Hoval UltraGas 2 Installation Instructions Manual

Gas condensing boilers for natural gas in modulating operation

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Operating instructions manual (84 pages)

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Installation instructions manual (86 pages)

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Technical information

Installation instructions

UltraGas

2 (125-1550)

Gas condensing boilers

for natural gas in modulating operation

Hoval products must be installed and commissioned

by specialists only. These instructions are intended for

service engineers. Electrical installation must be per-

formed by a licensed electrical company.

Subject to modiﬁ cations

4 220 456 / 02 - 03/21

These instructions are applicable to the fol-

lowing types:

Nominal output ranges at 50/30°C

and natural gas

51-UltraGas

Floor-standing gas condensing boilers UltraGas

(125-1550) 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 95 °C

. They are designed for continuously con-

trolled reduced operation in heating systems.

See technical data

2 (125)

25 - 126 kW

2 (150)

35 - 151 kW

2 (190)

38 - 191 kW

2 (230)

51 - 233 kW

2 (300)

67 - 302 kW

2 (350)

73 - 350 kW

2 (400)

85 - 401 kW

2 (450)

96 - 453 kW

2 (530)

110 - 533 kW

2 (620)

136 - 622 kW

2 (700)

146 - 703 kW

2 (800)

166 - 804 kW

2 (1000)

205 - 999 kW

2 (1100)

229 - 1112 kW

2 (1300)

269 - 1320 kW

2 (1550)

324 - 1550 kW

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Summary of Contents for Hoval UltraGas 2

Page 1 (125-1550) 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 Hoval products must be installed and commissioned up to 95 °C . They are designed for continuously con- by specialists only.
Page 2: Table Of Contents
TABLE OF CONTENTS Important notices 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 Guarantee ....................................5 Instructions ..................................5 Regulations, standards, ordinances to be complied with for proper use......................6 Installation Set-up ....................................7 2.1.1...
Page 3 TABLE OF CONTENTS Initial commissioning Safety instructions ................................46 Filling the heating system ..............................46 Water quality in heating systems ............................47 Parameterisation ................................49 Venting the gas pipe ................................49 Switching on ..................................49 Gas inlet pressure ................................49 Functional check of pressure monitoring device......................49 5.8.1 Checking the function of the pressure switch (safety check) ....................49 Setting the gas quantity, measuring the O ) and NOx/CO content in the flue gas ..........50...
Page 4: Important Notices
IMPORTANT NOTICES Important notices Explanation of the symbols 1.2.1 Warnings General safety instructions The plant may only be placed in operation if all DANGER the relevant standards and safety regulations ... indicates a situation of immediate danger have been complied with. which will lead to serious or fatal injuries if not avoided.
Page 5: Information
(see chapter 5.3) Instructions All instructions relevant to your plant can be found in the Hoval system manual - please keep all manuals! In ex- ceptional cases, the instructions can be found with the components! Further sources of information: •...
Page 6: Regulations, Standards, Ordinances To Be Complied With For Proper Use
IMPORTANT NOTICES Regulations, standards, ordinances to be • Accident prevention regulations - DGUV Regulation 1 Accident prevention regulations complied with for proper use - Guidelines for prevention - DGUV Regulation 4 Accident prevention regulations The locally applicable heating system regulations must - Electrical installations and equipment be followed when planning, installing and operating the gas heat generator:...
Page 7: Installation
INSTAllATION Installation Set-up WARNING The boiler must only be suspended using the four points marked as the crane suspension option in Fig. 02. The hooks on the rear of the boiler must not be used to suspend it. 2.1.1 Space requirement of UltraGas 2 (125-1550) ®...
Page 8 IMPORTANT NOTICES UltraGas 2 with shortened boiler feet ® (Dimensions in mm) UltraGas ® Type (125,150) 1933 (190,230) 1978 (300,350) 2038 (400,450) 2108 (530-700) 2244 (800-1100) 2265 (1300,1550) 2405 UltraGas 2 with walled-in base and adjustable feet ® UltraGas ® Type (125,150) 1934...
Page 9: Suspension Option
IMPORTANT NOTICES 2.1.2 Suspension option Crane suspension option Notice The chains must be at least 1.5 m long! Notice Do not suspend the crane here! Fig. 02 4 220 456 / 02...
Page 10: Set-Up Of Ultragas ® 2 (125,150)
IMPORTANT NOTICES 2.1.3 Set-up of UltraGas 2 (125,150) 6. Carefully lower the boiler again (danger of tipping over) ® - The boiler remains on 3 feet. 7. Remove the pallet from under the boiler. WARNING 8. Mount the 4th boiler foot (4). Tip hazard during set-up.
Page 11 IMPORTANT NOTICES 2.1.4 Set-up of UltraGas 2 (190-1550) 3. Using a winch (4), raise the front of the boiler. ® 4. Remove both side beams (5) to the front and side 1. Remove climbing aid (1). (see Fig. 07). 5. Pre-assemble front feet (6) (tighten screws by hand). 6.
Page 12: Installation Of The Thermal Insulation
IMPORTANT NOTICES Installation of the thermal insulation 1. Place the insulation mat (1) around the UltraGas 2 boiler. ® - Start at the front of the boiler. - Make sure that the recesses are seated correctly. 2. Fit tension springs (2) to hold the ends of the insulation mat (1) together. 3.
Page 13: Installation Of The Cladding
Installation of the cladding Cladding sections UltraGas 2 (125-1100) in installation sequence ® 1.1/1.2 Cable duct Side wall bottom Terminal plate Electrical box Rear wall bottom 6.1/6.2 Rear wall centre Side wall top 8.1/8.2 Rear wall top Blind cover for rear wall top –...
Page 14 10.1 10.2 Cladding sections UltraGas 2 (1300.1550) in installation sequence ® 1.1/1.2 Cable duct 1.2 1.1 2.1/2.2 Side wall bottom Clamping plate Electrical box Rear wall bottom 6.1/6.2 Rear wall centre Side wall top 8.1/8.2 Rear wall top Blind cover for rear wall top Side wall spacer 10.1/10.2 Cover plate Front top...
Page 15 IMPORTANT NOTICES Detail C Detail A Detail B Fig. 11 1. Set up climbing aid for installation: - Loosely fasten the lower side wall (2 or 2.1/2.2) Adjust the supplied climbing aid to the required length at the fastening positions (2b) using a hexagon nut using the extension piece (0a) and set it up.
Page 16 IMPORTANT NOTICES 5. Route all cables (a-h, Fig. 09/Fig. 10) and establish plug-in connections (wiring in accordance with Fig. 09 or Fig. 10). - Cables passing through one of the two cable ducts (1.1/1.2) must be inserted through the openings at the bottom of the terminal plate (3c, Fig.
Page 17 IMPORTANT NOTICES - Installing the rear wall section (6.2): - Installing the rear wall section (8.1): - Position the slots (6b) in the rear wall section (6.2) Position the slots in the rear wall section (8.1) on on the corresponding screw heads of the rear wall the corresponding screw heads of the upper side section (6.1) and then fix the two sections together walls (7) and then fix with the side walls by pulling...
Page 18 IMPORTANT NOTICES 12. Installing the upper front (11): - Installing the front base strip (14): Place the slots of the front base strip (14) on the cor- responding screw heads on the side base strips (13) and then fix all three base strips together by pushing the front base strip (14) downwards.
Page 19: Removing The Cladding For Maintenance And Service Work
IMPORTANT NOTICES Removing the cladding for mainte- 4. Remove the cover plates (4 or 4.1/4.2): - UltraGas 2 (125 - 1100): ® nance and service work Fig. 25 - UltraGas 2 (1300.1550): ® Fig. 23 1. Removing front cover (1): - Pull front cover away at the top (1a).
Page 20 IMPORTANT NOTICES 6. Removing 3-section upper rear wall (6.1/6.2/6.3): 8. Opening the electrical box (8): - Remove blind cover (6.1). - Remove screw (8a). - Remove screws (6a). - Lift the electrical box (8) and fold it out. - Lift the rear wall section (6.2) slightly and pull it away. - Lift the rear wall section (6.3) slightly and pull it away.
Page 21: Technical Information
TECHNICAl INFORMATION Technical information Description of the boiler The UltraGas 2 is a low-pollution and energy-saving ® gas condensing boiler with the Ultraclean burner system, a gas-fired premix burner with combustion air fan. The UltraGas 2 has a vertically arranged combustion cham- ®...
Page 22: Meaning Of The Data On The Data Plate
Hoval s.r.l. I-24050 Zanica Hoval d.o.o. HR-10250 Lučko Hoval EOOD BG-1797 Sofia Vendita Hoval GmbH D-85609 Aschheim Hoval SK spol. s r.o. SK-040 01 Košice Sale Hoval spol. s r.o. CZ-312 04 Plzen Hoval s.r.l. RO-Voluntari 077190, Jud IIfov Hoval SAS F-67118 Geispolsheim Hoval Sp.
Page 23: Ultragas ® 2 Technical Data
TECHNICAl INFORMATION UltraGas 2 technical data ® 3.3.1 UltraGas 2 (125-230) ® Type (125) (150) (190) (230) • Nominal heat output at 80/60 °C, natural gas 21-114 33-139 35-177 47-218 • Nominal heat output at 50/30 °C, natural gas 25-126 35-151 38-191 51-233...
Page 24 TECHNICAl INFORMATION 3.3.2 UltraGas 2 (300-450) ® Type (300) (350) (400) (450) • Nominal heat output at 80/60 °C, natural gas 62-283 70-332 80-378 87-429 • Nominal heat output at 50/30 °C, natural gas 67-302 73-350 85-401 96-453 • Nominal heat output at 80/60 °C, propane •...
Page 25 TECHNICAl INFORMATION 3.3.3 UltraGas 2 (530-800) ® Type (530) (620) (700) (800) • Nominal heat output at 80/60 °C, natural gas 100-497 125-580 132-653 150-743 • Nominal heat output at 50/30 °C, natural gas 110-533 136-622 146-703 166-804 • Nominal heat output at 80/60 °C, propane •...
Page 26 TECHNICAl INFORMATION 3.3.4 UltraGas 2 (1000-1550) ® Type (1000) (1100) (1300) (1550) • Nominal heat output at 80/60 °C, natural gas 185-926 203-1038 241-1230 297-1447 • Nominal heat output at 50/30 °C, natural gas 205-999 229-1112 269-1320 324-1550 • Nominal heat output at 80/60 °C, propane •...
Page 27: Dimensions/Space Required
TECHNICAl INFORMATION Dimensions/space required (Dimensions in mm) Notice For required space, see chapter 2.1. Heating flow Low-temperature return Gas connection Safety flow (safety valve, air vent) High-temperature return Electrical connection on the left or right Drainage (behind the front door) Flue gas outlet left or right Control panel Condensate drain with siphon and...
Page 28: Overall Unit Dimensions
TECHNICAl INFORMATION 3.4.1 Overall unit dimensions Boiler without cladding and insulation (Dimensions in mm) WARNING The boiler must only be suspended using the four points marked as the crane suspension option in Fig. 02. The hooks on the rear of the boiler must not be used to suspend it. Fig.
Page 29: Heating Water Side Flow Resistance
TECHNICAl INFORMATION Heating water side flow resistance UltraGas® 2 (125,150) UltraGas® 2 (190,230) UltraGas 2 (125,150) UltraGas 2 (190.230) ® ® Volumenstrom (m Volumenstrom (m Flow rate (m Flow rate (m UltraGas® 2 (300,350,400,450) UltraGas® 2 (530,620,700) UltraGas 2 (300-450) UltraGas 2 (530-700) ® ® Volumenstrom (m Volumenstrom (m Flow rate (m Flow rate (m UltraGas® 2 (800,1000,1100) UltraGas® 2 (1300,1550)
Page 30: Short Description Of The Functions Of The Automatic Function Device Bic 970
TECHNICAl INFORMATION Short description of the functions of the automatic function device BIC 970 The automatic function device BIC 970 of the UltraGas ® is only used in conjunction with the heating controller TopTronic E/UltraGas 2, which means many familiar ®...
Page 31: 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- er” (optional): CAUTION • When configuring the intake tube, comply Cutting injuries as a result of sharp edges. with the following: Handle sections of the cladding carefully and - If the air intake opening at the facade is...
Page 32: Flue Gas Connection, Flue Gas Line
INSTAllATION Flue gas connection, flue gas line The following only applies to countries in Due to the low flue gas temperature, condensate forms in which the wall duct is allowed: the flue gas line and wind protection equipment. For C53 construction boilers, the air intake opening for the combustion air must not be on The following directives must be complied the opposing wall of the exhaust opening of...
Page 33: Standard Values For Flue Gas Line Dimensions
INSTAllATION 4.3.1 Standard values for flue gas line dimensions Standard values for the flue gas line dimensions can be The first 2 m of the flue gas line must be con- found in the following table. figured with the same dimension as the flue gas connector, after which the size of the flue Table with bases for calculation gas system can be selected according to the...
Page 34: Air/Flue Gas Routing
INSTAllATION 4.3.2 Air/flue gas routing Design variants Combustion air taken from the surrounding environment B23 P Flue gas outlet into the chimney, suction of air from the surrounding environment. End piece of the flue gas outlet above the roof Air intake and flue gas outlet outside in areas with different pressure.
Page 35: Condensate Drain
INSTAllATION Condensate drain NOTICE 4.4.1 Condensate drain engineering guidelines Condensate with corrosive effect The condensate should be led from the condensate drip Depending on the sewer system (materials tray of the gas condensing boiler to a siphon and from used and waste water in the sewer system), there via a hose or fixed pipework for condensate drain- the acid condensate from the heat generator age to the sewer system or independent waste water...
Page 36: Installation Of The Siphon And Condensate Drain
INSTAllATION 4.4.2 Installation of the siphon and condensate drain NOTICE 4.4.2.1 Installation of the condensate drain siphon – Flue gas accumulation in the heat generator sewer system (standard design) If the condensate cannot drain off, it will ac- When installing the siphon and condensate cumulate in the boiler / flue gas collector.
Page 37: Installation Of The Condensate Drain Siphon - Condensate Pump - Sewer System At Higher Level
- 0.5 m hose is included with the condensate pump • Check all connections for leaks: purchased at Hoval. - Double nipple – siphon - Hose connection (5) condensate pump – drain - Siphon – neutralisation unit - Hose is included with the condensate pump pur- - Neutralisation unit –...
Page 38: Installation Of The Condensate Drain Siphon - Neutralisation Unit - Condensate Pump - Sewer System At Higher Level
3. Position condensate pump next to the neutralisation unit. - A hose is included with the condensate pump pur- chased at Hoval for the hydraulic connection. 4. Install the neutralisation unit and condensate pump in accordance with the corresponding installation and operating instructions.
Page 39: Hydraulic Connection
INSTAllATION Hydraulic connection 4.6.1 To be observed on site A pressure expansion tank is to be installed appropriate According to EN 12828:2003, the following safety-techni- for the heating system, water volume and hydrostatic cal equipment is integrated into the boiler: pressure.
Page 40: 4.6.2.1 Example
Hydraulic schematic BDHE050 TTE-GW TTE-GW TTE-WEZ TTE-FE TTE-WEZ TTE-FE B1.1 B1.2 B1.1 B1.2 UltraGas 2 UltraGas 2 Fig. 36 TTE-WEZ TopTronic E basic module heat generator (installed) ® Important notices: Flow sensor 1 • The example schematics merely show the B1.1...
Page 41: 4.6.2.2 Cascades
• Connect circulating pumps to the piping network using (at least 12 minute burner run time). expansion joints. Please observe the notes in the engineering documents of the responsible Hoval sales company with respect to the appropriate hy- draulic switching! 4 220 456 / 02...
Page 42: Electrical Connection
INSTAllATION Electrical connection • A licensed electrical company must install the electrical supply to the equipment. • The connection diagram is located in the electrical box of the heat generator; the cir- cuit diagram is supplied separately. • The country-specific regulations must be adhered to.
Page 43: Safety Precaution For Installation In Line With Emc Requirements
INSTAllATION 4.8.1 Safety precaution for installation in line • Measures must be taken in the building and on electri- cal equipment to protect the units against overvoltage with EMC requirements caused by lightning strikes. • The mains connection for the heating system must be •...
Page 44 INSTAllATION In the case of star-shaped data bus networks, double To ensure correct electrical installation, unit connec- tion and equipotential bonding (energy supply com- earthing is not permitted. The earthing must be carried out on one side at the star point. pany and building installation), all applicable laws, regulations and standards must be complied with;...
Page 45: Recommended Cable Cross-Sections And Maximum Permitted Cable Lengths
INSTAllATION 4.8.2 Recommended cable cross-sections and maximum permitted cable lengths Line type Cross-section Length Electrical supply of the heat generator • 230 V (UltraGas min. 2.5 mm unlimited m ® (125-1550)) with 16 A fuse • 400 V (UltraGas min. 2.5 mm unlimited m ®...
Page 46: Initial Commissioning
• Risk of injury for non-expert personnel. • Initial commissioning, maintenance and cleaning work are only allowed to be per- formed by trained specialist personnel or by Hoval customer service. NOTICE Damage to the system by filling unauthorised liquids. • The filling and replacement water must be of the required water quality (see chapter 5.3).
Page 47: Water Quality In Heating Systems
Water quality in heating systems Germany and Austria Filling and replacement water, heating water Additional notices • Hoval boilers and calorifi ers are suitable for heating systems without signifi cant oxygen intake. (System The following applies: type I according to EN 14868).
Page 48 INITIAl COMMISSIONING Switzerland Manufacturer-specific specifications Filling and replacement water, heating water • Hoval boilers and calorifi ers are suitable for heating The following applies: systems without signifi cant oxygen intake. (System type I according to EN 14868). • Directive SWKI BT 102-01 “Water quality for building services systems”...
Page 49: Parameterisation
• Switch on the blocking switch on the control panel to WARNING release the burner. The settings must only be changed by a spe- cialist trained by Hoval or by Hoval customer WARNING service. The heat generator is live when it has been connected to the mains.
Page 50: Setting The Gas Quantity, Measuring The O (Co ) And Nox/Co Content In The Flue Gas
Higher values indicate faulty burner tion must only be made by a specialist trained setting, dirt build-up on the gas burner or heat ex- by Hoval or by Hoval customer service. changer or a defective gas burner. Screwdriver, hex socket 3 mm, Torx T40 If the legal limit values or 150 ppm CO are §...
Page 51: Flue Gas Measurement Ultragas ® 2 (800-1550)
6. Set O ) value by turning offset screw B. by Hoval or by Hoval customer service. - The flue gas value must lie in the following range: = 5.5 - 5.9 (CO = 8.8 - 8.5) % by vol.
Page 52: Handover To The Owner/User
INITIAl COMMISSIONING 5.10 Handover to the owner/user The manufacturer of the unit is responsible for providing operating instructions for the com- plete system. The following points must be carried out on the handover to the owner: • instructions for operation, maintenance and safety equipment of the plant have been received.
Page 53: Activation Of Screed Function
INITIAl COMMISSIONING 5.11 Activation of screed function NOTICE The activation of the screed function must only be made by a specialist trained by Hoval or by Hoval cus- tomer service. Description of function The control module of the TopTronic E contains a functional sequence used for drying out screed fl oors. To start the ®...
Page 54 INITIAl COMMISSIONING Settings in the TopTronic E control module ® Can only be set in the corresponding user level. Settings under Start screen > Main menu > Service > H-GEN > Heating circuit > Heating circuit 1, 2, 3* > Screen > 04-060 to 04-064.
Page 55: Maintenance
1. Set the blocking switch to “0” and disconnect the heat personnel or by Hoval customer service. generator from the mains (e.g. main switch, fuses). 2. Remove the front cladding according to the proce- NOTICE dure in chapter 4.8...
Page 56: 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 57: Cleaning And Maintaining The Gas Boiler
The boiler is only allowed to be cleaned and maintained by a licensed specialist or Hoval customer service technician. Bracing The Hoval gas boiler must be cleaned and serviced at least 1x 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 58 MAINTENANCE 10. If the burner cylinder web is dirty or damaged, carry Burner cylinder out the following steps: - Swivel the burner with boiler door closed down- wards. - Removing burner cylinder: - Unfasten the earth wire on the burner cylinder. Fig.
Page 59 - Swivel the burner upwards, with the boiler door agents. (Fig. 45) • Wear safety gloves and protective goggles 4219076 ETL Brenner 50-UltraGas 2 11. Clean and adjust ignition and ionisation devices. when using cleansing agents. (300-450) - Sand ignition and ionisation devices with fine sand- •...
Page 60 MAINTENANCE - Separate the condensate drain with siphon from the 13. Remove the cover from the cleaning opening. condensate drain socket and ensure that the cleaning water is directed into a collection tank or, if local regula- tions permit, into the sewer system. - Thoroughly flush the heating surfaces (combustion chamber and TurboFer stainless steel composite...
Page 61 19. Check the seal of the cleaning opening (Fig. 54) for wear and replace if necessary. Fig. 57 4219076 ETL Brenner 50-UltraGas 2 (300-450) 27.05.2020 HOJK 4 220 456 / 02 12976673 C84 000 02...
Page 62: Setting The Gas Quantity, Measuring The O (Co ) And Nox/Co Content In The Flue Gas
MAINTENANCE 31. Perform a functional check of pressure monitoring de- vice. See chapter 5.8. - To check the function of the pressure switch B18, set it to the minimum value and restart the heat Bracing generator. - If a restart of the heat generator is not possible, the pressure switch functions.
Page 63: Bic 970 Automatic Function Device Parameter List
BIC 970 automatic function device parameter list 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! 6.8.1 Automatic function device UltraGas ®...
Page 64 Parameters CAN bus Description Tree 37633 Function flue gas sensor Flue gas sensor 0=OFF 1=Flue gas sensor (AGF) 37639 Blocking temperature AGF Flue gas sensor °C 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 37641 Locking temperature AGF Flue gas sensor...
Page 65 4 220 456 / 02...
Page 66 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:

51-ultragas 2 125 51-ultragas 2 150 51-ultragas 2 190 51-ultragas 2 230 51-ultragas 2 300 51-ultragas 2 350 ... Show all

Hoval UltraGas 2 Installation Instructions Manual

1 Important Notices

2 Installation

3 Technical Information

4 Installation

5 Initial Commissioning

6 Maintenance

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