary
boiler temperature is set by means of the automatic
heating controller.
If the boiler is also used for water heating it remains
switched on for the whole year.
Fuel
The boiler is only to be operated
with the type of gas stated on the
rating plate. Settings are made by
the installer.
Checking prior to commissioning
A new system may only be placed in operation when
clearance to do so has been given by the heating
installer.
Filling the heating system
The heating system is filled with mains water according
to the specifications of the installer. All air must be bled
from the system. Check the pressure at the pressure
gauge or hydrometer.
Filling the separate calorifier
The calorifier is to be filled on the service water-side
according to the specifications of the installer. The
boiler can also be operated when the calorifier is not
filled with water.
Safety valves
The heating system and the hot water system are
each to be fitted with a safety valve against
impermissible over-pressures.
Filling pump (boiler with separate calorifier)
The speed and flow regulation must be appropriate to
the requirements of the calorifier. Settings are made
by the heating specialist.
Heating pumps
The speed and flow regulation must be appropriate to
the requirements of the system. Settings are made by
the heating specialist.
Electrical connection
The electrical connection is to be made by a qualified
electrician. The electrical circuit diagram is located
inside the control cover.

4 200 191 / 01
4
If you detect a smell of gas, please
close the main gas cock before the
gas meter immediately and call the
emergency service of your gas supply
authority.
To ensure that no toxic flue gases occur, the combustion
air must flow unobstructed to the gas boiler. Therefore,
with room air dependent operation, the air inlet openings
(e.g. cellar window) must never be closed. The boiler
itself must also never be closed off.
Keep the room in which your boiler is installed clean
and before cleaning, switch off the burner as dust
laden combustion air can lead to faults.
Faults
For your safety the burner shuts down automatically in
the case of faults in the burner system, if the gas
pressure is too low, if gas is absent or if the maximum
permissible boiler temperature is exceeded. Wait about
5 minutes before attempting to place the burner back
in operation, by actuating the reset button on the boiler
control panel. If this is not successful, please close the
gas cock and call your after-sales service or heating
installer.
Absolutely imperative!
Fault-free function is only guaranteed
if the operating instructions are
complied with and both boiler and
burner are regularly maintained by a
specialist.
Faults and damage caused by installing in unsuitable
rooms, e.g. hobby rooms, workshops etc., also by
contaminated operating media (gas, water, combustion
air), unsuitable chemical additives to the heating water,
incorrect handling, faulty installation and damage due
to the exercising of force are not covered by our
guarantee; this also applies to corrosion due to halo-
gen compounds, e.g. from spraycans, paints,
adhesives, solvents and cleaning agents.
Important information
Important information
Installation and assembly instructions
• The installer has handed you the installation and
assembly instructions. Keep these important
documents carefully so that where necessary the
after-sales service can obtain technical information
on-site.

4 200 191 / 01
5
Commissioning / taking out of operation,
boiler cleaning
Preparations for commissioning
A newly installed system may only be commissioned
by a specialist. A full installation check must be carried
out.
• Place the main SYSTEM switch to ”0”.
• Open the cut-off valve in the heating feed and return.
• Ensure an air supply (fresh air) by opening the
window of the boiler installation room. Comply with
the boiler installation room guidelines in the case of
boiler outputs from 46 kW.
• Open the gas shut-off cock in the gas supply pipeline.
• Switch on the main switch outside the boiler
installation room. Frequently the heating system has
an additional emergency switch which switches off
only the gas burner.
• With the UltraGas AM condens, fill the odour trap
(siphon) in the condensate drain pipeline with water
before commissioning.
Commissioning
These instructions are accompanied by
operating instructions for the boiler control
(pages 6 and 7) with an illustration of the
operating panel and detailed information.
These operating instructions for the boiler
control are to be complied with.
• Place the main SYSTEM switch to ”I” and set the
desired boiler temperature at the boiler temperature
controller.
• Please refer to the section ”Faults” on page 4 if fault
lamps light.
Placing out of operation
• Place the main SYSTEM switch to ”0”.
• Close the gas shut-off cock.
• In the case of a long break, e.g. vacation, you can
shut down the heating system.
• If there is a risk of frost, speak to your heating
installer about suitable preventive measures. Anti-
freeze agents are never to be allowed to enter the
boiler circuit.
Maintenance and checking
Boiler and burner
Have your burner and boiler checked and serviced
regularly; DIN 4756 recommends this is carried out
once a year. In order to achieve optimal yearly efficiency,
this maintenance is especially important for a high
efficiency boiler such as this Hoval UltraGas AM
condens. You can conclude a maintenance contract
with your heating installer or the responsible after-
sales service organisation.
Hot water supply
Regular checks increase the life and cost-effectiveness
of any installed calorifier. This work is carried out by the
maintenance service.
In the interest of an economic hot water supply, in
regions in which the water has a high lime content it is
recommended to have the calorifier periodically
delimed. Do not delime the storage tank with iron or
steel tools. The installation of a water softener is
recommended if lime deposits are heavy.

4 200 191 / 01
6The boiler operating elementsls
0I
ON
Boiler in operation
SYSTEM
OFF
Boiler & burner are
inoperative
Attention:
No frost protection
SYSTEM
I
Legend Function
2
675
8
1
3
10
11
49
Operating elements
1. Operating mode
selector
ON/OFF
2. Fuse
3. Basic control
4. Electronic heating
controller
5. Setpoint setting ”nor-
mal”
Check 6.3A fuse if all displays remain dark.
- Controls the internal boiler functions
Settings and changes are only to be made by the heating specialist.
The indication flashes if a fault is present. To reset, fold down the
cover and press the reset button.
- Provides for the correct room temperature according to the
outside temperature.
- Controls the heating up of the calorifier etc.
Special instructions are supplied with the heating
controller.
- Middle setting 20°C
Here the room temperature can be changed by ±8°C

4 200 191 / 01
7
Legend Function
The boiler operating elements
6. Setpoint setting
”reduced”
7. Program switch
8. Interrogation and
programming level
9. Display field
10.Operating instructions
11.Room station
- The desired room temperature for the night can be set here.
Middle setting 14°C ±6°C
The heating program can be selected here:
Heating and hot water filling ”OFF”.
Frost protection guaranteed
The room temperature set for the night is also effective
during the day
Hot water according to clock program 2
Automatic control corresponding to the switching times
entered for the 1st program
(interim reduction for the day)
Automatic control corresponding to the switching times
entered for the 2nd program
(normal setting)
Automatic control corresponding to the switching times
entered for the 3nd program
(longer operating time)
The room temperature is not reduced in the night
Hot water according to clock program 2
Summer operation: Heating ”OFF”
Frost protection, hot water filling is effective according to
clock program 2
Manual operation for the specialist. Burner and
circulation pump in operation. No supply to the mixer
valve, hot water filling in operation
Settings such as time of day and values can be interrogated here.
Setting according to special operating instructions.
Displayed here are the current time, boiler temperature and where
applicable the calorifier temperature.
Quick-reference operating instructions for heating controller only (4)
Optional
Permits operation of the heating controller (4) in the living room. If a
room station is connected, settings 5-6-7 are replaced by the settings
at the room station
3
2
1

4 200 191 / 01
8
Check the neutralisation system (where
installed, see page 1)
Before commissioning the granulate
container is to be filled with the neutralising
granulate NEUTRALAT, as described.
Once a year or after consumption (dissolving) the
neutralisation system should be thoroughly cleaned,
i.e. rinsed with water. To clean the neutralisation
system please follow the instruction below.
Maintenance and checks
Maintenance and checks
The work operations described below are
normally carried out by the specialist at
the time of the annual maintenance.
However, carry out the following checks
in the course of the year and where
necessary, carry out the work described.
Checking the water level
If the system water pressure is low (read
from the pressure gauge), notify your
installer or refill with water.
Refilling the heating system
• Set the main SYSTEM switch to ”0”.
• The shut-off valves for the heating feed and return
must be open.
• The boiler filling and draining cock is accessible after
removing the front cover at the front of the boiler.
• Connect the filling cock to the water tap by a hose;
unscrew this after filling, to safely break the
connection.
• Note the water quality: Drinking water quality; the pH
value must not exceed 9.5.
• Fill with water slowly, check the water level at the
hydrometer or pressure gauge.
• Keep the bleed valves on the radiators open until air-
free water flows out.
• No chemical additives (inhibitors) or anti-freeze
agents are to be used in the boiler circuit.
Attention:
Never add cold water to the hot
heating system.
1. Take off the bottom front boiler cover (remove 2
screws) (on the UG-AM-c (200-350) take off the
bottom cover at the side.
2. Disconnect any condensate connectors (see page
1 for model without condensate lifting pump)
3. Pull out the granulate container.
4. Dispose of any residual granulate with the domestic
waste.
5. Clean the neutralisation system carefully, i.e. flush
out with water.
6. Fill up with new granulate.
The following quantities are required:
- For the UG-AM-c (50-150) – 9 kg of granulate
(3 bags)
- For the UG-AM-c (200-350) – 12 kg of granulate
(bags)
After removing the first wrapper, shake out the fine
dust resulting from transport. Then place the
granulate on the grid, respectively on the filter mat
of the granulate container and distribute it evenly.
7. Push the granulate container back in.
8. Reconnect the condensate connection.
9. Replace the boiler front cover (UG-AM-c (200-350)
bottom cover at the side).

4 200 191 / 01
9
Please note!
In the case of operating faults please
carry out the checks according to the list
above.
If you are unable to rectify the
fault, please call the heating
installer or the Hoval after-sales
service.
Checklist in the case of faults
Fault Check/Cause Rectification See page
Gas boiler -Is current present -Check fuses, switch on main or where applicable,
does not start emergency switch
-Is the gas cock open -Open
-Is a number flashing on the basic control -Press reset button
-Notify after-sales service
-Is gas present -Enquire at your gas supplier
Radiators -Are the gate valves in the heating feed -Open
are not hot and return open
-Is the main switch in the -Changeover 6
”OFF” position
-Is the clock of the TopTronic -Carry out check according to the separate operating
correctly set instructions for the heating controller
-Check the water level, respectively pressure -Refill and bleed the system 4
-Are the radiator valves open -Open
-The heating circulation pump is not running -Remove sealing screw
Turn end of shaft vigorously with a screwdriver
until resistance ceases.
-The mixer does not open automatically - Open manually, call service
No -The filling pump is not running -Remove sealing screw
hot water Turn end of shaft vigorously with a screwdriver
until resistance ceases.
-Is there air in the filling pipeline -Bleed manually where applicable
-Actuate automatic bleeding by hand
-Has the temperature limiter been activated -Unscrew nut and unlock by pressing the knob.

4 200 191 / 01
10
The room temperatures and
heating system operating
times have a decisive
influence on fuel
consumption.
A 1°C lower room temperature
yields a fuel saving of up to 6%. So
note the following tips:
•Avoid room temperatures of
over 20°C and set your heating
system accordingly.
•It is worthwhile closing the
radiator valves in unused rooms
providing there is no risk of frost
and no damage to the building
structure or furnishings is
anticipated.
•Heat recycling takes place in the
main living rooms through body
heat, television sets, chimneys
and also solar radiation. These
cannot be compensated with a
weather dependent control. It is
worthwhile installing individual
thermostatic radiator valves in
these rooms.
When there is a draught, it’s
not only unpleasant but it
also means a loss of heat
energy.
So you’ll save fuel if you . . .
•Keep doors and windows
closed in the winter
•Close flue flaps when the fire is
out
•Use kitchen and bathroom fans
only when steam and odours
have to be extracted
•Ventilate for short periods, but
frequently.
•Seal doors and windows to
avoid permanent leakage
losses.
Keep in valuable heat with
insulation.
Utilise these possibilities and . . .
•Close door and window shutters
at night
•Make sure heating and hot
water pipes in unheated rooms
are insulated.
The lowest possible radiator
temperature prevents
unnecessary heat loss.
So radiators must always be
able to transfer their heat to
the room unhindered. Avoid
therefore:
•Covered radiators
•Windowsills which allow no heat
to pass through because they
are occupied by objects.
Savings are also possible
with hot water systems.
•Set the calorifier temperature as
low as possible. Find the lowest
possible temperature setting at
which sufficient hot water is still
available.
•If your system includes a hot
water circulation pump, it’s
worthwhile switching this off at
night with a timer clock.
How to save energy!