Hoval UltraGas 70 Manual

Subject to modi cations | EN

Technical information

Installation instructions

UltraGas®(70,100)

Condensing gas heating boilers

for natural gas and liquid gas

for modulating operation

The oor-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 ow temperature of

up to 85 °C1). They are designed for continuously cont-

rolled reduced operation in heating systems.

1) See technical data

These instructions apply to the following types:

Rated output levels at 40/30 ºC

and for natural gas

45-UltraGas® (70) 13.6 - 69.9 kW

45-UltraGas® (100) 20.9 - 100.0 kW

Hoval products may only be installed and commissioned

by appropriately qualied experts. These instructions

are intended exclusively for the specialist. Electrical

in stal lations may only be carried out by a qualied

electrician.

4 217 214 / 02 - 11/19

24 217 214 / 02

TABLE OF CONTENTS

1. Important notes

1.1 General safety instructions.................................................................................................................................................4

1.2 Explanation of the symbols ................................................................................................................................................4

1.2.1 Warnings ..........................................................................................................................................................................4

1.2.2 Warning symbols...............................................................................................................................................................4

1.2.3 Information........................................................................................................................................................................5

1.3 On delivery...........................................................................................................................................................................5

1.4 Warranty...............................................................................................................................................................................5

1.5 Manuals................................................................................................................................................................................5

1.6 Regulations, official approvals ...........................................................................................................................................6

1.6.1 Germany §........................................................................................................................................................................6

1.6.2 Austria § ...........................................................................................................................................................................6

1.6.3 Switzerland § ....................................................................................................................................................................6

2. Installation

2.1 Set-up...................................................................................................................................................................................7

3. Technical information

3.1 Description of the boiler .....................................................................................................................................................8

3.2 Technical data UltraGas®(70,100).......................................................................................................................................9

3.3 Dimensions........................................................................................................................................................................10

3.4 Space requirement ............................................................................................................................................................11

3.5 Boiler flow resistance........................................................................................................................................................12

3.6 Brief description of the automatic firing device...............................................................................................................12

4. Installation

4.1 Safety instructions ............................................................................................................................................................13

4.2 Requirements on the boilerhouse ....................................................................................................................................13

4.2.1 Room air dependent installation......................................................................................................................................13

4.2.2 Room air independent installation ...................................................................................................................................13

4.3 Flue gas connection and flue gas line..............................................................................................................................14

4.3.1 Project planning instructions, flue gas systems ...............................................................................................................15

4.3.2 Design examples for room air dependent operation.........................................................................................................16

4.3.3 Design examples for room air independent operation......................................................................................................17

4.3.4 Design examples for room air independent operation......................................................................................................18

4.4 Condensate drain ..............................................................................................................................................................19

4.4.1 Design variants...............................................................................................................................................................19

4.5 Gas connection..................................................................................................................................................................20

4.6 Hydraulic connection ........................................................................................................................................................21

4.6.1 To be provided on-site.....................................................................................................................................................21

4.6.2 Hydraulic integration .......................................................................................................................................................21

4.7 Electrical connection.........................................................................................................................................................22

4.7.1 Safety measures for EMC according assembly................................................................................................................23

4.7.2 Recommended cable cross sections and permissible maximum length of cable ..............................................................25

34 217 214 / 02

TABLE OF CONTENTS

5. Commissioning

5.1 Safety instructions ............................................................................................................................................................26

5.2 Filling the heating system.................................................................................................................................................26

5.3 Water quality......................................................................................................................................................................27

5.3.1 Heating water..................................................................................................................................................................27

5.4 Venting the gas pipe..........................................................................................................................................................28

5.5 Switching on......................................................................................................................................................................28

5.6 Gas inlet pressure .............................................................................................................................................................28

5.7 Functional check of combustion cylinder pressure monitoring .....................................................................................28

5.7.1 Check pressure in the combustion cylinder (safety check during commissioning) ............................................................29

5.8 Setting the gas quantity, measuring the CO2 (O2) and NOx/CO content in the flue gas (flue gas measurement)..........30

5.9 Changing to a different type of gas ..................................................................................................................................31

5.9.1 Changing from natural gas H to natural gas L..................................................................................................................31

5.9.2 Changing from natural gas to liquid gas ..........................................................................................................................31

5.10 Handover to the operator ..................................................................................................................................................31

5.11 Record - Activation of screed function.............................................................................................................................32

6. Maintenance

6.1 Safety instructions ............................................................................................................................................................34

6.2 Deaeration..........................................................................................................................................................................34

6.3 Top up with water ..............................................................................................................................................................34

6.4 Renewing fuse ...................................................................................................................................................................34

6.5 Information for combustion controller / chimney sweep regarding emission monitor key ...........................................35

6.6 Cleaning.............................................................................................................................................................................36

6.6.1 Cleaning the burner cylinder ...........................................................................................................................................36

6.6.2 Cleaning the combustion chamber and burner cylinder on the outside.............................................................................37

6.6.3 Cleaning/setting ignition ionisation device .......................................................................................................................38

6.7 Setting the gas quantity, measuring the CO2 (O2) and NOx/CO content in the flue gas (according to point 5.8) ..........39

6.8 Maintaining the neutraliser box (if fitted) .........................................................................................................................40

6.9 Cleaning the condensation trap........................................................................................................................................41

6.10 Parameter list - automatic firing device BIC 960..............................................................................................................42

44 217 214 / 02

IMPORTANT NOTES

1. Important notes

1.1 General safety instructions

The system may only be placed in operation

if all the relevant standards and safety regula

tions have been complied with.

At least the following conditions must be satised for

a trial operation:

• Safety valve installed (system sealed)

• Control system in operation (connected to the power

supply)

• Sensor for safety temperature limiter connected (= boi-

ler temperature sensor)

• System lled with water

• Condensation trap lled with water

• Expansion tank connected

• Flue gas outlet with ue gas conduit connected to ue

gas system.

• Burner preset (see point 6.6).

WARNING

The heat generator can only be de-energised

by disconnection from the mains (e.g. all-pole

switch).

WARNING

All electric power supply circuits must be

switched o󰀨 before accessing the terminals.

1.2 Explanation of the symbols

1.2.1 Warnings

DANGER

... indicates a situation of immediate danger

which will lead to serious or fatal injuries if

not avoided.

WARNING

... indicates a situation of possible danger

which can lead to serious or fatal injuries if

not avoided.

CAUTION

... indicates a situation of possible danger

which can lead to minor or slight injuries if

not avoided.

NOTICE

... indicates a situation of possible danger

which can lead to damage to property if not

avoided.

1.2.2 Warning symbols

The following warning signs are combined for the war-

ning notes with signal words CAUTION, WARNING and

DANGER.

General warning of a danger zone.

“Warning: dangerous electrical voltage” as a

warning for accident prevention.

Ensures that people do not come into contact

with electrical voltage. The danger sign with

the black lighting symbol warns against the

danger of electrical voltage.

“Warning of hot surface” sign for indicating

safety.

Indicates dangers of injury and burns on hot

surfaces.

Incorrect handling of potentially explosive

substances can lead to serious damage, po

tentially fatal injuries and incalculable costs.

Danger: Substances with a corrosive e󰀨ect on

skin, eyes and respiratory organs; can cause

irritation.

Handling: Do not inhale vapours and avoid

contact with skin and eyes.

54 217 214 / 02

IMPORTANT NOTES

Warning of cutting injuries:

Avoid cutting injuries. Clearly indicate the dan

ger of cutting on sharp-edged parts to avoid

serious and costly injuries.

1.2.3 Information

Information:

Provides important information.

Follow the instructions for use.

Requirements to comply with the instructions.

Tool:

Which tools and other equipment are requi

red.

Provides important information.

Refers to standards and directives.

1.3 On delivery

Carry out a visual inspection immediately on receiving the

boiler. If any damage is found, take the necessary steps

as dened in the delivery contract. The respective risk

carrier bears the cost of repairs.

1.4 Warranty

The warranty does not cover defects attributable to:

• Failure to comply with these instructions

• Failure to comply with the operating instructions

• Incorrect installation

• Impermissible modications

• Incorrect handling

• Contaminated operating materials (gas, water, com-

bustion air)

• Unsuitable chemical additives to the heating water

• Damage caused by the application of force

• Corrosion by halogen compounds (e.g. paints, adhesi-

ves, solvents)

• Corrosion caused by not observing the required water

quality

1.5 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

• Standards, regulations

64 217 214 / 02

IMPORTANT NOTES

1.6.3 Switzerland §

• SN EN 12831 Heating systems in buildings - Procedure

for calculation of the standard heating load

• SN EN 13384 Flue gas systems - Heat and ow

calculation methods

• SN EN 12828 Heating systems in buildings - Design of

hot water heating systems.

• VKF – Association of Cantonal Fire Insurers.

• Fire prevention authority regulations.

• SVGW Swiss Association for Gas and Water.

• SNV 27 10 20 Aeration and ventilation of the boiler

installation room.

• SWKI BT102-01 Water quality for building services

systems.

• Technical tank regulations TTV 1990.

• EKAS - Guidelines for liquid gas Part 2

and further regulations and standards issued by CEN,

CEN ELEC, DIN, VDE, DVGW, TRD and the legislative

body. The regulations of the local building authorities,

insurance companies and chimney sweeps must also be

taken into account. The regulations of the responsible

gas supply company are to be complied with if using gas.

Approval by the authorities may be required.

1.6 Regulations, official approvals

The standards and directives stated under points 1.6.1 to

1.6.3 must be taken into account during installation and

operation of the system.

1.6.1 Germany §

• DIN EN 12831 Heating systems in buildings – Method

for calculation of the design heat load

• DIN EN 13384 Flue gas systems – Calculation methods

in heat and ow engineering

• DIN EN 12828 Heating systems in buildings - Design of

hot water systems.

• DIN 4755 Oil-red systems. Design, construction and

safety engineering requirements.

• DIN 4756 Gas-red combustion systems: design, cons-

truction and safety engineering requirements, design

and construction (for operation with gas burners).

• DIN 18160 House chimneys; requirements, planning

and execution.

• TRD 702 Steam boiler plants with caloriers of the

group II.

• TRD 721 Safety devices against excess pressures / sa-

fety valves / for steam boilers of Group II.

• VDI 2035 Prevention of damage by corrosion and the

formation of scale in hot water heating systems.

• DIN 57 116 / VDI 0116 Electrical equipment for ring

systems (VDE Regulation).

• For further standards applicable in Germany, see

appendix N-430 020.

1.6.2 Austria §

• ÖNORM 12831 Heating systems in buildings -

Procedure for calculation of the standard heating load

• ÖNORM 13384 Waste gas systems – Procedures for

heat and ow calculations

• ÖNORM 12828 Heating systems in buildings - Design

of hot water systems.

• ÖNORM B 8130 Open water heating systems; safety

devices.

• Norm B 8131 Closed water heating systems; safety,

execution and testing requirements.

• ÖNORM B 8133 Hot water production systems; techni-

cal safety requirements.

• ÖNORM B 8136 Heating systems, space requirements

and other building requirements.

• ÖNORM M 7515 Calculations of dimensions of

chimneys; terminology, calculation procedure.

• ÖNORM H 5171 Heating systems – construction

engineering requirements.

• ÖVGW TR-gas (Austrian Gas and Water Confederation

- Technical Guidelines)

74 217 214 / 02

INSTALLATION

Fig. 03

4. Using a winch (4, Fig. 03) raise the front of the boiler

and remove the front crossbeam (5).

Fig. 04

5. Push the side bar (6, Fig. 04) to the outside in the

front area and lower the boiler.

7 8

Fig. 05

6. Remove screws (3, Fig. 02) at the back. Lift rear

wall and cover and take o󰀨 the rear wall towards the

bottom. Using a winch (7, Fig. 05) raise the boiler at

the back in the centre (8) and remove crossbeam and

side beams. Lower the boiler.

7. A󰀩x the included type label clearly visibly on the boiler.

2. Installation

2.1 Set-up

Hoval recommends setting up the boiler on a

foundation slab.

Fig. 01

1. Remove the wooden crate (1, Fig. 01)

CAUTION

Sharp edges (Fig. 02)!

3 2

Fig. 02

2. Remove transportation straps (2, Fig. 02)

3. Remove screws (3) at the front

84 217 214 / 02

TECHNICAL INFORMATION

The secondary heating surface is so designed that part

of the water vapour contained in the ue gas condenses

and the heat of evaporation is utilised for the heating cir-

cuit. The gas burner is congured as a vertical burner

that can be swivelled up easily for maintenance work.

The UltraGas®is provided for operation with natural gas

and liqueed gas. The design principle is shown in the

following drawing.

3. Technical information

3.1 Description of the boiler

The Hoval UltraGas®is a low-pollution and energy-saving

condensing gas boiler with the Ultraclean burner system,

a gas-red pre-mix burner with combustion air blow er.

The Hoval UltraGas®has a combustion chamber arran-

ged vertically and fabricated from non-corroding stainless

steel as its primary heating surface and a secondary

heating surface made from corrosion-resistant aluminium

alloy.

Concentric ue gas connection

Connection hose for room

air-independent operation

Flow left and/or right

Internal ue gas conduit

High-temperature

return left and/or right

Low-temperature return

left and/or right

Gas, safety and

control systems

Combustion air blower

Electrode for ignition

and ame monitoring

TopTronic® E control

aluFer®heat exchanger

Condensate drip tray

Horizontal ue gas connec-

tion possible as an option

Fig. 06

94 217 214 / 02

TECHNICAL INFORMATION

3.2 Technical data UltraGas®(70,100)

Type (70) (100)

• Nominal heat output at 80/60 °C, natural gas kW 12.2-64.0 19.0-92.0

• Nominal heat output at 40/30 °C, natural gas kW 13.6-69.9 20.9-100.0

• Nominal heat output at 80/60 °C, propane 2kW 15.4-63.3 23.0-92.0

• Nominal heat output at 40/30 °C, propane 2kW 17.1-69.9 25.3-100.0

• Nominal load with natural gas 1kW 12.5-65.7 19.6-94.1

• Nominal load with propane 2kW 16.0-65.7 23.8-94.1

• Working pressure heating maximum/minimum bar 4.0/1.0 4.0/1.0

• Test pressure bar 6.0 6.0

• Working temperature maximum °C 85 85

• Boiler water content l 157 144

• Flow resistance boiler 3z value 1.5 1.5

•Minimum water ow l/h 0 0

• Boiler weight (without water content, incl. casing) kg 302 331

•Boiler e󰀩ciency at 80/60 °C in full-load operation

(related to net caloric value NCV / gross caloric value GCV) % 98.0/88.3 97.6/87.9

•Boiler e󰀩ciency at 30 % partial load (EN 15502)

(related to net caloric value NCV / gross caloric value GCV) % 108.1/97.4 108.1/97.4

•Standard e󰀩ciency (DIN 4702-8) 40/30 °C % 109.6/98.7 109.1/98.3

(related to net caloric value NCV / gross caloric value GCV) 75/60 °C % 107.1/96.5 107.1/96.5

• Stand-by loss at 70 °C Watt 290 290

• NOx class (EN 15502) 6 6

• Standard emission rate Nitrogen oxides mg/kWh 32 39

• Content of CO2 in the ue gas maximum/minimum output % 9.0/8.8 9.0 / 8.8

• Dimensions

• Connections Flow/return Inches R 1 ½″R 1 ½″

Gas Inches R ¾″ R ¾″

Flue gas/combustion air Ø mm C100/150 C100/150

•Gas ow pressure minimum/maximum

Natural gas E/LL mbar 17.4-50 17.4-50

Propane mbar 37-50 37-50

• Gas connection value at 15 °C/1013 mbar:

Natural gas E (Wo = 15.0 kWh/m3) NCV = 9.97 kWh/m3m3/h 6.6 9.4

Natural gas LL (Wo = 12.4 kWh/m3) NCV = 8.57 kWh/m3m3/h 7.6 11.0

Propane (NCV = 25.9 kWh/m3) m3/h 2.5 3.6

• Operation voltage V/Hz 230/50 230/50

• Control voltage V/Hz 24/50 24/50

• Electrical power consumption min./max. Watt 25/85 21/148

• Stand-by Watt 12 12

• IP rating (integral protection) IP 20 20

• Lowest ambient temperature during operation °C 5 5

• Highest ambient temperature during operation °C 40 40

• Sound power level

- 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

• Sound pressure level (depending on installation conditions) 4dB(A) 57 59

• Condensate quantity (natural gas) at 40/30 °C l/h 6.2 8.9

• pH value of the condensate approx. 4.2 approx. 4.2

• Flue gas system: requirements, values

Temperature class T120 T120

Type of connection

Flue gas mass ow at nominal heat load kg/h 109.0 157.0

Flue gas mass ow at lowest nominal heat load kg/h 18.8 29.5

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 44

Flue gas temperature at lowest nominal heat load and operation 40/30 °C °C 31 32

Maximum permitted temperature of the combustion air °C 50 50

Volume ow rate combustion air Nm3/h 81 117

Feed pressure total at the combustion air/ue gas line Pa 130 130

Maximum draught/depression at ue gas outlet Pa -50 - 50

1Data related to NCV. The boiler series is tested for EE/H-settings. With a factory setting of the Wobbe coe󰀩cient of 15.0 kWh/m3operation

at a Wobbe coe󰀩cient of 12.0 up to 15.7 kWh/m3is possible without new settings (readjustment might be necessary).

2Data related to NCV.

3Flow resistance boiler in mbar = Volume ow (m3/h)2x z factor; or see diagrams

4See also notes at “Engineering”.

10 4 217 214 / 02

TECHNICAL INFORMATION

3.3 Dimensions

UltraGas®(70,100) with connection set AS40-S/NT/HT and heating armature group HA40

(All dimensions in mm)

UltraGas®type (70) (100)

1. Heating ow / safety ow R1½″ R1½″

2. Low-temperature return R1½″ R1½″

2a. High-temperature return R1½″ R1½"

3. Feed-through duct for gas line

left or right

R ¾″ R ¾″

4. LAS ue gas supply air connection C100/150 C100/150

4a. Flue gas connection at the back (Option) E 100 E 100

5. Boiler controller

6. Condensate drain (left or right)

(incl. condensate drain (DN25) and 2 m

PVC passage hose inside Ø 19x4 mm

7. Electrical connection on the left or right

hand side

8. Drain

9. Connection set (option)

10. Heating armature group or charging group (option)

Fig. 07

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