Hoval UltraGas 125 Installation Instructions Manual
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Hoval UltraGas 125 Installation Instructions Manual

Condensing gas boilers
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Technical information
Installation instructions
UltraGas
(125 - 1000)
®
Condensing gas boilers
for natural gas and liquefied gas
for modulating operation
Hoval products may only be installed and commissioned
by appropriately qualified experts. These instructions
are intended exclusively for the specialist. Electrical
installations may only be carried out by a qualified
electrician.
Subject to modifi cations
|
4 213 783 / 00 - 06/15
These instructions are applicable to the
following types:
Nominal output ranges at 40/30°C and
with natural gas
41-UltraGas
®
41-UltraGas
®
41-UltraGas
®
41-UltraGas
®
41-UltraGas
®
41-UltraGas
®
41-UltraGas
®
41-UltraGas
®
41-UltraGas
®
41-UltraGas
®
41-UltraGas
®
41-UltraGas
®
41-UltraGas
®
41-UltraGas
®
41-UltraGas
®
41-UltraGas
®
Vertical gas condensing boilers UltraGas
acc. to EN 483 and EN 677 are suitable and licensed for
use as heat generators for hot water heating systems
with a permissible flow temperature of up to 90 °C
They are designed for continuously controlled reduced
operation in a heating system.
See technical data
1)
(125)
28 - 123 kW
(150)
28 - 150 kW
(200)
44 - 200 kW
(250)
49 - 250 kW
(300)
57 - 300 kW
(350)
58 - 350 kW
(400)
97 - 400 kW
(450)
97 - 450 kW
(500)
97 - 500 kW
(575)
136 - 575 kW
(650)
136 - 650 kW
(720)
142 - 720 kW
(850)
166 - 850 kW
(1000) 224 - 1000 kW
H (720)
142 - 720 kW
H (1000) 224 - 1000 kW
(125-1000)
®
EN
.
1)

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Summary of Contents for Hoval UltraGas 125

  • Page 1 142 - 720 kW ® 41-UltraGas H (1000) 224 - 1000 kW ® Hoval products may only be installed and commissioned Vertical gas condensing boilers UltraGas (125-1000) ® by appropriately qualified experts. These instructions acc. to EN 483 and EN 677 are suitable and licensed for are intended exclusively for the specialist.

  • Page 2: Table Of Contents

    TABLE OF CONTENTS Important notes General safety instructions ..............................4 Explanation of the symbols ..............................4 1.2.1 Warnings ..................................4 1.2.2 Icons ....................................4 On delivery ...................................5 Warranty ....................................5 Manuals ....................................5 Regulations, official approvals ............................6 1.6.1 Germany § ..................................6 1.6.2 Austria § ...................................6 1.6.3 Switzerland §...
  • Page 3 TABLE OF CONTENTS Maintenance Safety instructions ................................38 Deaeration ..................................38 Top up with water ................................38 Renewing fuse ...................................38 Information for fire inspector / chimney sweep regarding emission and manual operation settings ......39 Cleaning .....................................40 6.6.1 Cleaning the burner cylinder (inside and out) ........................40 6.6.2 Cleaning the combustion chamber and burner cylinder on the outside ................41 6.6.3...

  • Page 4: Important Notes

    IMPORTANT NOTES Important notes Explanation of the symbols 1.2.1 Warnings General safety instructions The system may only be placed in operation DANGER if all the relevant standards and safety regula- ... indicates a situation of immediate danger tions have been complied with. which will lead to serious or fatal injuries if not avoided.

  • Page 5: On Delivery

    • Corrosion caused by not observing the required water quality Manuals All instructions relevant to your system can be found in the Hoval system manual! In exceptional cases, the in- structions can be found with the components! Further sources of information: • Hoval catalogue •...

  • Page 6: Regulations, Official Approvals

    IMPORTANT NOTES Regulations, official approvals 1.6.3 Switzerland § The standards and directives stated under points 1.6.1 to - SN EN 12831 Heating systems in buildings - Procedure 1.6.3 must be taken into account during installation and for calculation of the standard heating load operation of the system.

  • Page 7: Installation

    INSTALLATION Installation Set-up Space requirement of UltraGas (125-1000) ® (All dimensions in mm) CAUTION The cables must not touch any hot parts. For swinging out the burner this area must remain free Straight gas connection line route to the rear Fig.
  • Page 8 INSTALLATION UltraGas with shortened boiler feet ® (All dimensions in mm) UltraGas peak load boiler ® Model (125, 150) 1723 - 1783 (200 - 300) 1823 - 1883 (350 - 500) 1970 - 2030 (575 - 720) / H (720) 1986 - 2046 (850, 1000) / H (1000) 2039 - 2099...
  • Page 9 INSTALLATION Procedure: 1. Remove the top two screw connections (1, Fig. 02) on the boiler foot (1a, Fig. 02). 2. Remove front wooden crossbeam. 3. Using a winch (3, Fig. 02) raise the front of the boiler. 4. Take out the side beam (4, Fig. 02) at the front to the side (see Fig. 02). 5.

  • Page 10: Fitting The Thermal Insulation

    INSTALLATION Fitting the thermal insulation Place the insulation mat (1, Fig. 03) around the UltraGas boiler and attach with plastic straps (1a, Fig. 03) and strap ® fasteners (1b, Fig. 03). - Tension springs (1c, Fig. 03) serve for additional fixing - Do not overtighten the straps (reduced insulating value).

  • Page 11: Fitting The Casing

    INSTALLATION Fitting the casing 9. Hook in the upper rear walls (10, Fig. 09) and fit the dummy cover (10a). 1. Hook the cable duct (2, Fig. 04) into the pins on the left and right and attach with the middle hexagon nuts 10.
  • Page 12 INSTALLATION Secure the service pedestal (7c, Fig. 08) in the folded-up status with pin (1b, Fig. 02)! S e i t e n w a n d s t ü t z e 2 1 - U l t r a G a s ( 8 5 0 ) Illustration shown without burner Fig.
  • Page 13 INSTALLATION Models (850,1000) in two-piece design Type (125,720) in one-piece design Burner wiring Model (125-850); 2 plug connections Model (1000); 3 plug connections Ignition cable Boiler temperature sen- Flue gas sensor Mains cable Condensate box Water pressure (if fitted) sensor Fig.

  • Page 14: Fitting The Pedestal Casing

    INSTALLATION Fitting the pedestal casing Attach the condensate trap (13, Fig. 10), which is supplied loose, incl. double nipple (13a, Fig. 10). 1. Place the condensate box (option) under the boiler and establish the electrical connection. Make the condensate drain or connection line according to sep- arate instructions.
  • Page 15 INSTALLATION Fig. 11 Only types UG (850,1000) If you are using the variant with shortened boiler feet or you place the boiler on a concrete pedestal, you will have to shorten the supplied conductors (saw off at the watch) or extend them. Fig.

  • Page 16: Technical Information

    TECHNICAL INFORMATION Technical information Description of the boiler The Hoval UltraGas is a low-pollution and energy-saving so designed that part of the water vapour contained in the ® condensing gas boiler with the Ultraclean burner system, flue gas condenses and the heat of evaporation is utilised a gas-fired pre-mix burner with combustion air blower.

  • Page 17: Ultragas ® (125-300) Technical Data

    , operation in the Wobbe value range from 12.0 to 15.7 kWh/m possible without re-set. Figures relate to Hu. Compare notes for planning. Figures for multiple boiler systems (cascades) with common flue gas conduit: see Hoval UltraGas (250D-2000D) ® • Boiler flow resistance see diagrams.
  • Page 18 , operation in the Wobbe value range from 12.0 to 15.7 kWh/m possible without re-set. Figures relate to H Compare notes for planning. Figures for multiple boiler systems (cascades) with common flue gas conduit: see Hoval UltraGas (250D-2000D) ® • Boiler flow resistance see diagrams.
  • Page 19 , operation in the Wobbe value range from 12.0 to 15.7 kWh/m possible without re-set. Figures relate to H Compare notes for planning. Figures for multiple boiler systems (cascades) with common flue gas conduit: see Hoval UltraGas (250D-2000D) ® • Boiler flow resistance see diagrams.

  • Page 20: Dimensions Space / Required

    TECHNICAL INFORMATION Dimensions space / required (All dimensions in mm) Fig. 14 Heating flow Condensate drain with odour trap and screw connection for plastic pipe Fresh air connection (option) Low-temperature return Boiler flows adjustable up to 80 mm Gas connection Safety valves connection supply line (option) Safety flow Safety valves connection return flow (option)

  • Page 21: Overall Unit Dimensions

    TECHNICAL INFORMATION 3.3.1 Overall unit dimensions Boiler without casing and insulation Fig. 15 UltraGas peak load boiler Measurements for installation as individual parts ® Model (125.15) 1520 1072 1295 1380 1191 1040 (200-300) 1585 1422 1330 1355 1445 1260 1390 (350) 1610 1530...

  • Page 22: Boiler Flow Resistance

    TECHNICAL INFORMATION Boiler flow resistance UltraGas (125,15 0) UltraGas (200 - 300) ® ® 9 10 11 12 13 14 15 Volume flow [m Volume flow [m Volumenstrom [m3/h] Volumenstrom [m3/h] UltraGas (350 - 500) UltraGas (575-720) / UltraGas H (720) ®...

  • Page 23: Brief Description Of The Automatic Firing Device

    TECHNICAL INFORMATION Brief description of the automatic firing device The automatic firing device BIC 960 of the UltraGas ® only works in connection with the heating regulator TopTronic E/UG. As a result, the automatic firing device ® only has to take over the last missing functions for correct operation of a modulating gas boiler.

  • Page 24: Installation

    INSTALLATION Installation 4.2.2 Room air independent installation Safety instructions Variant using "Connection for direct combus- tion air supply" or "Motorised air intake damp- CAUTION er" (optional): Cutting injuries as a result of sharp edges. - When configuring the intake tube, comply Handle parts of the casing carefully and with the following: avoid contact with sharp edges.

  • Page 25: Flue Gas Connection, Flue Gas Conduit

    Condensate drain Low flue gas temperatures mean that condensation forms The boiler condensate drain must be made of in the chimney. This means that Hoval gas boilers cannot corrosion-resistant material. be connected to conventional domestic chimneys. The following materials are suitable for the...

  • Page 26: Gas Connection

    INSTALLATION Gas connection DANGER Danger of explosion due to leaking gas con- nection. Following installation of the boiler, check the gas connection for leaks. For gas connection, see dimension drawings under point 3.3. Route gas connection straight to the rear! Fig.

  • Page 27: To Be Provided On-Site

    4.6.2.1 Cascades regulations. As a basic principle, the Hoval TopTronic should per- • With underfloor heating, a flow temperature form cascade control. This ensures an environmentally limit thermostat must be installed.

  • Page 28: Electrical Connection

    INSTALLATION Electrical connection The electrical connection must be connected in accordance with the applicable standards • A qualified technician must install the elec- of nationally or internationally recognised pro- trical supply to the equipment. fessional associations. • The connection schematic is located in the boiler controller.

  • Page 29: Commissioning

    • Risk of injury for non-expert personnel. • Initial start-up, maintenance and cleaning work are only allowed to be performed by trained specialist personnel or by Hoval customer service. NOTICE Damage to the system by filling unauthorised liquids.

  • Page 30: Water Quality

    In particular, attention must be paid to the following stipu- lations: Filling and replacement water • Hoval boilers and calorifi ers are designed for heating • For a plant using Hoval boilers untreated drinking water plants without signifi cant oxygen intake (plant type I ac- is generally best suited as heating medium, i.e.

  • Page 31: Venting The Gas Pipe

    COMMISSIONING Venting the gas pipe Comply with the necessary regulations when § venting the gas pipe. • Open the gas cut-off valve. • Vent the gas pipe up to the gas valve. Switch on • Switch on blocking switch to release the burner. WARNING The heat generator is live when it has been connected to the mains.

  • Page 32: Setting The Gas Quantity, Measuring The Co ) And Nox/Co Content In The Flue Gas

    COMMISSIONING Setting the gas quantity, measuring the CO Measure the NOx and CO content. The meas- ) and NOx/CO content in the flue gas ured values must lie within the limits prescribed 5.7.1 UltraGas (125-720) flue gas measurement by law. Higher values indicate faulty burner ®...

  • Page 33: Changing To A Different Type Of Gas

    The control automatically switches to normal operation after 20 min. The changeover is only allowed to be carried out by a recognised specialist or Hoval cus- Position the emission meter in the flue gas pipe. tomer service. Set the boiler to maximum output (100%).
  • Page 34 COMMISSIONING For UltraGas (400-720) The conversion kit includes: ® Only approved for propane Yellow sticker. Orifice with seal. 4 M5x16 screws Orifice diameter: UltraGas (400-500) Ø 16.5 mm ® UltraGas (575-720) Ø 21 mm ® UltraGas H (720) Ø 21 mm ®...

  • Page 35: Type (850, 1000) Setting The Stabilisation Damper (If Required)

    COMMISSIONING Type (850, 1000) setting the stabilisation damper (if required) The stabilisation damper reduces the outlet cross section of the blower during the starting phase. This optimises the starting behaviour of the boiler! Factory setting of the stroke: 20 mm. This is the optimum setting with normal chimney condi- tions.

  • Page 36: Activation Of Screed Function

    COMMISSIONING 5.11 Activation of screed function Description of function The control module of the TopTronic E contains a functional sequence used for drying out screed fl oors. To start the ® screed drying, it is necessary for the individual functions to be set accordingly. Flow temperature Heating-up phase Inertia phase...
  • Page 37 COMMISSIONING Function display Icon Function Screed drying active Various settings can be made as well. Prioritisation of the screed func- tion means the settings are only ac- tive at the end of the function. Information remaining run time Request of the active function phase, the ACT temperature as well as the remaining run time.

  • Page 38: Maintenance

    Electrical installations may only be carried lowed to be performed by trained specialist out by a qualified electrician. personnel or by Hoval customer service. 1. Set the blocking switch to "0" and disconnect the heat NOTICE generator from the mains (main switch, fuse).

  • Page 39: Information For Fire Inspector / Chimney Sweep Regarding Emission And Manual Operation Settings

    MAINTENANCE Information for fire inspector / chimney sweep regarding emission and manual operation settings This chapter is exclusively intended to describe the function of emissions and manual operation settings for the fi ring monitoring technician / chimney sweep. All operating elements are described in the operating instructions. CAUTION Danger of scalding with hot water, since the hot water temperature can exceed the target setpoint temperature.

  • Page 40: Cleaning

    The boiler is only allowed to be cleaned by a licensed specialist or Hoval customer ser- vice technician. The Hoval gas boiler must be cleaned and serviced at least once a year. NOTICE If the Hoval gas boiler was in operation dur- ing the building phase, it is essential to check the degree of contamination.

  • Page 41: Cleaning The Combustion Chamber And Burner Cylinder On The Outside

    MAINTENANCE Preparation: WARNING The heat generator must be de-energised for maintenance. Set the blocking switch to "0" and disconnect the heat generator from the mains (e.g. main switch). Fig. 32 1. Close main gas valve. 2. Remove absorber hood. 3. Undo all burner plug-in connections. 4.

  • Page 42: Clean/Adjust Ignition And Ionisation Devices

    MAINTENANCE Cleaning: • Spray combustion chamber and aluFer pipes (3, ® Fig. 37). - The best results are achieved with a spray gun and a wide spray nozzle (flat or conical jet). The following are to be recommended, for example: - Desoxin •...

  • Page 43: Cleaning The Gas Filter Hfvr050 (Only Applicable For Ultragas ® (450-720)) (If Fitted)

    5 3 5 , 8 MAINTENANCE 6.6.4 Cleaning the gas filter HFVR050 (only applica- Open the combustion chamber as described in ble for UltraGas (450-720)) (if fitted) ® point 6.6.2 (cleaning the combustion chamber and burner cylinder on the outside). Cleaning: Sand the ignition and ionisation devices with fine sandpaper.

  • Page 44: Setting The Gas Quantity, Measuring The Co ) And Nox/Co Content In The Flue Gas

    MAINTENANCE 21-UltraGas (850) Sifon Setting the gas quantity, measuring the CO ) and NOx/CO content in the flue gas See point 5.7. The maintenance should be performed at least every other year, or when the neutralisa- tion granulate has been used up (if necessary check the pH value with a litmus paper test).

  • Page 45: Maintaining The Neutralisation Unit For Type 23 And Type 24 (If Fitted)

    (check the ph-value if appropriate with litmus paper test). Neutralisation granulate for refi lling can be ordered from Hoval under the following item no.: • 1 pack (3 kg) neutralisation granules Part no. 2028 906 One fi lling requires 4 packs of 3 kg each.
  • Page 46 4 213 783 / 00...
  • Page 47 4 213 783 / 00...
  • Page 48 COPY FOR PLANT USER Confirmation The user (owner) of the system herewith confi rms that • he has received adequate instruction in the operating and maintenance of the installation, • received and taken note of the operating and maintenance instructions and, where applicable other documents con- cerning the heat generator and any further components.

This manual is also suitable for:

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