Hoval UltraGas 70 Manuel utilisateur

The oor standing gas condensing boiler UltraGas®(15-

90) are designed and approved for use as heat genera-

tors for hot water heating systems with a permissible

ow temperature of up to 85ºC1), in accordance with EN

483 and EN 677. They are designed for continuously

adjustable reduced output operation in heating systems.

1) See technical data

Rated output levels at 40/30ºC and for

natural gas

30-UltraGas® (70) 13,6 - 69,9 kW

30-UltraGas® (90) 16,1 - 91,5 kW

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 qualied experts. These instruc-

tions are intended exclusively for the specialist. Electri-

cal installations may only be carried out by a qualied

electrician.

Subject to modiﬁ cations | EN

Technical information

Installation instructions

4 210 266 / 03 - 04/12

4 210 266 / 032

1. Safety instructions

1.1 Key to symbols used ............................................................................................................................. 4

2. Important notes

2.1 Acceptance of delivery .......................................................................................................................... 5

2.2 Scope of guarantee................................................................................................................................. 5

2.3 Instruction manuals ............................................................................................................................... 5

2.4 Regulations, ofﬁcial permits ................................................................................................................. 5

2.4.1 Germany ................................................................................................................................................... 6

2.4.2 Austria ....................................................................................................................................................... 6

2.4.3 Switzerland................................................................................................................................................ 6

3. Assembly

3.1 Placement ................................................................................................................................................ 7

4. Technical data

4.1 Description of the boiler......................................................................................................................... 8

4.2 Technical data ......................................................................................................................................... 9

4.3 Dimensions / Space requirements ...................................................................................................... 10

4.4 Space requirements.............................................................................................................................. 11

4.5 Boiler-Flow resistance.......................................................................................................................... 12

4.6 Brief description of the automatic ﬁring device ................................................................................ 13

5. Installation

5.1 Safety information................................................................................................................................. 14

5.2 Boiler room requirements .................................................................................................................... 14

5.2.1 Room air dependent installation.............................................................................................................. 14

5.2.2 Room sealed installation......................................................................................................................... 14

5.3 Flue gas connection and ﬂue............................................................................................................... 15

5.4 Condensate drainage............................................................................................................................ 15

5.4.1 Design variants ....................................................................................................................................... 16

5.5 Gas connection ..................................................................................................................................... 17

5.6 Hydraulic connection............................................................................................................................ 18

5.6.1 Customer-side requirements................................................................................................................... 18

5.6.2 Hydraulic interconnection........................................................................................................................ 18

6. Commissioning

6.1 Safety information ................................................................................................................................ 20

6.2 Filling with water................................................................................................................................... 20

6.3 Water quality.......................................................................................................................................... 21

6.3.1 Heating Water ......................................................................................................................................... 21

6.4 Bleeding the air from the gas line ....................................................................................................... 22

6.5 Switching on the system ...................................................................................................................... 22

6.6 Gas inlet pressure................................................................................................................................. 22

6.7 Setting the gas ﬂow rate CO2(O2) and measurement of NOx/CO content in the ﬂue gas (ﬂue gas

measurement)........................................................................................................................................ 23

6.8 Changing over to a different gas type................................................................................................. 24

6.9 Handover to the user ............................................................................................................................ 24

6.10 Record - Activation of screed function ............................................................................................... 25

4 210 266 / 03 3

Table of contents

7. Maintenance

7.1 Safety information ................................................................................................................................ 27

7.2 Bleeding ................................................................................................................................................ 27

7.3 Water reﬁlling ....................................................................................................................................... 27

7.4 Information for combustion controller/chimney sweep regarding emission monitor key ............. 28

7.5 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.............................................................................. 31

7.6 Setting the gas ﬂow rate CO2(O2) and measurement of NOx/CO content in the ﬂue gas............... 32

7.7 Servicing the neutralisation installation (if ﬁtted).............................................................................. 33

7.8 Clean siphon.......................................................................................................................................... 34

8. Overview of settings

8.1 Table of parameters .............................................................................................................................. 35

8.2 Automatic ﬁring device UltraGas®(70,90)........................................................................................... 42

8.3 Fault Reporting overview TopTronic®T................................................................................................ 47

8.4 Automatic ﬁring device (Warning, Blocking, Lock-out)..................................................................... 49

4 210 266 / 034 Safety instructions

1. 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

- Siphon ﬁlled with water

- Expansion tank connected

- Flue gas adapter pipe with ﬂue gas pipe connected to ﬂue .

- Burner is preset (see point 6.7).

1.1 Key to symbols used

Tools:

Shows the tools required for the following work.

Instruction:

Prompts you to carry out an action.

Result:

Shows the expected reaction to your action.

Note:

Provides important information

Safety information:

Indicates an immediate hazard to persons

Safety information:

Warning of dangerous electrical voltage

Warning information

Indicates danger to machines and Installations

Provides important information.

Reference to standards and regulations.

4 210 266 / 03 5

Important notes

2. Important notes

2.1 Acceptance of delivery

A visual control of the heating boiler should be conducted upon delivery.

In the event of damage, the necessary steps should be followed as speciﬁed

in the delivery contract.

The costs for correcting the damage shall be taken over by the individual risk

bearer.

2.2 Scope of guarantee

The guarantee does not cover defects caused by:

- non-observance of these instructions

- non-observance of the operating instructions

- incorrect Installation

- unauthorised alterations

- improper use

- contaminated operating media (gas, water, combustion air)

- unsuitable chemical additives to the heating water

- damage due to the exercise of force

- corrosion through halogen compounds

- corrosion through nonconforming water quality

2.3 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!

Additional sources of information:

- Hoval catalogue

- Standards and regulations

2.4 Regulations, ofﬁcial permits

When installing and operating the system, the standards and regulations

speciﬁed in point 2.4.1 to 2.4.3 must be complied with at all times.

4 210 266 / 036 Important notes

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.

Construction, design, safety requirements.

DIN 4756 Gas ﬁred combustion systems. Construction, design, safety requirements, design and execu-

tion (for gas burner operation).

DIN 18160 Domestic chimneys, requirements, design and construction.

TRD 702 Steam boilers with group II hot water generators.

TRD 721 Safety equipment against excessive pressure / safety valves for group II steam boilers.

VDI 2035 Prevention of damage through corrosion and scale formation in hot water heating systems.

DIN 57 116 / VDI 0116 Electrical equipment in combustion systems

(VDE regulation).

See enclosure N-430 020 for further standards applicable in Germany.

2.4.2 Austria

OENORM 12831 Heating systems in buildings - Methods for calculating the design heat load

OENORM 13384 Flue gas systems - Heat and ﬂow calculation methods

OENORM 12828 Heating systems in buildings - Planning of hot water heating systems.

ÖNorm B 8130 Open water heating systems; safety equipment.

ÖNorm B 8131 Closed water heating systems; requirements to safety, construction and testing.

ÖNorm B 8133 Hot water supply systems; safety requirements.

ÖNorm B 8136 Heating systems, space and other building requirements.

ÖNorm M 7515 Dimensioning of chimneys; deﬁnitions and calculation procedure.

ÖNorm H 5171 Heating systems - construction requirements for buildings.

ÖVGW TR-Gas

2.4.3 Switzerland

SN EN 12831 Heating systems in buildings - Methods for calculating the design heat load

SN EN 13384 Flue gas systems - Heat and ﬂow calculation methods

SN EN 12828 Heating systems in buildings - Planning of hot water heating systems.

VKF - Association of Cantonal Fire Insurances.

Fire service regulations.

SVGW Switzerland. Association of the gas and water trade.

SNV 27 10 20 Ventilation requirements for the boiler Installation room.

SWKI BT102-01 Quality of water in installations of building technology

Technical tank regulations TTV 1990.

and further standards and regulations issued by CEN, CEN ELEC, DIN, VDE, DVGW, TRD and by the

legislator. Regulations from the local building authority, insurance companies and chimney sweeps must

also be complied with. When using gas as fuel, the regulations of the responsible gas board must also

be observed. An ofﬁcial permit may be required.

4 210 266 / 03 7

Assembly

4. Using a winch (4, ﬁg. 3) raise the front of the boi-

ler and remove the front crossbeam (5).

6 Fig. 4

5. Push the lateral bars (4, ﬁg. 4) out on the front

and lower the boiler back onto the ﬂoor.

7 8

Fig. 5

6. Remove screws (3, ﬁg. 2) at the back. Lift rear

wall and cover and take off the rear wall towards

the bottom. Using a winch (7, ﬁg. 5) raise the

boiler at the back in the centre (8) and remove

crossbeam and side beams. Lower the boiler

back onto the ﬂoor.

7. Afﬁx the enclosed type sticker visibly on the boi-

ler.

3. Assembly

3.1 Placement

Hoval recommends the Installation of the heat-

ing boiler on a foundation plate.

Fig. 1 1

1. Remove wooden crate (1, ﬁg. 1)

Caution: sharp edges (Figure 2)!

Fig. 2 3 2

2. Remove transportation straps (2, ﬁg. 2)

3. Remove front screws (3)

Fig. 3 4 5

4 210 266 / 038 Technical data

4. Technical data

4.1 Description of the boiler

TheHovalUltraGas®isalow emission,energy-saving

condensing gas boiler comprising the Ultraclean

burner system, a gas ﬁred premix burner with com-

bustion air fan. The Hoval UltraGas®has a vertically

disposed combustion chamber of stainless steel as

a primary heating surface and a secondary heat-

ing surface of a corrosion resistant aluminium alloy.

The secondary heating surface is designed so that

part of the water vapour contained in the ﬂue gas is

condensed and the vaporisation heat it contains is

utilised for the heating circuit.The gas burner is in the

form of a break draught burner, which can easily be

swung up for maintenance purposes.The UltraGas®

is designed to operate with natural and liquid gas.The

ﬁgure below shows the design principle.

Concentric ﬂue gas connection

Connection hose for room sealed

operation

Feed tube on left and/or right side

Internal ﬂue gas conduit

High temperature return on

left and/or right side

Low temperature return

on left and/or right side

Gas safety and

control devices

Combustion air fan

Electrode for ignition and

ﬂame monitoring

TopTronic®Tcontroller

aluFer®heat exchanger

Condensate collection tray

Horizional ﬂue gas pipe optional

4 210 266 / 03 9

Technical data

4.2 Technical data

UltraGas®(70,90)

Type (70) (90)

•Nominal output 80/60°C with natural gas 1kW 12,2 - 63,3 14,4 - 83,3

•Nominal output 40/30°C with natural gas 1kW 13,6 - 69,9 16,1 - 91,5

•Nominal output 80/60°C with liquid gas 3kW 15,4 - 63,3 17,4 - 83,3

•Nominal output 40/30°C with liquid gas 3kW 17,1 - 69,9 19,3 - 91,5

•Nominal load with natural gas 1kW 12,5 - 65,5 14,7 - 86,0

•Nominal load with liquid gas 3kW 16,0 - 65,5 18,0 - 86,0

•Working pressure heating max./min. bar 4,0 / 1,0 4,0 / 1,0

•Working temperature max.. °C 85 85

•Boiler water capacity l 157 149

•Min. water circulation l/h 0 0

•Boiler Weight (without water) kg 249 268

•Boiler efﬁciency at partial load 30% (according to EN 303)

(related to net / gross caloriﬁc value) % 107,1 / 96,5 107,2 / 96,6

•Standard efﬁciency (according to DIN 4702 part 8)40/30°C % 109,6 / 98,7 109,6 / 98,7

(net caloriﬁc value / gross caloriﬁc value) 75/60°C % 107,1 / 96,5 107,1 / 96,5

•Heat loss rate at 70°C Watt 290 290

•Standard emission rate Nitrogen oxides mg/kWh 32 39

Carbon monoxide mg/kWh 3 3

•Content of CO2in the exhaust gas max./min. power % 9,0 / 8,8 9,0 / 8,8

•Dimensions See table of dimensions

•Connections Flow /Return Zoll R 1 ½" R 1 ½"

Gas Zoll R ¾" R ¾"

Flue gas / combustion

air Ø mm C100/150 C100/150

•Gas ﬂow pressure min./ max.

Natural gas E/LL mbar 18-50 18-50

Liquid gas mbar 37-50 37-50

•Gas connection value at 0°C / 1013 mbar:

Natural gas E - (Wo = 15,0 kWh/m3) Hu = 9,97 kWh/m3m3/h 6,6 8,6

Natural gas LL- (Wo = 12,4 kWh/m3) Hu = 8,57 kWh/m3m3/h 7,6 10,0

Propangas (Hu = 25,9 kWh/m3) m3/h 2,5 3,3

•Operation voltage V/Hz 230/50 230/50

•Control voltage V/Hz 24/50 24/50

•Min./Max. electrical power consumption Watt 27 / 93 28 / 138

•Standby Watt 12 12

•IP rating (integral protection) IP 20 20

•Acoustic capacity

- Heating noise (EN 15036 part 1) (room air-dependent) dB(A) 64 67

- Exhaust noise is radiated from the mouth

(DIN 45635 part 47) (room air-dependent/room air-independent) dB(A) 55 59

•Acoustic pressure level (depending on installation)2dB(A) 57 59

•Condensate quantity (Natural gas ) at 40/30°C l/h 6,2 8,1

•pH value of the condensate ca. 4,2 ca. 4,2

•Value for ﬂue calculation

Temperature class T120 T120

Flue gas mass ﬂow kg/h 109,0 143,0

Flue gas temperature at nominal output and operation 80/60°C °C 63 65

Flue gas temperature at nominal output and operation 40/30°C °C 43 43

Mass ﬂow combustion air Nm3/h 81 106

Feed pressure for combustion air/ ﬂue gas system Pa 130 130

Maximal Draft / negative pressure ﬂue gas outlet Pa - 50 - 50

1Data reladet to Hu. The boiler series is tested for EE/H-settings. With a factory setting of the Wobbe coefﬁcient of 15.0 kWH/m3operation at a

Wobbe oefﬁcient of 12,0 up to 15,7 kWh/m3is possible without new settings.

2See also notes at „Engineering“.

3Data reladet to Hu.

4 210 266 / 0310 Technical data

4.3 Dimensions / Space requirements

UltraGas®(70,90) with connection set AS40-S/NT/ HT and heating armature groupe HA40

(All dimensions in mm)

Type UltraGas®(70) (90)

1. Flow Heating R1½" R1½"

2. Low temperature-return R1½" R1½"

2a. High temperature-return R1½" R1½"

3. Electrical connection left or right R ¾" R ¾"

4. Gas connection left or right C100/150 C100/150

4a. Flue gas connection rear (option) E100/150 E 100

5. Control panel

6. Condensate drain (left or right)

incl. siphon DN25 and 2 m PVC

continuous-ﬂow tube inner Ø 19x4

7. Electrical connection left or right

8. Draining

9. Connection set (option)

10. Heating armature group or

loading group (option)

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