Hoval UltraGas 125 Technical Information

Condensing gas heating boilers for natural gas and liquid gas for modulating operation

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Installation instructions manual (68 pages)

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Technical information

Installation instructions

UltraGas

(125-1150)

Condensing gas heating boilers

for natural gas and liquid 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

4 217 215 / 00 - 12/18 UK

These instructions apply to the following types:

Rated output levels at 40/30ºC and for natural

gas

45-UltraGas

The floor-standing gas condensing boilers UltraGas

(125-1150) 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 flow temperature of

up to 90 °C

. They are designed for continuously con-

trolled reduced operation in heating systems.

See technical data

(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

(1150) 233 - 1150 kW

H (720)

142 - 720 kW

H (1000) 224 - 1000 kW

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Summary of Contents for Hoval UltraGas 125

Page 1 142 - 720 kW ® 45-UltraGas H (1000) 224 - 1000 kW ® Hoval products may only be installed and commissioned The floor-standing gas condensing boilers UltraGas ® by appropriately qualified experts. These instructions (125-1150) acc. to EN 15502-1/15502-2-1 are suitable 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 Warning symbols................................4 1.2.3 Information ..................................5 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 5.8.2 UltraGas (850-1150) flue gas measurement ........................39 ® Changing to a different type of gas ..........................40 5.9.1 Changing from natural gas H to natural gas L ........................40 5.9.2 Changing from natural gas to liquid gas ..........................40 5.10 Type (850-1150) setting the stabilisation damper (if required) ..................42 5.11 Handover to the operator ..............................42...
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: Information
Manuals § standards and directives. 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 • Standards, regulations...
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 (125-1150) ® (All dimensions in mm) For swinging out the burner this area must remain free (see dimension table) If the gas line is routed horizon- tally to the left, the minimum dis- tance D must be observed.
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 - 1150) / 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 (2, Fig. 02) raise the front of the boiler. 4. Take out the side beam (3, 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 3. Attach rear wall (terminal plate 3, Fig. 06) of the termi- nal box using 4 screws (3a, Fig. 06). 1. Hook the cable duct (1, Fig. 04) into the pins on the left and right and attach with the middle hexagon nuts 4.
Page 12 INSTALLATION 6. Route the cable for the water pressure sensor (6, Fig. 09) down out of the control and connect to the boiler at the bottom (cable routing acc. to Fig. 09). Route all other cables on the left or right of the boiler and make the plug connections.
Page 13 INSTALLATION Models (850-1150) in two-piece design Typ (125,720) in one-piece design Burner wiring: - Model (125-850): 2 plug connections - Model (1000-1150): 3 plug connections Ignition cable Boiler temperature sensor Pressure switch B17, B18 Flue gas sensor Mains cable Condensate box Water pressure (if fitted) sensor...
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). 13. 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 (850-1150) 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
Description of the boiler es and the heat of evaporation is utilised for the heating The Hoval UltraGas is a low-pollution and energy-saving ® circuit. The gas burner is configured as a vertical burn- condensing gas boiler with the Ultraclean burner system, er that can be swivelled up easily for maintenance work.
Page 17: Ultragas ® (125-1150) Technical Data
Data related to NCV. See also notes at “Engineering”. See also notes at “Engineering”. Details for multi-boiler plants (cascade) with common flue gas line: see Hoval UltraGas (250D-2000D). ® Details for multi-boiler plants (cascade) with common flue gas line: see Hoval UltraGas (250D-2000D).
Page 18 Wobbe coefficient of 12.0 up to 15.7 kWh/m is possible without new settings. Data related to NCV. See also notes at “Engineering”. Details for multi-boiler plants (cascade) with common flue gas line: see Hoval UltraGas (250D-2000D). ® 4 217 215 / 00...
Page 19 Wobbe coefficient of 12.0 up to 15.7 kWh/m is possible without new settings. Data related to NCV. See also notes at “Engineering”. Details for multi-boiler plants (cascade) with common flue gas line: see Hoval UltraGas (250D-2000D). ® 4 217 215 / 00 UK...
Page 20: Dimensions Space / Required
TECHNICAL INFORMATION Dimensions space / required (All dimensions in mm) <( => 0:::: >- >- Hinweis Space requirement - see chapter 2.1. Fig. 14 10. Kondensatablauf mit Geruchsverschluss und Verschraubung für Kunststoffrohr 1. Vorlauf Heizung Heating flow Condensate drain with odour trap and screw connection for plastic pipe 11.
Page 21: Overall Unit Dimensions
Example calculation for the required corridor width Door width T = 1000 Data related to NCV. See also notes at “Engineering”. Details for multi-boiler plants (cascade) with common flue gas line: see Hoval UltraGas (250D-2000D). ® UltraGas (400-500) K = 1000 x 1531 = corridor width ≥...
Page 22: Boiler Flow Resistance
TECHNICAL INFORMATION Boiler flow resistance UltraGas (125,150) 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
Wobbe coefficient of 12.0 up to 15.7 kWh/m is possible without new settings. Data related to NCV. See also notes at “Engineering”. Details for multi-boiler plants (cascade) with common flue gas line: see Hoval UltraGas (250D-2000D). ® 4 217 215 / 00 UK...
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
INSTALLATION Flue gas connection, flue gas conduit • The cross sections and the maximum Due to the low flue gas temperature, condensate forms in lengths are calculated with reference to dia- the flue gas line and wind protection equipment. grams or tables. •...
Page 26 INSTALLATION Guidance values for the flue gas pipe dimensions Flue gas line Boiler Number of bow 90° (flue gas + air supply) (smooth walled) type Flue gas dim. mm Dimension Total pipe length in m (flue gas + air supply) UltraGas internal ®...
Page 27: Condensate Drain
INSTALLATION Condensate drain The boiler condensate drain must be made of corrosion-resistant material. The following materials are suitable for the condensate dis- charge: • PVC • PE • PP • ABS Local regulations pertaining to the conden- sate discharge must be observed. Fig.
Page 28: Gas Connection
INSTALLATION Gas connection Hydraulic connection According to EN 12828:2003 the following safety-techni- DANGER cal equipment is integrated into the boiler: Danger of explosion due to leaking gas con- • Minimum pressure limiter DBmin nection. • Safety maximum pressure limiter DBmax •...
Page 29: Hydraulic Integration
Important information: 4.6.2.1 Cascades • The example schematics merely show the As a basic principle, the Hoval TopTronic should per- basic principle and do not contain all in- form cascade control. This ensures an environmentally formation required for installation. Instal- and product-friendly method of operation.
Page 30: Sound Insulation
INSTALLATION Sound insulation Procedure to remove the front casing The following measures are possible for sound insulation: 1. Remove front cover (1, Fig. 22) after first releasing • If there are living areas above or below the boiler room, the lateral locking bolt (1a, Fig. 22) (turn approx. ¼ make boiler room walls, ceiling and floor as solid as turn to the left and pull out as far as the stop).
Page 31: Safety Measures For Emc According Assembly
COMMISSIONING 4.8.1 Safety measures for EMC according assembly • Measures must be taken in the building and on electri- cal equipment to protect the units against overvoltage caused by lightning strikes. • Cables carrying mains voltage must be routed sepa- •...
Page 32 COMMISSIONING In the case of star-shaped data bus networks, double Disadvantages of an inter-building installation earthing is not permitted. The earthing must be carried - Increased susceptibility to interference, communica- out on one side at the star point. tion problems - Voltage surge damage To ensure correct electrical installation, unit connec- Abschirmung...
Page 33: Recommended Cable Cross Sections And Permissible Maximum Length Of Cable
COMMISSIONING 4.8.2 Recommended cable cross sections and permissible maximum length of cable Line type Cross-section Length Power supply of the min. 2.5 mm unlimited m heat generator (230 V) with 16 A fuse Power supply of the min. 1.0 mm unlimited m heat generator (400 V)* with 10 A fuse...
Page 34: 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 35: 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 36: Venting The Gas Pipe
WARNING flue gas is discharged. The heat generator is live when it has been connected to the mains. In order to ensure safety, the Hoval UltraGas is equipped ® with a pressure monitoring device on the combustion cyl- inder. The combustion cylinder pressure monitoring de-...
Page 37: Check Pressure In The Combustion Cylinder (Safety Check During Commissioning)
- Compare measured value with the nominal meas- WARNING ured value in the following table (deviation toler- ance of the two values: ±10 %). The settings must only be changed by a spe- cialist trained by Hoval or by Hoval customer UltraGas type Factory setting ®...
Page 38: Setting The Gas Quantity, Measuring The Co ) And Nox/Co Content In The Flue Gas
- value is not correct - set lower value - ulation must only be made by a specialist check upper value - ... trained by Hoval or by Hoval customer ser- vice. 1. Start the «Emission» menu on the control module.
Page 39: Ultragas (850-1150) Flue Gas Measurement
COMMISSIONING 5.8.2 UltraGas (850-1150) flue gas measurement ® Setting procedure: If you have to make a setting on the venturi, Screwdriver, 2.5 mm Allen key always check both flue gas values. For example: set upper value - check lower value - value is not correct - set lower value - check upper value - ...
Page 40: Changing To A Different Type Of Gas
COMMISSIONING Changing to a different type of gas The changeover is only allowed to be carried out by a recognised specialist or Hoval cus- tomer service. After changing to a different type of gas, the adjusting device must be sealed.
Page 41 COMMISSIONING For UltraGas (400-720) 7. For a boiler which is already connected: ® only approved for propane liquefied gas type - Open the gas cock. - Energise the heat generator (e.g.. main switch, fuse) The conversion kit includes: and set blocking switch to «I». •...
Page 42: Type (850-1150) Setting The Stabilisation Damper (If Required)
COMMISSIONING 5.10 Type (850-1150) 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 43: Activation Of Screed Function
COMMISSIONING 5.12 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 44 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 45: 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 46: 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 47: 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 48: 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 49: 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 50: 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). Gas valve Cleaning: Sand the ignition and ionisation devices with...
Page 51: Setting The Gas Quantity, Measuring The Co (O ) 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 5.8. 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 52: 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 53: Parameter List - Automatic Firing Device Bic 960
Parameter list - automatic firing device BIC 960 WARNING Changes to the BIC may only be made by authorised Hoval customer service technicians. The following table is intended solely to provide information for the Hoval customer service technician! 6.10.1 Automatic firing device UltraGas (125-450) ®...
Page 54 PARAMETER LIST - AUTOMATIC FIRING DEVICE BIC 960 Parameter Description 30 2FI 32798 Minimum fan speed 1100 1200 900 1000 1100 1000 900 –1 31 2FJ 32799 Upward ramp of the fan during venting /s OEM –1 32 2FK 32800 Downward ramp of the fan during venting /s OEM –1 33 2FL 32801 Upward ramp of the fan during operation...
Page 55: Automatic Firing Device Ultragas ® (500-1150)
PARAMETER LIST - AUTOMATIC FIRING DEVICE BIC 960 6.10.2 Automatic firing device UltraGas (500-1150) ® Parameter Description 2AA 32769 Blocking temperature °C 2AC 32770 Maximum reference value °C 2AD 32771 Switch-off hysteresis above reference value °C 2AE 32772 Switch-on difference relating to tripping point °C 2AF 32773 Proportional part °C...
Page 56 PARAMETER LIST - AUTOMATIC FIRING DEVICE BIC 960 Parameter Description 34 2FM 32802 Downward ramp of the fan during operation /s OEM –1 35 2FN 32803 Post-venting of the fan after lock-out Fan speed after a normal switch-off 36 2FO 32804 1000 1000 1000 1200 1600 –1...
Page 57 4 217 215 / 00...
Page 58 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.

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Hoval UltraGas 125 Technical Information

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