Hoval UltraGas Series User manual

Subject to modi cations | EN
Technical information
Installation instructions
Hoval products must be installed and commissioned
only by appropriately qualied experts. These instruc-
tions are intended exclusively for the specialist. Electri-
cal installations may only be carried out by a qualied
electrician.
Rated output levels at 40/30ºC and for
natural gas
30-UltraGas® (125) 28 - 123 kW
30-UltraGas® (150) 28 - 150 kW
30-UltraGas® (200) 44 - 200 kW
30-UltraGas® (250) 49 - 250 kW
30-UltraGas® (300) 57 - 300 kW
30-UltraGas® (350) 58 - 350 kW
30/31-UltraGas® (400) 97 - 400 kW
30/31-UltraGas® (450) 97 - 450 kW
30/31-UltraGas® (500) 97 - 500 kW
30/31-UltraGas® (575) 136 - 575 kW
30/31-UltraGas® (650) 136 - 650 kW
30/31-UltraGas® (720) 142 - 720 kW
30-UltraGas® (850) 166 - 850 kW
30-UltraGas® (1000) 224 - 1000 kW
UltraGas®(125-1000)
Condensing gas heating boilers
for natural gas and liquid gas
for modulating operation
The oor standing gas condensing boiler UltraGas®
(125-1000) are designed and approved for use as
heat generators for hot water heating systems with a
permissible ow temperature of up to 90°C1), in accord-
ance with EN 483 and EN 677. They are designed for
continuously adjustable reduced output operation in
heating systems.
1) see technical data
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1. Safety instructions
1.1 Key to symbols used ............................................................................................................................. 4
2. Important notes
2.1 Acceptance of delivery .......................................................................................................................... 5
2.2 Scope of guarantee................................................................................................................................. 5
2.3 Instruction manuals ................................................................................................................................ 5
2.4 Regulations, official permits .................................................................................................................. 5
2.4.1 Germany ................................................................................................................................................... 6
2.4.2 Austria ....................................................................................................................................................... 6
2.4.3 Switzerland ............................................................................................................................................... 6
3. Assembly
3.1 Placement ................................................................................................................................................ 7
3.2 Mounting of heat insulation ................................................................................................................. 10
3.3 Mounting the casing ............................................................................................................................. 11
3.4 Mounting of base casing ...................................................................................................................... 14
3.5 Adjusting the length of the ladder types (850,1000) .......................................................................... 15
4. Technical information
4.1 Description of the boiler....................................................................................................................... 16
4.2 Technical data ....................................................................................................................................... 17
4.3 Dimensions / Space requirements ...................................................................................................... 20
4.3.1 Opening dimension ................................................................................................................................. 21
4.4 Hydraulic resistance............................................................................................................................. 22
4.5 Brief description of the automatic firing device ................................................................................ 23
5. Installation
5.1 Safety information................................................................................................................................. 24
5.2 Boiler room requirements .................................................................................................................... 24
5.2.1 Room air dependent installation.............................................................................................................. 24
5.2.2 Room air independent installation........................................................................................................... 24
5.3 Flue gas connection and flue............................................................................................................... 25
5.4 Condensate drainage............................................................................................................................ 26
5.4.1 Execution variants................................................................................................................................... 26
5.5 Gas connection ..................................................................................................................................... 27
5.6 Hydraulic connection............................................................................................................................ 27
5.6.1 Customer-side requirements................................................................................................................... 28
5.6.2 Hydraulic interconnection........................................................................................................................ 28
5.6.3 Cascade control ...................................................................................................................................... 28
5.7 Electrical connection ........................................................................................................................... 29
6. Commissioning
6.1 Safety information................................................................................................................................. 30
6.2 Filling with water................................................................................................................................... 30
6.3 Water quality.......................................................................................................................................... 31
6.4 Bleeding the air from the gas line ....................................................................................................... 32
6.5 Switching on the system ...................................................................................................................... 32
6.6 Gas inlet pressure................................................................................................................................. 32
6.7 Setting the gas flow rate CO2(O2) and measurement of NOx/CO content in the flue gas............... 33
6.7.1 Flue gas measurement UltraGas®(125-720) .......................................................................................... 33
6.7.2 Flue gas measurement UltraGas®(850,1000) ........................................................................................ 34
6.8 Changing over to a different gas type................................................................................................. 35
6.9 Type (850,1000) Setting for the stabilisation damper (if necessary) ................................................ 37
6.10 Handover to the user ............................................................................................................................ 38
6.11 Record - Activation of screed function ............................................................................................... 39
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Table of contents

7. Maintenance
7.1 Safety information ................................................................................................................................ 41
7.2 Bleeding................................................................................................................................................. 41
7.3 Water refilling ........................................................................................................................................ 41
7.4 Information for combustion controller/chimney sweep regarding emission monitor key ............. 42
7.5 Cleaning................................................................................................................................................. 43
7.5.1 Cleaning the burner cylinder (inside and outside)................................................................................... 43
7.5.2 Cleaning the exterior of the combustion chamber and burner cylinder .................................................. 44
7.5.3 Cleaning/adjusting the ignition and ionisation device.............................................................................. 45
7.6 Setting the gas flow rate CO2(O2) and measurement of NOx/CO content in the flue gas............... 46
7.7 Clean siphon.......................................................................................................................................... 46
7.8 Servicing the neutralisation installation for types 23 and 24 (if fitted) ............................................ 47
8. Overview of settings
8.1 Table of parameters .............................................................................................................................. 48
8.2 Fault Reporting overview TopTronic®T................................................................................................ 63
8.3 Automatic firing device (Warning, Blocking, Lock-out) ..................................................................... 65
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Table of contents

1. Safety instructions
The system shall not be put into operation until all relevant standards and safety
regulations are met.
For a test run, the following minimum conditions must be satisfied:
- Safety valve installed (closed system)
- Controls operative (connected to power supply)
- Sensor for safety temperature limiter is connected
(= boiler temperature sensor)
- System filled with water
- Siphon filled with water
- Expansion tank connected
- Flue gas adapter pipe with flue gas pipe connected to flue .
- Burner is preset (see point 6.7).
1.1 Key to symbols used
Tools:
Shows the tools required for the following work.
Instruction:
Prompts you to carry out an action.
Result:
Shows the expected reaction to your action.
i
Note:
Provides important information
Safety information:
Indicates an immediate hazard to persons
Warning of dangerous electrical voltage
Warning information
Indicates danger to machines and Installations
Provides important information.
§Reference to standards and regulations.
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Safety instructions

2. Important notes
2.1 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 specified in the
delivery contract.
The costs for correcting the damage shall be taken over by the individual risk bearer.
2.2 Scope of guarantee
The guarantee does not cover defects caused by:
- non-observance of these instructions
- non-observance of the operating instructions
- incorrect Installation
- unauthorised alterations
- improper use
- contaminated operating media (gas, water, combustion air)
- unsuitable chemical additives to the heating water
- damage due to the exercise of force
- corrosion through halogen compounds
- corrosion through nonconforming water quality
2.3 Instruction manuals
A summary of all the instruction manuals relevant to this system can be found in the
Hoval System User Guide!
In exceptional cases the instructions are kept with the respective components!
Additional sources of information:
- Hoval catalogue
- Standards and regulations
2.4 Regulations, official permits
When installing and operating the system, the standards and regulations specified
in sections 2.4.1 to 2.4.3 must be complied with at all times.
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Important information

2.4.1 Germany
DIN EN 12831 Heating systems in buildings - Methods for calculating the design heat load
DIN EN 13384 Flue gas systems - Heat and flow calculation methods
DIN EN 12828 Heating systems in buildings - Planning of hot water heating systems.
DIN 4755 Oil fired combustion systems.
Construction, design, safety requirements.
DIN 4756 Gas fired combustion systems. Construction, design, safety requirements, design and execu-
tion (for gas burner operation).
DIN 18160 Domestic chimneys, requirements, design and construction.
TRD 702 Steam boilers with group II hot water generators.
TRD 721 Safety equipment against excessive pressure / safety valves for group II steam boilers.
VDI 2035 Prevention of damage through corrosion and scale formation in hot water heating systems.
DIN 57 116 / VDI 0116 Electrical equipment in combustion systems
(VDE regulation).
See enclosure N-430 020 for further standards applicable in Germany.
2.4.2 Austria
OENORM 12831 12831Heating systems in buildings - Methods for calculating the design heat load
OENORM 13384 Flue gas systems - Heat and flow calculation methods
OENORM 12828 Heating systems in buildings - Planning of hot water heating systems.
ÖNorm B 8130 Open water heating systems; safety equipment.
ÖNorm B 8131 Closed water heating systems; requirements to safety, construction and testing.
ÖNorm B 8133 Hot water supply systems; safety requirements.
ÖNorm B 8136 Heating systems, space and other building requirements.
ÖNorm M 7515 Dimensioning of chimneys; definitions and calculation procedure.
ÖNorm H 5171 Heating systems - construction requirements for buildings.
ÖVGW TR-Gas
2.4.3 Switzerland
SN EN 12831 Heating systems in buildings - Methods for calculating the design heat load
SN EN 13384 Flue gas systems - Heat and flow calculation methods
SN EN 12828 Heating systems in buildings - Planning of hot water heating systems.
VKF - Association of Cantonal Fire Insurances.
Fire service regulations.
SVGW Switzerland. Association of the gas and water trade.
SNV 27 10 20 Ventilation requirements for the boiler Installation room.
SWKI BT102-01 Quality of water in installations of building technology.
Technical tank regulations TTV 1990.
and further standards and regulations issued by CEN, CEN ELEC, DIN, VDE, DVGW, TRD and by the
legislator. Regulations from the local building authority, insurance companies and chimney sweeps must
also be complied with. When using gas as fuel, the regulations of the responsible gas board must also
be observed. An official permit may be required.
§
§
§
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Important information

3. Assembly
3.1 Placement
Make sure that the cable does not touch any hot
locations!
Fig. 01
Space requirements UltraGas®(125-1000)
Dimensions (mm)
The boiler may be placed against the wall on one side.
For the mounting of the casing yet a wall clearance of 100 mm min. must be provided.
For swing out of burner this
clearence must be ensured
Install gas line
straight to the back
UltraGas®
Type A A minimal B C D H H minimum
(125, 150) 180 180 2820 1237 981 1823 1711 3
(200 - 300) 360 1160 2930 1584 1247 1923 1811 3
(350 - 500) 200 1100 21110 1679 1268 2070 1958 3
(575 - 720) 200 1100 21290 1843 1438 2086 1984 3
(850, 1000) 420 1230 21550 2154 1703 2139 2037 3
1If room height is too small: Reduction of measures possible. See A minimum.
2Attention! With A minimum the burner is no longer swing-out completely! Cleaning makes more difficult!
3Boiler foot can be shortened, no base casing possible! Details see next page.
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Assembly

UltraGas®with shortened boiler feet
(All measurements in mm)
UltraGas®
Type a
(125, 150) 1723 - 1783
(200 - 300) 1823 - 1883
(350 - 500) 1970 - 2030
(575 - 720) 1986 - 2046
(850, 1000) 2039 - 2099
UltraGas®
Type a
(125, 150) 1711 - 1771
(200 - 300) 1811 - 1871
(350 - 500) 1958 - 2018
(575 - 720) 1984 - 2044
(850, 1000) 2037 - 2097
UltraGas®
Type a
(125, 150) 1721
(200 - 300) 1821
(350 - 500) 1968
(575 - 720) 1994
(850, 1000) 2047
UltraGas®with masonry base and adjustable feet
UltraGas®with masonry base without adjustable feet
Base plates and feeds
will not be refunded!
1 Neutralisation box
2 Condensate pump
3 Masonry base
4 Adjustable feed 20-80 mm
UltraGas®(575-1000)
UltraGas®(575-1000) cut off
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Assembly

Procedure:
1. Remove the two upper threaded elements (1) on the boiler base (1a).
2. Take off the front wooden beam.
3. Raise the front of the boiler with a jack (3).
4. Move aside the side beam (4) at the front (see fig. 2) Introduce the front feet and screw in place.
5. Raise the back of the boiler with a jack (3).
6. Move aside the side beam (4) at the back (see fig. 2). Introduce rear feet and screw in place.
7. Remove footboard locking device (5). Remove the locking pin (6) and fold open the footboard carefully.
In the case of models 850 and 1000, fold open the 2nd and 3rd footboard and remove the ladder.
Adjustment of the adjustable feet is carried out takes place after installing the neutralisation unit
4 1a
1
3
Typen (850, 1000)
with six feet
6
5
Typen (575-1000)
Hanging up possibilities for crane hooks
1b
Fig. 02
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Assembly

3.2 Mounting of heat insulation
1. Place the insulation blanket (1) around the UltraGas®boiler and fix with plastic bands (1a) and clips (1b)
- tension springs (1c) are used for additional fixing
- do not fit the band too tightly (reduces insulation value).
1
1a
1b
1c
Fig. 03
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Assembly