Table of Contents
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Technical information
Installation instructions
UltraGas
(70,90)
®
Condensing gas heating boilers
for natural gas and liquid gas
for modulating operation
Hoval products must be installed and commissioned
only by appropriately qualified experts. These instruc-
tions are intended exclusively for the specialist. Electri-
cal installations may only be carried out by a qualified
electrician.
Subject to modifi cations
|
4 210 266 / 03 - 04/12
Rated output levels at 40/30ºC and for
natural gas
30-UltraGas
®
30-UltraGas
®
The floor standing gas condensing boiler UltraGas
90) are designed and approved for use as heat genera-
tors for hot water heating systems with a permissible
flow temperature of up to 85ºC
483 and EN 677. They are designed for continuously
adjustable reduced output operation in heating systems.
See technical data
1)
(70)
13,6 - 69,9 kW
(90)
16,1 - 91,5 kW
, in accordance with EN
1)
EN
(15-
®
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Table of Contents
Related Manuals for Hoval UltraGas 70
Summary of Contents for Hoval UltraGas 70
- Page 1 ® 30-UltraGas (90) 16,1 - 91,5 kW ® Hoval products must be installed and commissioned The floor standing gas condensing boiler UltraGas (15- ® only by appropriately qualified experts. These instruc- 90) are designed and approved for use as heat genera- tions are intended exclusively for the specialist.
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Page 2: Table Of Contents
Safety instructions Key to symbols used ..........................4 Important notes Acceptance of delivery .......................... 5 Scope of guarantee ..........................5 Instruction manuals ..........................5 Regulations, official permits ......................... 5 2.4.1 Germany ..............................6 2.4.2 Austria ............................... 6 2.4.3 Switzerland ..............................6 Assembly Placement .............................. - Page 3 Maintenance Safety information ..........................27 Bleeding ..............................27 Water refilling ............................27 Information for combustion controller/chimney sweep regarding emission monitor key ..... 28 Cleaning ..............................29 7.5.1 Cleaning the burner cylinder ........................29 7.5.2 Cleaning the exterior of the combustion chamber and burner cylinder ..........30 7.5.3 Cleaning/adjusting the ignition and ionisation device ................
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Page 4: Safety Instructions
Safety instructions The system shall not be put into operation until all relevant standards and safety regulations are met. For a test run, the following minimum conditions must be satisfied: - Safety valve installed (closed system) - Controls operative (connected to power supply) - Sensor for safety temperature limiter is connected (= boiler temperature sensor) - System filled with water... -
Page 5: Important Notes
- corrosion through nonconforming water quality Instruction manuals A summary of all the instruction manuals relevant to this system can be found in the Hoval System User Guide! In exceptional cases the instructions are kept with the respective compo- nents! -
Page 6: Germany
§ 2.4.1 Germany DIN EN 12831 Heating systems in buildings - Methods for calculating the design heat load DIN EN 13384 Flue gas systems - Heat and flow calculation methods DIN EN 12828 Heating systems in buildings - Planning of hot water heating systems. DIN 4755 Oil fired combustion systems. -
Page 7: Assembly 3.1 Placement
4. Using a winch (4, fig. 3) raise the front of the boi- ler and remove the front crossbeam (5). Placement Hoval recommends the Installation of the heat- ing boiler on a foundation plate. Fig. 4 5. Push the lateral bars (4, fig. 4) out on the front Fig. -
Page 8: Technical Data
The gas burner is in the bustion air fan. The Hoval UltraGas has a vertically form of a break draught burner, which can easily be ®... -
Page 9: Technical Data
Technical data UltraGas (70,90) ® Type (70) (90) • Nominal output 80/60°C with natural gas 12,2 - 63,3 14,4 - 83,3 • Nominal output 40/30°C with natural gas 13,6 - 69,9 16,1 - 91,5 • Nominal output 80/60°C with liquid gas 15,4 - 63,3 17,4 - 83,3 •... -
Page 10: Dimensions / Space Requirements
Dimensions / Space requirements UltraGas (70,90) with connection set AS40-S/NT/ HT and heating armature groupe HA40 ® (All dimensions in mm) UltraGas (70) (90) Type ® 1. Flow Heating R1½" R1½" 2. Low temperature-return R1½" R1½" 2a. High temperature-return R1½" R1½"... -
Page 11: Space Requirements
Space requirements UltraGas (70,90) ® (All dimensions in mm) Boiler door incl. burner swivels upwards and to the left or to the front. A = minimal 150 mm * Burner service position front - boiler cleaning from the right A = optimal 300 mm * Burner service position left - boiler cleaning from the front * without heating armature group 500 mm with heating armature group... -
Page 12: Boiler-Flow Resistance
Boiler-Flow resistance UltraGas (70,90) ® /h = Through put flow rate mbar = Flow resistance [m3/h] Technical data 4 210 266 / 03... -
Page 13: Brief Description Of The Automatic Firing Device
Brief description of the automatic firing device The automatic firing device BIC960 of the UltraGas only operates in conjunction with the heating control- ® TopTronic ® UG. For this reason, the automatic firing device only needs to take care of the last re- maining functions to ensure the correct operation of a modulating gas boiler. -
Page 14: Installation
Installation Safety information Caution! Sharp edges pose a cutting hazard. Handle the cladding parts with care and avoid contact with sharp edges. Boiler room requirements § The boiler room must satisfy the applicable local building regulations. § The boiler room ventilation must satisfy the applicable local regulations in this regard. §... -
Page 15: Flue Gas Connection And Flue
Flue gas connection and flue site Due to the low flue gas temperatures, condensate forms within the flue. For this reason, Hoval gas Condensate drainage heating boilers can not be connected to convention- al house chimneys. -
Page 16: Design Variants
5.4.1 Design variants Possibility 3 • Siphon and condensate delivery pump • Without neutralisation, condensate discharge into Before commissioning, the neutralisation higher drain line. box (if fitted) must be filled with neutrali- sation granulate (figure, chapter 6.4). The condensate delivery pump must be Before putting into service, the si- installed in accordance with the enclosed phon and the neutralisation box must... -
Page 17: Gas Connection
Gas connection Hazard! Explosion hazard due to leaky gas connection. Check the gas connection for gas tightness after completing the boiler installation. The gas connection can be located on the left or right hand side of the boiler. The gas line is supplied loose with the boiler. The connection diameter is ¾“. Check for gas tightness after installation! 4 210 266 / 03 Installation... -
Page 18: Hydraulic Connection
When combining a calorifier with floor heating, a mixer needs to be installed. A minimum amount of circulating water is not required. Regarding suitable hydraulic connections, please observe the notes in the planning documentation of the relevant Hoval sales company! Example TopTronic T... - Page 19 Electrical connection Procedure to remove the front covering panel 1. Remove front cover (1, fig. 6), after first releasing the lateral locking bolt (1a) (turn approx. ¼ turn - The electrical connection must be car- to the left and pull out as far as the stop). Lift ried out by an approved electrician.
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Page 20: Commissioning
Caution! Danger of injury for unqualified personnel. Maintenance and cleaning work may only be performed by trained personnel or by the Hoval Customer Service. Caution! Danger of damaging the system by filling it with incorrect liquids. Water filled into the system must have drinking quality. -
Page 21: Water Quality
8.3 and 9.5 after 6-12 weeks of heating operation. In particular, attention must be paid to the following stipu- lations: • Hoval boilers and calorifi ers are designed for heating Filling and replacement water plants without signifi cant oxygen intake (plant type I ac- cording to EN 14868). -
Page 22: Bleeding The Air From The Gas Line
Bleeding the air from the gas line § Observe the relevant regulations when bleeding the gas line Open the gas shut-off valve. Bleed the air up to the gas armature. Switching on the system Switch on the main switch on the boiler. Gas inlet pressure The gas flow may only be adjusted and the heating system therefore started up, if the minimum flow pressure values are achieved (see point 6.7 Adjusting... -
Page 23: Setting The Gas Flow Rate Co ) And Measurement Of Nox/Co Content In The Flue Gas (Flue Gas Measurement)
Setting the gas flow rate CO ) and measurement of NOx/CO content in the flue gas (flue gas measurement) TorxT40, screwdriver, size 5 and/or allen key 4 mm The Honeywell multiple actuator allows measuring the inlet pressure on meas uring nipple A. A Measuring nipple gas inlet pressure B Measuring nipple gas outlet pressure C Gas choke... -
Page 24: Changing Over To A Different Gas Type
Changing over to a different gas type This changeover may only be carried out by an authorised specialist or by the Hoval Customer Service. Changeover from natural gas H to natural gas L An emission check is required when changing to a natural gas of lower calo- rific value;... -
Page 25: Record - Activation Of Screed Function
6.10 Record - Activation of screed function Cross where applicable; cut out record and fasten to the control during the active screed function. Minimum requirements for the activation of the screed function: Minimum age cement screed 21 days Minimum age calcium sulphate screed 7 days Flow temperature monitor installed and connected For newly laid screed - see „Recommendation of the Federal Association of Radiant Panel Heating“. - Page 26 Parameter 16 „Screed function“ (Parameter HC, MC1 or MC2) Example: Maximum fl ow temperature 40°C 1 Function heating Starting day + 7 days [°C] VLSol 55°C maximum set level! maximal 55°C einstellbar! 1=Funktionsheizen 1 = Function heating Funktionsheizen START DAYS START 1 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 TAGE] START 1...
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Page 27: Safety Information
Caution! Danger of injury for unqualified personnel. Maintenance and cleaning work may only be performed by trained personnel or by the Hoval Customer Service. Caution! After repair work respectively exchanging boiler parts, a flue gas measure- ment according to point 6.7 must be carried out imperatively. -
Page 28: Information For Combustion Controller/Chimney Sweep Regarding Emission Monitor Key
Information for combustion controller/chimney sweep regarding emission monitor All other control elements of the control unit are described in the operating instructions. The emission monitor key can also be used to change over to manual operating mode. Emission monitor key / Manual operation To protect under fl... -
Page 29: Cleaning
Cleaning The boiler may only be cleaned by an authorised technician or by the Hoval Customer Service. The Hoval gas heating boiler should be cleaned and maintained once every year. If the Hoval gas heating boiler was in operation during the building phase, it will be necessary to carry out a check for cleanliness. -
Page 30: Cleaning The Exterior Of The Combustion Chamber And Burner Cylinder
7.5.2 Cleaning the exterior of the combustion chamber and burner cylinder Warning! Chemical burn hazard through cleaning agents. Safety gloves and eye protection must be worn when using cleaning agents. Observe the information on the original packaging. Caution! The system can be damaged when using incorrect cleaning agents. Use only cleaning agents approved for gas boilers with aluminium compo- nents. -
Page 31: Cleaning/Adjusting The Ignition And Ionisation Device
Cleaning : Spray the combustion chamber and aluFer tubes (3, fig. 13). The best results are obtained with a spray gun with a suitable wide jet noz- zle (fan or conical jet). We recommend, e.g.: “SOTIN 230“; Spraytherm- Konzentrat-W“ (from R. Zimmermann, 8700 Küsnacht); “durgo forte“, Art. No. -
Page 32: Setting The Gas Flow Rate Co
Adjustment: Heat the ignition electrode at the kink with the blowtorch until it glows red. (1, fig. 14). Bend the ignition electrode with the long-nosed pliers (2, fig. 15). Distance to the burner cylinder 4 mm Figure 14 Figure 15 Reassembly: Replace the gasket at the gas connection. -
Page 33: Servicing The Neutralisation Installation (If Fitted)
Servicing the neutralisation installa- Neutralisationsgranulat tion (if fitted) Die Wartung sollte mindestens jedes zweite Jahr erfolgen oder nach Verbrauch des Neutralisationsgranulat (evtl. ph-Wert überprüfen mit Lackmuspapier-Test). Das Neutralisationsgranulat zum Nachfüllen kann bei Ho- val unter folgender Art. Nr. bestellt werden: •... -
Page 34: Clean Siphon
Clean siphon • Loosen siphon and remove from boiler. • Rinse siphon. • Check if siphon gaskets (1) are not damaged, replace if necessary. Caution: poisoning! If siphon is not filled with water or if it is contaminated or obstructed by con- tamination, leaking flue gas may put people in danger of life. -
Page 35: Overview Of Settings
Overview of settings Table of parameters Regulator Setting range / Designation Factory Setting values Type of device: DHW: Address: Surface operation Key : Heating curve HC OFF, 0,20 ..3,5 Heating curve MC1 OFF, 0,20 ..3,5 Heating curve MC2 OFF, 0,20 .. - Page 36 Table for Time programs DHW circuit Time program P1 Time program P2 Time program P3 Cycle 1 Cycle 2 Cycle 3 Cycle 1 Cycle 2 Cycle 3 Cycle 1 Cycle 2 Cycle 3 from from from from from from from from from Direct circuit...
- Page 37 HYDRAULIC Par. Designation Factory Lev. Function allocation of the output DHW charging pump Function allocation of the output Mixer circuit 1 Function allocation of the output Mixer circuit 2 Function allocation of the output Direct circuit Pump Function allocation of the variable output 1 Function allocation of the variable output 2 OFF/ 4/ 43 Function allocation of the variable input 1...
- Page 38 Par. Designation Factory Lev. DHW-NIGHT DHW - economy temperature 40/ 45 °C DHW-legionella protection-day 2:00 DHW-egionella protection-time 50/ 55/ 65/ DHW-legionella protection-temperature 70 °C DHW-temperature recording 50/ 55/ 65/ DHW-maximum temperature limit 70 °C DHW-mode of operation ON/ OFF DHW-tank discharge protection DHW-charging temperature excess 7/ 20 K DHW-switching difference...
- Page 39 MIX. VALVE-1 Par. Designation Factory Lev. Type of reduced operation ECO/ ABS MK= 1,10 Heating system (exponent) Room override (in connection with room sensor) Room factor 100 % Adaptation heating curve Switch-on optimisation Heating limit Room frost protection limit 10 °C Room thermostat function Outside temperature allocation Constant temperature reference value...
- Page 40 MIX. VALVE-2 Par. Designation Factory Lev. Type of reduced operation ECO/ ABS MK= 1,10 Heating system (exponent) Room override (in connection with room sensor) Room factor 100 % Adaptation heating curve Switch-on optimisation Heating limit Room frost protection limit 10 °C Room thermostat function Outside temperature allocation Constant temperature reference value...
- Page 41 HEAT GENER. Par. Designation Factory Lev. H-GEN model 1/ 2/ 5 OFF/ 3 Start-up protection H-GEN 5/ 48/ 65/ 75 Minimum temperature limit H-GEN °C 75/ 85 °C Maximum temperature limit H-GEN Mode of action minimum temperature limit H-GEN Sensor mode operation for H-GEN Minimum burner running time 2 min Burner switching difference I...
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Page 42: Automatic Firing Device Ultragas ® (70,90)
AUTOMATIC FIRING DEVICE UltraGas (70,90) ® Description Blocking temperature °C Maximum setpoint °C Switch-off hysteresis via setpoint °C Switching difference to switch-off point °C Proportional range °C Integral part Differential part Setpoint for bus interrupt °C Maximum temperature rise for low flow temperature °C/s Maximum temperature rise for high flow temperature °C/s... - Page 43 AUTOMATIC FIRING DEVICE UltraGas (70,90) ® Description Ignition (0-> internal, 1-> internal + external, 2-> external) 44 2KM Stepped modulation (0-> off, 1-> rising, 2-> rising and falling) Action mode fault relays ADC/4 value at 0 bar ADC/4 value at 6/10 bar (V3) 145/ 145/ Extended external ignition time...
- Page 44 RETURN CONTR Par. Designation Factory Lev. Minimum limit return temperature / reference value return 38 °C temperature Switch-off difference Pump follow-on time 1 min SOLAR Par. Designation Factory Lev. 10 K Switch-on difference Switch-off difference Minimum running time SOP 3 min Solar collector maximum temperature 100 °C Solar tank maximum limit (KSPF)
- Page 45 BUFFER Par. Designation Factory Lev. Minimum temperature 5/ 20 °C 95 °C Maximum temperature 8/ 10/ 12K Temperature elevation, H-GEN Switching difference 2/ 5/ 10K Forced discharge Skimming function switch-on difference 10 K Skimming function switch-off difference Start-up protection Discharge protection Buffer mode of operation 2/ 3 Pump follow-on time...
- Page 46 SERVICE Par. Designation Factory Lev. Service 1 (Cleaning ST1 ) Suspend message «CLEANING ST-1» for X days Cleaning according to fi xed date Cleaning according to fi xed interval Cleaning according to cleaning counter Reset cleaning display 1 Service 2 (Cleaning ST2) Suspend message «CLEANING ST-2»...
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Page 47: Fault Reporting Overview Toptronic
FAULT REPORTING OVERVIEW TopTronic ® Status Designation Fault type Code Remark System External sensor Interruption 10-0 System External sensor Short-circuit 10-1 System Boiler sensor Interruption 11-0 System Boiler sensor Short-circuit 11-1 System Flow sensor 1 Interruption 12-0 MC1=off, YK1=no current System Flow sensor 1 Short-circuit... - Page 48 Regulator with address 10 is System Activity 70-8 missing System Activity Data bus error 70-9 No Hoval regulator System HP return sensor Return min. temp. below setpoint 85-4 System HP return sensor Return max. temp. exceeded 85-5 Heat source min. temp. below...
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Page 49: Automatic Firing Device (Warning, Blocking, Lock-Out)
Automatic firing device (Warning, Blocking, Lock-out) Code Failure Type Description W:01 Warning Water pressure too low W:02 Warning Ionisation too low B:03 Blocking Gas pressure too low/ Gas pressure switch defective/ external blockings B:04 Blocking *Main gas valve (possibly LPG- valve)/ Heating room fan B:05 Blocking Water pressure outside of limits... - Page 52 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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