Hoval UltraGas 2 Installation Instructions Manual

Floor-standing gas condensing boiler

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Technical information

Installation instructions

UltraGas

2 (125-1550)

Floor-standing gas condensing boiler

Hoval products must be installed and commissioned by

specialists only. These instructions are intended exclu-

sively for the specialist. Electrical installation must be

performed by a licenced electrical company.

Subject to modiﬁ cations

4 220 950 / 02 - 05/23

These instructions are applicable to the fol-

lowing types:

Nominal output ranges at 50/30 °C and

natural gas

52-UltraGas

Floor-standing

gas

UltraGas

2 (125-1550) acc. to EN 15502-1/15502-2-1

are suitable and licenced for use as heat generators

for hot water heating systems with a permissible flow

temperature of up to 95 °C

continuously controlled 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)

58-299 kW

2 (350)

70-352 kW

2 (400)

69-399 kW

2 (450)

77-451 kW

2 (500)

77-491 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

2 H (700)

146-703 kW

2 H (1100)

229-1112 kW

2 H (1550)

324-1550 kW

condensing

boilers

. They are designed for

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Summary of Contents for Hoval UltraGas 2

Page 1 UltraGas 2 (125-1550) acc. to EN 15502-1/15502-2-1 ® Hoval products must be installed and commissioned by are suitable and licenced for use as heat generators specialists only. These instructions are intended exclu- for hot water heating systems with a permissible flow sively for the specialist.
Page 2: Table Of Contents
TABLE OF CONTENTS Important notices System manual ..................................4 General safety instructions ..............................4 Explanation of the symbols ..............................5 1.3.1 Warnings ..................................5 1.3.2 Warning symbols................................5 1.3.3 Information ..................................6 On delivery ...................................6 Transport ....................................6 Guarantee ....................................6 Regulations, standards and directives ..........................7 Technical information Description ..................................8 2.1.1 Function descriptions ................................9...
Page 3 TABLE OF CONTENTS Hydraulic connection ................................47 4.5.1 Hydraulic integration ...............................48 4.5.1.1 Heat generator cascades ................................49 4.5.2 Water quality in heating systems .............................50 4.5.3 Filling the heating system ..............................52 Electrical connection .................................52 4.6.1 Safety precaution for installation in line with EMC requirements ..................54 4.6.2 Recommended cable cross-sections and maximum permitted cable lengths ..............56 Commissioning...
Page 4: Important Notices
All instructions relevant to your plant can be found in the Danger of explosion if there is a fuel gas leak. Hoval system manual – please keep all manuals. In ex- • If you smell gas: ceptional cases, the instructions can be found with the - Do not smoke components.
Page 5: Explanation Of The Symbols
IMPORTAnT nOTICES Explanation of the symbols CAUTION 1.3.1 Warnings Sharp edges If the cladding has not yet been fitted or if DANGER parts of the cladding have been dismantled ... indicates an imminently hazardous situa- and/or the boiler door is open, there is a risk tion which, if not avoided, will result in death of cuts from sharp edges.
Page 6: Information
• The heat generator must be transported and stored § standards and directives. safely and protected from damage. • Interim storage of Hoval condensing boilers may only take place in locations protected against the elements and against damage. Read the operating instructions before instal- •...
Page 7: Regulations, Standards And Directives
IMPORTAnT nOTICES Regulations, standards and directives Austria § • ÖNORM EN 12828 Heating systems in buildings – The locally applicable heating system regulations must Design of hot water heating systems be followed when planning, installing and operating the • ÖNORM EN 12831 Energy efficiency of buildings – gas heat generator: Method for calculation of the design heat load •...
Page 8: Technical Information Description
TECHnICAl InFORMATIOn Technical information Description UltraGas 2 is approved for burning the following fuels: The UltraGas 2 is a low-pollution and energy-saving ® ® • Natural gas E gas condensing boiler with the Ultraclean burner system, • Natural gas E with a hydrogen content (H ) of up to 20 % a gas-fired premix burner with combustion air fan.
Page 9: Function Descriptions
TECHnICAl InFORMATIOn 2.1.1 Function descriptions 2.1.1.1 Automatic function device BIC 970 (brief description) The automatic function device BIC 970 of the UltraGas ® is only used in conjunction with the heating control Top- Tronic E/UltraGas 2, which means many familiar func- ®...
Page 10: Technical Data
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 Hoval Oriental Beijing CN-100120 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 11: Technical Data Ultragas ® 2 (125-1550)
TECHnICAl InFORMATIOn 2.2.2 Technical data UltraGas 2 (125-1550) ® 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 12 TECHnICAl InFORMATIOn Type (300) (350) (400) (450) • Nominal heat output at 80/60 °C, natural gas 54-274 67-315 62-362 73-415 • Nominal heat output at 50/30 °C, natural gas 58-299 70-352 69-399 77-451 • Nominal heat output at 80/60 °C, propane 83-274 115-311 97-361...
Page 13 TECHnICAl InFORMATIOn Type (500) (530) (620) (700) • Nominal heat output at 80/60 °C, natural gas 71-449 100-497 125-580 132-653 • Nominal heat output at 50/30 °C, natural gas 77-491 110-533 136-622 146-703 • Nominal heat output at 80/60 °C, propane 111-441 137-489 168-569...
Page 14 TECHnICAl InFORMATIOn Type (800) (1000) (1100) (1300) • Nominal heat output at 80/60 °C, natural gas 150-743 185-926 203-1038 241-1230 • Nominal heat output at 50/30 °C, natural gas 166-804 205-999 229-1112 269-1320 • Nominal heat output at 80/60 °C, propane 233-744 245-926 299-1033...
Page 15 TECHnICAl InFORMATIOn Type (1550) H (700) H (1100) H (1550) • Nominal heat output at 80/60 °C, natural gas 297-1447 132-653 203-1038 297-1447 • Nominal heat output at 50/30 °C, natural gas 324-1550 146-703 229-1112 324-1550 • Nominal heat output at 80/60 °C, propane 427-1439 174-643 299-1033...
Page 16: Heating Water Side Flow Resistance
TECHnICAl InFORMATIOn 2.2.3 Heating water side flow resistance UltraGas 2 (125,150) UltraGas 2 (190,230) ® ® Flow rate (m Flow rate (m UltraGas 2 (300-500) UltraGas 2 (530-700) ® ® Flow rate (m Flow rate (m UltraGas 2 (800-1100) UltraGas 2 (1300,1550) ®...
Page 17: Dimensions
TECHnICAl InFORMATIOn Dimensions 2.3.1 UltraGas 2 (125-1550) dimensions ® (Dimensions in mm) Flow Low-temperature return Gas connection Safety flow (safety valve, air vent) High-temperature return Electrical connection on the left or right Filling/drain valve (behind the front door) Flue gas outlet left or right Control panel Condensate drain with siphon and screw connection for plastic pipe...
Page 18: Overall Unit Dimensions
TECHnICAl InFORMATIOn 2.3.2 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 sus- pension option in Fig. 02. The hooks on the rear of the boiler must not be used to suspend it.
Page 19: 2.3.3 Space Requirement
TECHnICAl InFORMATIOn 2.3.3 Space requirement (Dimensions in mm) For swinging out the burner, this area must remain free Route gas connection straight to the rear UltraGas ® type A minimum H minimum (125,150) 1060 1953 1934 (190,230) 1160 1998 1979 (300-500) 1510 1953...
Page 20: 2.3.3.1 Installation Variants With Reduced Height Requirements
TECHnICAl InFORMATIOn 2.3.3.1 Installation variants with reduced height requirements (Dimensions in mm) UltraGas 2 with masonry base and adjustable feet ® UltraGas ® type H minimum (125,150) 1934 (190,230) 1979 (300-500) 1937 (530-700) 2255 (800-1100) 2276 (1300,1550) 2416 H (700) 2255 H (1100) 2276...
Page 21: Installation
InSTAllATIOn Installation The boiler room in which the heat generator is installed must meet the following conditions regarding combustion CAUTION air supply: • An adequate combustion air supply must be guaranteed, Sharp edges according to local regulations. If the cladding has not yet been fitted or if •...
Page 22: Setting Up Heat Generator
InSTAllATIOn Setting up heat generator 3.2.1.1 Suspension option 3.2.1 Requirements for installation and setting up WARNING • For overall unit dimensions, see chapter 2.3.2 • For required space, see chapter 2.3.3 • The boiler is only allowed to be attached •...
Page 23: Set-Up Of Ultragas ® 2 (125,150)
InSTAllATIOn 3.2.2 Set-up of UltraGas 2 (125,150) 7. Pre-assemble 3 boiler feet (4) (tighten screws by hand). ® 8. Carefully lower the boiler again (danger of tipping over) - The boiler remains on 3 boiler feet. WARNING 9. Remove the pallet from under the boiler. Tip hazard during set-up 10.
Page 24 InSTAllATIOn 3.2.3 Set-up of UltraGas 2 (190-1550) ® UltraGas 2 (800-1550): ® We recommend using at least two people for setting up and fastening the cladding to the boiler. 1. Remove climbing aid (1). 2. If the gas line compensator (2) is supplied loose, screw the gas line compensator (2) tightly onto the gas line, aligning it towards the rear.
Page 25: Installing Thermal Insulation
InSTAllATIOn Installing 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 26: Mounting Cladding
Mounting cladding UltraGas 2 (800-1550): ® We recommend using at least two peo- ple for setting up and fastening the clad- ding to the boiler. 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...
Page 27 10.1 10.2 Cladding sections UltraGas 2 (1300,1550) in installation sequence ® 1.2 1.1 1.1/1.2 Cable duct 2.1/2.2 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 Side wall spacer 10.1/10.2 Cover plate Front top...
Page 28 InSTAllATIOn Detail C Detail A Detail B Fig. 12 1. Set up climbing aid for installation: 4. Mount terminal plate (3) of the electrical box: Adjust the supplied climbing aid to the required length - Position the slots in the terminal plate (3) on the cor- using the extension piece (0a) and set it up.
Page 29 InSTAllATIOn (1.1/1.2) must be inserted through the openings at the bottom of the terminal plate (3c, Fig. 14). - Fix cables to a strain relief strap. CAUTION The cables must not touch any hot parts. • All cables must be routed through the cable ducts.
Page 30 InSTAllATIOn - Installing the rear wall section (6.2): - In heat generator cascades: - Position the slots (6b) in the rear wall section (6.2) Ensure that the components for the combustion air on the corresponding screw heads of the rear wall supply are fitted to the boiler.
Page 31 InSTAllATIOn - UltraGas 2 (1300,1550): 14. Hang the climbing aid on the previously installed wall ® First put on the rear cover plate (10.1), then the bracket (see Fig. 10 and Fig. 11). front cover plate (10.2) so that: 15. Installing the base cladding: - the large lug on the cover plate section points to the front.
Page 32: Removing The Cladding For Maintenance And Service Work
InSTAllATIOn Removing the cladding for mainte- 4. Remove cover plate (4 or 4.1/4.2): - UltraGas 2 (125-1100): ® nance and service work Fig. 26 - UltraGas 2 (1300,1550): ® Fig. 24 1. Removing front cover (1): - Pull front cover away at the top (1a). - Unhook front cover at the bottom (1b).
Page 33 InSTAllATIOn 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 34: Combustion Air Supply
InSTAllATIOn Installation 4.1.1 Operation dependent and inde- pendent of room air CAUTION The combustion air can be supplied to the heat generator Sharp edges as follows: If the cladding has not yet been fitted or if • room air dependent from the boiler room parts of the cladding have been dismantled •...
Page 35: Flue Gas Connection, Flue Gas Line
InSTAllATIOn Flue gas connection, flue gas line Condensing gas boilers must be connected to a flue gas system. Due to the water vapour content in the flue gases The following directives must be complied at low temperatures and the resulting further condensa- §...
Page 36: Standard Values For Flue Gas Line Dimensions
InSTAllATIOn 4.2.1 Standard values for flue gas line dimensions Calculation of the flue gas line dimensions • The cross sections and the maximum lengths are cal- Standard values for the flue gas line dimensions can be culated with reference to software or tables. found in the following table.
Page 37 InSTAllATIOn Table “Standard values for flue gas line dimensions” Heat generator Smooth-walled flue gas line Number of bends 90° (flue gas + combustion air) UltraGas Internal Ø flue gas outlet Designation Total pipe length in m (flue gas + combustion air) ®...
Page 38: Combustion Air/Flue Gas Ducting
InSTAllATIOn 4.2.2 Combustion air/flue gas ducting Design variants Room air dependent operation (construction B) B23, 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 Operation independent of room air (construction C) Air intake and flue gas outlet outside in areas with different pressure.
Page 39: Condensate Drain Line
InSTAllATIOn Condensate drain line NOTICE 4.3.1 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 heat generator to a siphon and from there via used and waste water in the sewer system), a hose or fixed pipework for condensate drainage to the the acid condensate from the heat generator...
Page 40 InSTAllATIOn Before commissioning of the heat generator NOTICE WARNING Flue gas accumulation in the heat gener- Flue gas leak ator If there is insufficient water in the siphon (the If the condensate cannot drain away, this will level is below the necessary minimum height lead to a condensate build-up in the conden- of the water dam in the siphon), then flue gas sate drip tray.
Page 41: Installing Siphon And Condensate Drain Line
InSTAllATIOn 4.3.2 Installing siphon and condensate drain line 4.3.2.1 Installing condensate drain line siphon – sewer system (standard design) When installing the siphon and condensate drain, the engineering guidelines for conden- sate drains must be complied with, see chap- ter 4.3.1. 1.
Page 42: Installing Condensate Drain Line Siphon - Condensate Pump - Sewer System At Higher Level
3. Establishing hose connections: - Hose connection (3) siphon – condensate pump - 0.5 m hose is included with the condensate pump purchased at Hoval. - Hose connection (5) condensate pump – drain - Hose is included with the condensate pump pur- chased at Hoval.
Page 43: Installing The Condensate Drain Line Siphon - Neutralisation Unit - Sewer System
InSTAllATIOn 4.3.2.3 Installing the condensate drain line siphon – neutralisation unit – sewer system When installing the siphon and condensate drain, the engineering guidelines for conden- sate drains must be complied with, see chap- ter 4.3.1. NOTICE Blockage by granulate dust Fine granulate dust can block the neutralisa- tion unit and the condensate drain line.
Page 44: Installing The Condensate Drain Line 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. For double condensate pumps, the instruc- tions in the separate document “Assembly in- structions for double condensate pump” must be followed.
Page 45: Gas Connection
InSTAllATIOn Gas connection • The corresponding gas flow pressure must be present at the gas valve inlet as WARNING specified in chapter «2.2.2 Technical data Poisoning and explosion hazard due to UltraGas 2 (125-1550)», page 11. ® leaking gas • The pressure losses over the distance of the If the gas line is mounted exposed to stress gas line must be taken into account in the or installed improperly, fuel gas can escape...
Page 46: Venting The Gas Line
InSTAllATIOn 4.4.1 Venting the gas line - There are significant fluctuations of the gas flow pres- sure. Comply with the necessary regulations when - Pressure fluctuations in the gas network must be § venting the gas line. prevented by suitable measures (e.g. gas storage tanks or pressure regulators).
Page 47: Hydraulic Connection
High-temperature return HT (e.g. fan • Additional safety fittings (if required by the system con- group or calorifier) figuration) Safety-related components available from Hoval as accessories Low-temperature return LT (e.g. under- Safety armature set: floor heating) - Pressure gauge...
Page 48: Hydraulic Integration
UltraGas 2 - Safety temperature limiter UltraGas 2 Diaphragm pressure expansion tank UltraGas 2 Fig. 38 Refer to the Hoval system technology to find 17.08.2020 Achtung ! Für die Installation muss das anlagenbezo Verbindungshinweise / diagrams of sample applications. Hydr.
Page 49: 4.5.1.1 Heat Generator Cascades
50 %. • If the operating pressure drops below Please observe the notes in the engineering 0.5 bar, the heat generator automatically documents of the responsible Hoval sales switches to lockout. company with respect to the appropriate hy- draulic switching.
Page 50: Water Quality In Heating Systems
Water quality in heating systems Germany and Austria Filling and replacement water, heating water Additional notices • Hoval heat generators are suitable for heating systems without signifi cant oxygen intake (system type I in ac- The following applies: cordance with EN 14868.) •...
Page 51 InSTAllATIOn Switzerland Additional notices Filling and replacement water, heating water • Hoval heat generators are suitable for heating systems The following applies: without signifi cant oxygen intake (system type I in ac- cordance with EN 14868.) • Directive SWKI BT 102-01 “Water quality for building services systems”...
Page 52: Filling The Heating System
• If frost protection agent is being used, a cuit diagram is supplied separately. separate engineering sheet is available • The country-specific regulations must be from Hoval. adhered to. Country-specific regulations and manufactur- WARNING §...
Page 53 InSTAllATIOn Procedure to remove the front cladding 1. Removing front cover (1): - Pull front cover away at the top (1a). - Unhook front cover at the bottom (1b). 2. Set up climbing aid (2). 3. Removing the upper front (3): - Remove securing screw (3a).
Page 54: Safety Precaution For Installation In Line With Emc Requirements
InSTAllATIOn 4.6.1 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 55 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 56: Recommended Cable Cross-Sections And Maximum Permitted Cable Lengths
InSTAllATIOn 4.6.2 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 57: Commissioning
• Safety valve is installed (system sealed). a heating specialist (only by trained spe- • Heating control is operating (on the electrical mains). cialist personnel or a Hoval customer ser- • The following are filled with water: vice technician). - Heating system •...
Page 58: Commissioning Procedure
COMMISSIOnInG Commissioning procedure 4. Check the setting of the basic program of the heating control (see operating instructions for 1. Performing an installation inspection: UltraGas 2 (125-1550)). ® The combustion air must be filtered if there is 5. Check whether the gas flow pressure is within the a heavy build-up of building dust.
Page 59: Switching The Heat Generator On
1. Check the gas flow pressure and net calorific value The settings are only allowed to be changed (NCV) of the fuel gas (gas connection values) in the by a specialist trained by Hoval or a Hoval gas connection line. customer service technician.
Page 60: Changing The Heat Generator To A Different Type Of Gas
Check pressure monitoring device for correct ulation must only be made by a heating fastening and leaks. specialist or by a Hoval customer service technician. • The values for the gas flow pressure and the Changing the heat generator to a differ-...
Page 61: Performing The Emission Measurement For Ultragas ® 2 (125-700)
COMMISSIOnInG 5.8.1 Performing the emission measurement for 4. If the value measured at full load is out of range: - Remove cover cap from the gas valve so that throt- UltraGas 2 (125-700) ® tle screw C is accessible. Use hex socket 3 mm to: - Turn throttle screw C until the emission meter indi- •...
Page 62: Performing The Emission Measurement For Ultragas ® 2 (800-1550)
COMMISSIOnInG 5.8.2 Performing the emission measurement for Setting procedure: 1. Start the “Emission” menu on the control module. UltraGas 2 (800-1550) ® - The heating control automatically switches to nor- Hex socket 2.5 mm mal operation after expiration of the remaining run time or after pressing the “Reset”...
Page 63 COMMISSIOnInG 7. If the gas quantity has been changed by means of throttle screw A or offset screw B: - Set the blocking switch to “0” and disconnect the heat generator from the mains (e.g. main switch, fuses). - Install all removed parts of the cladding and put away the climbing aid (see chapter 3.4).
Page 64: Monitoring Work Before Handover To The Operator
COMMISSIOnInG Monitoring work before handover to the 5.10 Heat generator handed over to the oper- operator ator Before the heat generator is handed over to the operator, The manufacturer of the unit is responsible for all commissioning or maintenance work must have been providing operating instructions for the com- completed and the heating system checked.
Page 65: Maintenance
In order to maintain the safety of heat generators and components, safety-relevant components as well as wear parts must be checked and, if necessary, replaced during WARNING maintenance by a Hoval customer service technician or a The heat generator must be de-energised for heating specialist. maintenance.
Page 66: Maintenance Work
MAInTEnAnCE Maintenance work - Fill the siphon and neutralisation unit, if present, with water through the cleaning opening. With every maintenance, the following seals - Check the seal of the cleaning opening for wear must be: and replace if necessary. •...
Page 67: Bleeding The Heating System
(see chapter 4.5.2). • If frost protection agent is being used, a separate engineering sheet is available from Hoval. Country-specific regulations and manufactur- § er-specific specifications for replacement wa- ter must be observed (see chapter «4.5.2 Wa- ter quality in heating systems», page 50).
Page 68: 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 69: Cleaning And Maintaining The Heat Generator
10. Disconnect gas connection from the gas valves, e.g. - If a higher cleaning effect is required: - Spray bottle with solvent-free cleaning using pipe grips. agent (e.g. soapy water or Hoval boiler cleaner) Unscrew hexagon nut - If there are deposits on the heating sur-...
Page 70 - If the burner cylinder fabric is damaged or there are cracks in the welds, the burner cylinder must be re- CAUTION newed (contact a Hoval customer service techni- Danger of burns cian or a heating specialist). • Let the heat generator cool down or wear protective clothing.
Page 71 MAInTEnAnCE - Assemble the burner in the reverse order according Burner cylinder to Fig. 51. - Replace the burner cylinder if it is defective. - Renew the following seals: - Seal for fan - Seal for adapter flange - Seal for burner cylinder - Fasten the earth wire (Fig.
Page 72 - If a higher cleaning effect is required: cleansing agents. Wet the heating surfaces with solvent-free cleans- ing agent (e.g. soapy water or Hoval boiler cleaner), allow to act for a few minutes and rinse with water. NOTICE - If deposits on the heating surfaces occur despite of an-...
Page 73 MAInTEnAnCE 17. Clean condensate drip tray. 19. If a neutralisation unit is present, maintain it accord- ing to the manufacturer’s operating instructions: NOTICE NOTICE Flue gas accumulation in the heat generator If the condensate cannot drain away, this will Reduction in the neutralisation effect lead to a condensate build-up in the conden- The neutralising agent in the neutralisation sate drip tray.
Page 74 MAInTEnAnCE 26. Replace the seal on the gas connection and connect the gas connection to gas valves, e.g. using two pipe grips. Cleaning opening cover Seal on gas Cleaning opening seal connection Fig. 58 23. Install the cover of the cleaning opening and check it is gas-tight.
Page 75 MAInTEnAnCE 36. Service any optional motorised combustion air damp- ers that are fitted, see chapter 6.6. 37. Check the gas flow pressure, see chapter 5.5. 38. Install all removed parts of the cladding and put away the climbing aid (see chapter 3.4). Position 4 39.
Page 76: Servicing Motorised Combustion Air Damper (Option)
MAInTEnAnCE Servicing motorised combustion air 1. Switch off all heat generators in the heat generator cascade: damper (option) - Set the blocking switch to “0” and disconnect the heat generator from the mains (e.g. main switch, WARNING fuses). Flue gas outlet via open combustion air - Close the gas shut-off valve.
Page 77 MAInTEnAnCE - Spray the oil strongly past the rotor into the lower - Use the locking lever to move the motorised com- bearings several times as can be seen in the photo. bustion air damper. Locking lever Fig. 67 Fig. 70 - Use the locking lever to move the motorised com- - Wait a few minutes until the oil has been absorbed.
Page 78: Renewing Fuse
MAInTEnAnCE Renewing fuse WARNING Electrical installations are only allowed to be carried out by an electrician. 1. Set the blocking switch to “0” and disconnect the heat generator from the mains (e.g. main switch, fuses). 2. Remove the front cladding according to the proce- dure in chapter 4.6 3.
Page 79: Monitoring Work Before Handover To The Operator
MAInTEnAnCE Monitoring work before handover to the operator Before the heat generator is handed over to the operator, all commissioning or maintenance work must have been completed and the plant checked. For the checking jobs to be carried out, see chapter 5.9. 4 220 950 / 02...
Page 80: Decommissioning
DECOMMISSIOnInG Decommissioning Safety flow (safety valve, air vent) NOTICE Damage to the unit Flow The heat generator might be damaged if the decommissioning is carried out improperly. • The decommissioning must be carried out by a heating specialist High-temperature return HT Disconnecting the heat generator from Low-temperature return LT the mains...
Page 81: Appendix
BIC 970 automatic function device parameter list WARNING Changes to the BIC are only allowed to be made by authorised Hoval customer service technicians. The following table is intended solely to provide information for the Hoval customer service technician! 8.1.1 Automatic function device UltraGas ®...
Page 82 Description Tree 37390 Heat gen. frost protection OFF Heat gen. sensor °C 37633 Function flue gas sensor Flue gas sensor 0=OFF 1=Flue gas sensor (AGF) 37639 Blocking temperature AGF Flue gas sensor °C 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 37641 Locking temperature AGF Flue gas sensor °C...
Page 83: Activate Screed Function
APPEnDIx Activate 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 technician. 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 84 APPEnDIx 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 85 4 220 950 / 02...
Page 86 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 installation and any further components.

Hoval UltraGas 2 Installation Instructions Manual

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