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UltraGas

®

 (575 - 1000)

UltraGas

®

 (575 - 1000)

UltraGas

®

 with shortened boiler feet

(All dimensions in mm)

UltraGas

®

 peak load boiler

Model

A

(125, 150)

1723 - 1783

(200 - 300)

1823 - 1883

(350 - 500)

1970 - 2030

(575 - 720) / H (720)

1986 - 2046

(850 - 1150) /  H (1000)

2039 - 2099

UltraGas

®

 peak load boiler

Model

A

(125, 150)

1711 - 1771

(200 - 300)

1811 - 1871

(350 - 500)

1958 - 2018

(575 - 720) / H (720)

1984 - 2044

(850 - 1150) / H (1000)

2037 - 2097

UltraGas

®

 peak load boiler

Model

A

(125, 150)

1721

(200 - 300)

1821

(350 - 500)

1968

(575 - 720) / H (720)

1994

(850 - 1150) / H (1000)

2047

UltraGas

®

 with walled-in pedestal and adjustable feet

UltraGas

®

 with walled-in pedestal without adjustable feet

1 

Neutraliser box

2 

Condensate pump

3 

Walled base

4 

Adjustable feet 20-80 mm

No refunds for pedestal sheets and adjusting 

feet!

8

4 217 215 / 00

INSTALLATION

Summary of Contents for UltraGas 1000

Page 1: ...esigned for continuously con trolled reduced operation in heating systems 1 See technical data UltraGas 125 1150 Condensing gas heating boilers for natural gas and liquid gas for modulating operation...

Page 2: ...on 24 4 2 2 Room air independent installation 24 4 3 Flue gas connection flue gas conduit 25 4 4 Condensate drain 27 4 4 1 Design variants 27 4 5 Gas connection 28 4 6 Hydraulic connection 28 4 6 1 To...

Page 3: ...manual operation settings 46 6 6 Cleaning 47 6 6 1 Cleaning the burner cylinder inside and out 47 6 6 2 Cleaning the combustion chamber and burner cylinder on the outside 48 6 6 3 Clean adjust ignitio...

Page 4: ...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...

Page 5: ...r 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 insta...

Page 6: ...n buildings Design of hot water systems NORM B 8130 Open water heating systems safety devices Norm B 8131 Closed water heating systems safety ex ecution and testing requirements NORM B 8133 Hot water...

Page 7: ...ight is too low the dimension can be reduced See A minimum 2 Caution At A minimum the burner can no longer be swivelled out completely Cleaning is made difficult 3 Feet can be shortened no pedestal ca...

Page 8: ...150 1711 1771 200 300 1811 1871 350 500 1958 2018 575 720 H 720 1984 2044 850 1150 H 1000 2037 2097 UltraGas peak load boiler Model A 125 150 1721 200 300 1821 350 500 1968 575 720 H 720 1994 850 1150...

Page 9: ...the boiler 7 Take out the side beam 3 Fig 02 at the rear to the side see Fig 02 8 Push in the rear feet and screw on 9 Remove the step board protection 4 Fig 02 Remove the securing pins 5 Fig 02 and...

Page 10: ...Fig 03 around the UltraGas boiler and attach with plastic straps 1a Fig 03 and strap fasteners 1b Fig 03 Tension springs 1c Fig 03 serve for additional fixing Do not overtighten the straps reduced in...

Page 11: ...ecure the service pedestal 7c Fig 07 in the folded up status with pin 1b Fig 02 3 Attach rear wall terminal plate 3 Fig 06 of the termi nal box using 4 screws 3a Fig 06 4 Remove the stud 4 Fig 06 on t...

Page 12: ...cial screws of the lower side walls and push in Secure the upper side walls using 4 self trapping screws 8b Fig 09 3 5 x 10 9 Hook in the upper rear walls 9 Fig 09 and fit the dummy cover 9a 10 Put on...

Page 13: ...ins cable Ignition cable Water pressure sensor Condensate box if fitted Boiler temperature sensor Models 850 1150 in two piece design Typ 125 720 in one piece design Fig 09 Flue gas sensor 10 10b 10a...

Page 14: ...rical connection Make the condensate drain or connection line according to sep arate instructions For UltraGas 575 1150 Fit condensate drain pipe 14 Fig 10 supplied with the boiler 14 Screw the right...

Page 15: ...850 1150 If you are using the variant with shortened boiler feet or you place the boiler on a concrete pedestal you will have to shorten the supplied conductors saw off at the watch or extend them Fig...

Page 16: ...that part of the water vapour contained in the flue gas condens es and the heat of evaporation is utilised for the heating circuit The gas burner is configured as a vertical burn er that can be swivel...

Page 17: ...ane 3 NCV 25 9 kWh m3 m3 h 4 5 5 4 7 3 9 1 10 9 Operation voltage V Hz 230 50 230 50 230 50 230 50 230 50 Control voltage V Hz 24 50 24 50 24 50 24 50 24 50 Electrical power consumption min max Watt 4...

Page 18: ...37 57 37 57 37 57 Gas connection value at 15 C 1013 mbar Natural gas E Wo 15 0 kWh m3 NCV 9 97 h m3 m3 h 32 6 37 7 42 4 47 1 54 2 61 3 Natural gas LL Wo 12 4 kWh m3 NCV 8 57 h m3 m3 h 38 0 44 49 5 55...

Page 19: ...as connection value at 15 C 1013 mbar Natural gas E Wo 15 0 kWh m3 NCV 9 97 h m3 m3 h 67 7 80 2 94 3 108 2 67 7 94 3 Natural gas LL Wo 12 4 kWh m3 NCV 8 57 h m3 m3 h 79 0 93 6 110 0 126 2 79 0 110 0 P...

Page 20: ...low 2 Low temperature return 3 Gas connection 4 Safety flow 5 High temperature return 6 Electrical connection on the left or right hand side 7 Drainage behind the front door 8 Flue gas outlet left or...

Page 21: ...027 1916 1483 1686 1375 2000 199 1410 458 Required minimum width of door and corridor for bringing in the boiler The following values are the calculated minimum values B K x L T B T x L K B Boiler wid...

Page 22: ...5 50 55 60 65 Volumenstrom m3 h Druckverlust mbar Volume flow m3 h Pressure drop mbar 0 5 10 15 20 25 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Volumenstrom m3 h Druckverlust mbar Volume flow m3 h Pressur...

Page 23: ...S 232 connection to the PC Number of start attempts maximum 4 Safety time 5 sec Pre ignition 5 sec Pre ventilation period 50 sec Follow on time for pump 230 VAC 5 min after a heat demand Fuses There a...

Page 24: ...oxygen for the op erating personnel to breathe Make sure there is an adequate supply of fresh air to the boiler room according to local regulations 4 2 1 Room air dependent installation Binding value...

Page 25: ...lues for the calculation can be found in the table under point 3 2 The flue gas conduit cross sections and lengths are calculated according to the specified technical data of the boilers Combustion ai...

Page 26: ...0 50 50 50 300 252 50 50 50 50 350 302 50 50 50 50 400 302 50 50 50 50 450 302 50 50 50 50 500 302 50 50 50 50 350 302 300 50 50 50 50 400 302 50 50 50 50 450 302 50 50 50 50 500 302 50 50 50 50 575 3...

Page 27: ...le Fig 17 Option 2 with neutralisation neutraliser box type KB 23 The condensate trap must be fitted and filled with water before commissioning The water can be filled into the condensate trap via the...

Page 28: ...ssure limiter DBmin Safety maximum pressure limiter DBmax Water pressure measuring device DBmax 50 Temperature regulator Temperature measurement device TBmax 20 Safety temperature limiter Make sure th...

Page 29: ...or heating a flow temperature limit thermostat must be installed Shut off devices to the safety equipment pressure expansion tank safety valve etc must be secured against unintentional closing Install...

Page 30: ...strip 4 Wear gloves Grip the switch control box by the left and right sides not by the underside Use cable ducts with separators The electrical connection must be connected in accordance with the appl...

Page 31: ...ng and on electri cal equipment to protect the units against overvoltage caused by lightning strikes The mains connection for the heating system must be designed as an independent electrical circuit N...

Page 32: ...uld be selected to im prove the decoupling Increase the spacing distance Route cables in a metal cable tray or metal cable duct that is enclosed on all sides and must be well earthed Use high quality...

Page 33: ...min 2 5 mm2 with 16 A fuse unlimited m Power supply of the heat generator 400 V min 1 0 mm2 with 10 A fuse unlimited m Cables carrying mains supply voltages from actuators min 1 0 mm2 unlimited m Cab...

Page 34: ...s Risk of injury for non expert personnel Initial start up maintenance and cleaning work are only allowed to be performed by trained specialist personnel or by Hoval customer service NOTICE Damage to...

Page 35: ...lie between 8 3 and 9 5 after 6 12 weeks of heating operation Filling and replacement water For a plant using Hoval boilers untreated drinking water is generally best suited as heating medium i e as f...

Page 36: ...quipped with a pressure monitoring device on the combustion cyl inder The combustion cylinder pressure monitoring de vice records the pressure in the combustion cylinder dur ing the boiler pre aeratio...

Page 37: ...5 mbar 3 mbar 300 3 1 mbar 2 1 mbar 4 mbar 350 2 9 mbar 2 1 mbar 4 mbar 400 5 mbar 4 mbar 7 5 mbar 450 7 mbar 5 mbar 10 mbar 500 8 4 mbar 6 mbar 12 5 mbar 575 10 7 mbar 7 mbar 15 mbar 650 13 8 mbar 9...

Page 38: ...menu on the control module The control automatically switches to normal oper ation after 20 min 2 Position emission meter in the flue gas line 3 Set the boiler to maximum output 100 4 Set the CO2 O2 v...

Page 39: ...Set the CO2 O2 value by turning throttle screw C The flue gas value must lie in the following range CO2 8 5 8 8 O2 5 9 5 5 by vol dry Factory setting throttle screw C Type 850 1000 12 7 mm 5 3 rotati...

Page 40: ...r propane liquid gas type Notes package insert 1 For a boiler which is already connected Close the gas valve Set the blocking switch to 0 and disconnect the heat generator from the mains e g main swit...

Page 41: ...of set gas type liquid gas stickers to the following places A sticker on the gas valve A sticker on the type plate 6 Attach sticker with the performance data for propane liquid gas on the type plate c...

Page 42: ...s required the stroke can be re duced using the setscrew For example 18 mm S t r o k e 2 0 m m Setscrew Fig 28 5 11 Handover to the operator The manufacturer of the unit is responsible for providing o...

Page 43: ...in per day falling Activate screed function 04 060 1 ON Start and stop screed drying NOTICE The graphic table shows the factory settings The time profile and the maximum flow temperature must be discu...

Page 44: ...ctive function phase the ACT temperature as well as the remaining run time Logging Please cut out the log and attach it to the controller during active screed function NOTICE The time profile and the...

Page 45: ...Deaeration 1 Open all radiator valves 2 Heat up the plant for at least half a day with a high flow temperature 3 Switch boiler off and wait for 5 minutes 4 Thoroughly bleed the system 6 3 Top up with...

Page 46: ...ivated if required Emission metering Setting at Home screen Main menu page 1 Emission For detailed information see operating instructions Emission chapter Power limitation with 2 stage burner 0 to 50...

Page 47: ...or from the mains e g main switch 3 Close main gas valve 4 Remove absorber hoods 5 Undo all burner plug in connections 6 Unfasten the earth wire 1 on the burner cylinder Figure 7 7 Disconnect gas conn...

Page 48: ...must be de energised for maintenance Set the blocking switch to 0 and disconnect the heat generator from the mains e g main switch 1 Close main gas valve 2 Remove absorber hood 3 Undo all burner plug...

Page 49: ...spray lance Clean and drive the boiler pan Clean the condensation trap Unscrew Clean Screw on Fill with water Clean the burner cylinder fabric with compressed air Connect gas and electrical connection...

Page 50: ...raubungen ist mittels Leckspray zu pr fen Beim Eindichten aller Gasamaturen darf mit dem Auftragen des Dichtungsmaterials fr hstens beim zweiten Gewindegang begonnen werden UltraGas 575 720 Aktiengese...

Page 51: ...condensation trap Release the condensation trap and remove it from the boiler Rinse the condensation trap Check condensation trap seal 1 for damage and replace if necessary CAUTION If the condensate...

Page 52: ...witch fuse Undo the bolts and withdraw the neutralisation box Only for neutralisation box of type KB24 Remove the condensate pump and clean the conden sate pump container Remove the neutralisation gra...

Page 53: ...60 60 60 60 12 2AM 32780 High flow temperature C OEM 80 80 80 80 80 80 80 80 13 2BC 32781 Lock out flue gas temperature C OEM 110 110 110 110 110 110 110 110 14 2BD 32782 Blocking flue gas temperatur...

Page 54: ...32809 Afterrun heating pump or shut off valve min HF 5 5 5 5 5 5 5 5 42 2HD 32810 Summer operation summer kick sek OEM 10 10 10 10 10 10 10 10 43 2IA 32811 Ignition 0 Internal 1 Internal External 2 E...

Page 55: ...EM 1 1 1 1 1 1 1 17 2DB 32785 Water pressure warning bar OEM 1 1 1 1 1 1 1 18 2DC 32786 Water pressure hysteresis bar OEM 0 2 0 2 0 2 0 2 0 2 0 2 0 2 19 2DD 32787 Blocking pressure min bar OEM 0 5 0 5...

Page 56: ...0 Internal 1 Internal External 2 External OEM 2 2 2 2 2 2 2 44 2KM 32812 Step modulation 0 off 1 increasing 2 increasing and decreasing HF 1 1 1 1 1 1 1 45 2LA 32813 Effect of the fault relay HF 2 2...

Page 57: ...57 4 217 215 00...

Page 58: ...ype Serial number Year of manufacture Place Date System installer System user Confirmation The user owner of the system herewith con rms that he has received adequate instruction in the operating and...

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