Table of Contents
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Technical information
Installation instructions
UltraGas
(70,100)
®
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
in stal lations may only be carried out by a qualified
electrician.
Subject to modifi cations
|
4 217 214 / 02 - 11/19
These instructions apply to the following types:
Rated output levels at 40/30 ºC
and for natural gas
45-UltraGas
®
45-UltraGas
®
The floor-standing gas condensing boilers UltraGas
(70,100) 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 85 °C
. They are designed for continuously cont-
1)
rolled reduced operation in heating systems.
See technical data
1)
(70)
13.6 - 69.9 kW
(100)
20.9 - 100.0 kW
EN
®
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Table of Contents
Related Manuals for Hoval UltraGas 70
Summary of Contents for Hoval UltraGas 70
- Page 1 ® 45-UltraGas (100) 20.9 - 100.0 kW ® Hoval products may only be installed and commissioned The floor-standing gas condensing boilers UltraGas ® by appropriately qualified experts. These instructions (70,100) acc. to EN 15502-1/15502-2-1 are suitable are intended exclusively for the specialist. Electrical...
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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 Commissioning Safety instructions ................................26 Filling the heating system ..............................26 Water quality ..................................27 5.3.1 Heating water..................................27 Venting the gas pipe ................................28 Switching on ..................................28 Gas inlet pressure ................................28 Functional check of combustion cylinder pressure monitoring ..................28 5.7.1 Check pressure in the combustion cylinder (safety check during commissioning) ............29 Setting the gas quantity, measuring the CO ) and NOx/CO content in the flue gas (flue gas measurement) ..30 Changing to a different type of gas ..........................31...
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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
§ Refers to stand ards and directives. Manuals All instructions relevant to your system can be found in the Hoval system manual. In exceptional cases, the instructions 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 § • SN EN 12831 Heating systems in buildings - Procedure The standards and directives stated under points 1.6.1 to for calculation of the standard heating load 1.6.3 must be taken into account during installation and •... -
Page 7: Installation
INSTALLATION Installation Set-up Hoval recommends setting up the boiler on a foundation slab. Fig. 03 4. Using a winch (4, Fig. 03) raise the front of the boiler and remove the front crossbeam (5). Fig. 01 1. Remove the wooden crate (1, Fig. 01) CAUTION Sharp edges (Fig. -
Page 8: Technical Information
Description of the boiler and the heat of evaporation is utilised for the heating cir- The Hoval UltraGas is a low-pollution and energy-sav ing ® cuit. The gas burner is configured as a vertical burner condensing gas boiler with the Ultraclean burner sys tem, that can be swivelled up easily for maintenance work. -
Page 9: Technical Data Ultragas ® (70,100)
TECHNICAL INFORMATION Technical data UltraGas (70,100) ® Type (70) (100) • Nominal heat output at 80/60 °C, natural gas 12.2-64.0 19.0-92.0 • Nominal heat output at 40/30 °C, natural gas 13.6-69.9 20.9-100.0 • Nominal heat output at 80/60 °C, propane 15.4-63.3 23.0-92.0 •... -
Page 10: Dimensions
TECHNICAL INFORMATION Dimensions UltraGas (70,100) with connection set AS40-S/NT/HT and heating armature group HA40 ® (All dimensions in mm) UltraGas type (70) (100) ® Heating flow / safety flow R1½″ R1½″ Low-temperature return R1½″ R1½″ 2a. High-temperature return R1½″ R1½" Feed-through duct for gas line R ¾″... -
Page 11: Space Requirement
TECHNICAL INFORMATION Space requirement UltraGas (70,100) ® (All dimensions in mm) Fig. 08 Boiler door incl. burner swivels upwards and to the left or to the front. minimum 150 mm * - Burner service position front - Boiler cleaning from right optimum 300 mm * - Burner service position left - Boiler cleaning from front... -
Page 12: Boiler Flow Resistance
TECHNICAL INFORMATION Boiler flow resistance Brief description of the automatic firing device UltraGas (70,100) ® The automatic firing device BIC960 of the UltraGas only ® works in connection with the heating regulator TopTronic E/UG. As a result, the automatic firing device ®... -
Page 13: Installation
INSTALLATION Installation 4.2.1 Room air dependent installation Binding values for the size of supply air openings are not Safety instructions generally specified in the relevant regulations. It is me- rely required that no partial vacuum in excess of 3 N/m CAUTION occurs. -
Page 14: Flue Gas Connection And Flue Gas Line
The flue gas system must meet the following Your Hoval dealer can supply an approved flue gas sys- requirements: tem suitable for your UltraGas (70,100). -
Page 15: Project Planning Instructions, Flue Gas Systems
(bearing rail or pipe clip). Flue gas temperature The Hoval flue duct systems E80 PP, E100 PP, E80 Flex PP, E100 Flex PP, C80/125 PP, C100/150 PP and E130 PP are long-term temperature resistant to 120°C. -
Page 16: Design Examples For Room Air Dependent Operation
Air supply grille E100 incl. tube, L = 115 mm, PP Use the suitable flue gas system from Hoval or a flue gas T-piece with measure opening E100 – 90° PP system certified in accordance with DIN EN 14471. Stain-... -
Page 17: Design Examples For Room Air Independent Operation
INSTALLATION 4.3.3 Design examples for UltraGas (70) ® Assembly kit UG C100/150 PP room air independent operation Assembly kit UG C100/150 Flex PP Combustion air UltraGas (70) ® If necessary, insert an inspection T-piece Maximum horizontal length connecting pipe (m) UltraGas (70) Example UG K C100/150 PP... -
Page 18: Design Examples For Room Air Independent Operation
Inspection T-piece with measure opening C100/150 PP Use the suitable flue gas system from Hoval or a flue gas Length adjustment piece C100/150 L = 315-440 mm system certified in accordance with DIN EN 14471. Stain-... -
Page 19: Condensate Drain
INSTALLATION Condensate drain Option 2 • Design with condensation trap and neutralisation box The boiler condensate drain must be made • For condensate discharge in lower drain line, incl. of corrosion-resistant material. The following condensate neutralisation. materials are suitable for the condensate •... -
Page 20: Gas Connection
INSTALLATION Gas connection Option 4 • Version with condensation trap, neutraliser box and con densate delivery pump DANGER • With condensate neutralisation - condensate discharge Danger of explosion due to leaking gas into higher drain line. connection. • Drain optionally on the left or right side. •... -
Page 21: Hydraulic Connection
A minimum circulation water quantity is not required. CAUTION Close unused connections tightly Please observe the notes in the configurati- on documents of the responsible Hoval sales com pa ny with respect to the appropriate hy- TTE-WEZ TopTronic E basic module heat generator (installed) ®... -
Page 22: Electrical Connection
INSTALLATION Electrical connection Important! A main switch must be installed on-site in the supply line A qualified technician must install the electri- which performs an all-poles cut-out and has a clearance cal supply to the equipment. of at least 3 mm between the open contacts. The connection diagram is located in the elec- trical box of the heat generator;... -
Page 23: Safety Measures For Emc According Assembly
INSTALLATION 4.7.1 Safety measures for EMC according as- • Measures must be taken in the building and on electri- cal equipment to protect the units against overvoltage sembly caused by lightning strikes. • The mains connection for the heating system must be •... - Page 24 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;...
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Page 25: Recommended Cable Cross Sections And Permissible Maximum Length Of Cable
INSTALLATION 4.7.2 Recommended cable cross sections and permissible maximum length of cable Line type Cross-section Length Power supply of the min. 1.5 mm unlimited m heat generator (230 V) with 13 A fuse Cables carrying mains supply voltages min. 1.0 mm unlimited m from actuators Cables carrying low... -
Page 26: 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 cus- tom er service. NOTICE Damage to the system by filling unauthorised liquids. -
Page 27: 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 28: Venting The Gas Pipe
Switching on • Ensure that combustion air is supplied and • Switch on blocking switch to release the burner. flue gas is discharged. In order to ensure safety, the Hoval UltraGas is equip- ® Gas inlet pressure ped with a pressure monitoring device on the combustion cylinder. -
Page 29: Check Pressure In The Combustion Cylinder (Safety Check During Commissioning)
B17 and B18 must be adjusted to the conditions on site. WARNING The settings must only be changed by a spe- cialist trained by Hoval or by Hoval customer service. 1. Slightly loosen top screw on pressure switch B17 (connection point for the measurement). -
Page 30: Setting The Gas Quantity, Measuring The Co (O ) And Nox/Co Content In The Flue Gas (Flue Gas Measurement)
The settings on the gas/air compound re- gulation must only be made by a specialist 1. Start the “Emission” menu on the control module. trained by Hoval or by Hoval customer ser- - The control automatically switches to normal opera- vice. -
Page 31: Changing To A Different Type Of Gas
- AMP connector at position 1 and 3. The changeover is only allowed to be carried 2. Stick the yellow “Change of set gas type: liquid gas” out by a recognised specialist or Hoval custo- stickers to the following places: mer service. -
Page 32: Record - Activation Of Screed Function
COMMISSIONING 5.11 Record - 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 33 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.
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Page 34: Maintenance
Replenishing replacement water (see point 5.2). Risk of injury for non-expert personnel. Initial start-up, maintenance and cleaning Renewing fuse work are only allowed to be performed by trained specialist personnel or by Hoval custo- mer service. WARNING Electrical installations may only be carried WARNING out by a qualified electrician. -
Page 35: Information For Combustion Controller / Chimney Sweep Regarding Emission Monitor Key
MAINTENANCE Information for combustion controller / chimney sweep regarding emission monitor key 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 36: Cleaning
The Hoval gas boiler must be cleaned and services at least once a year. If the Hoval gas boiler was in operation during the building phase, it is essential to check the degree of contaminati- on. Clean in the case of heavy dirt build-up. -
Page 37: Cleaning The Combustion Chamber And Burner Cylinder On The Outside
MAINTENANCE 6.6.2 Cleaning the combustion chamber and burner cylinder on the outside CAUTION Danger of chemical burns from cleaning agents. Wear safety gloves and protective goggles when using cleaning agents. Comply with the instructions on the original packaging. NOTICE Damage to the plant by using incorrect clea- ning agents. -
Page 38: Cleaning/Setting Ignition Ionisation Device
MAINTENANCE 6.6.3 Cleaning/setting ignition ionisation device Cleaning: Spray combustion chamber and aluFer pipes ® The distance between the ionisation elec- (23, Fig. 26) trode and the burner cylinder must be The best results are achieved with a spray gun approx. 5 ±1 mm. and a wide spray nozzle (flat or conical jet). -
Page 39: Setting The Gas Quantity, Measuring The Co ) And Nox/Co Content In The Flue Gas (According To Point 5.8)
MAINTENANCE Setting the gas quantity, measuring the Assembly: 1. Renew seal on gas connection. ) and NOx/CO content in the flue 2. Assemble burner in the reverse order. gas (according to point 5.8) 3. Check for gas leaks The maintenance should be performed at Ignition electrode least every other year, or when the neutralisa- Ignition/ionisation electrode... -
Page 40: Maintaining The Neutraliser Box (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 2 packs of 3 kg each. -
Page 41: Cleaning The Condensation Trap
MAINTENANCE Cleaning the condensation trap • Set blocking switch to "0". • Release the condensation trap and remove it from the boiler. • Rinse the condensation trap. • Check condensation trap seal (26, Fig. 30) for damage and replace if necessary. DANGER If the condensation trap is not filled with wa- ter or becomes clogged or soiled, escaping... -
Page 42: 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! Automatic firing device UltraGas (70,100) ®... - Page 43 PARAMETER LIST - AUTOMATIC FIRING DEVICE BIC 960 Parameter Description 2FK 32800 Downward ramp of the fan during venting /s OEM –1 2FL 32801 Upward ramp of the fan during operation /s OEM –1 34 2FM 32802 Downward ramp of the fan during operation /s OEM –1 35 2FN 32803 Post-venting of the fan after lock-out...
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- Page 46 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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