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22

4 217 901 / 02

INSTAllATION

4.3 

Exhaust gas connection, exhaust gas 

line

Due to the low exhaust gas temperature, condensate 

forms in the exhaust gas line and wind protection equip-

ment.

§

The following directives must be complied 

with regarding the exhaust gas evacuation:

•  DVGW (TRGI)

•  ÖVGW

•  SVGW/VKF

A exhaust gas temperature limiter as defined 

in the aforementioned guidelines is installed 

in the boiler.

§

The exhaust gas system must meet the fol-

lowing requirements:

•  Gas-tight

•  Water-tight

•  Acid-resistant

•  Approved for exhaust gas temperatures of up 

to 120 °C (T 120)

•  Approved for overpressure

!

WARNING

The exhaust gas lines must be secured 

against unwanted loosening of the plug con-

nections.

Horizontal connecting pipes must be installed 

with an inclination of at least 50 mm per metre 

of their length installed in the direction of the 

boiler to allow free return of condensation wa-

ter towards the boiler. The whole exhaust gas 

system must be installed so that condensate 

can never collect at any point.

•  The cross sections and the maximum 

lengths are calculated with reference to dia-

grams or tables. The tables are available from 

the exhaust gas line manufacturer. The values 

for the calculation can be found in the table 

under chapter 3.3.

•  The exhaust gas conduit cross sections and 

lengths are calculated according to the spe-

cified technical data of the boilers.

•  Combustion air:

 - For airtight operation (optional accesso-

ries), the air duct should have the same 

dimensions as the exhaust gas line.

 - If the exhaust gas line diameter is larger 

than the combustion air line, an individual 

calculation must be done. 

Standard values for the exhaust gas line dimensions 

can be found in the following table:

Table with bases for calculation

•  Calculation based on max. 1000 m above sea level.

The first 2 m of the exhaust gas line must be 

configured  with  the  same  dimension  as  the 

exhaust gas connector, after which the size of 

the exhaust gas system can be selected ac-

cording to the table below.

Standard values for the exhaust gas line dimensions

Boiler

Smooth-walled exhaust gas line

Number of 90° bends (exhaust gas + supply air)

Type

Exhaust gas dim. mm

Designation

Total pipe length in m (exhaust gas + supply air)

UltraGas

®

 peak load boiler

Inner

DN

1

2

3

4

5 *

(1550)

402

400

50

50

50

50

Notice: The data contained in the “exhaust gas line dimensions” table are standard values. 

An exact cal cu lation for the exhaust gas line must be made on site.

*  If there are 5 bends or more, the delivery pressure for the supply air/exhaust gas line must be reduced by 30%.

With total pipe lengths exceeding 50 m, a separate calculation is necessary.

Summary of Contents for UltraGas 1550

Page 1: ...traGas 1550 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 flow temperature of up to 90 C1 They are designed for cont...

Page 2: ...s on the boiler room 21 4 2 1 Room air dependent installation 21 4 3 Exhaust gas connection exhaust gas line 22 4 4 Condensate drain 23 4 4 1 Design variants 23 4 5 Gas connection 24 4 6 Hydraulic con...

Page 3: ...out 39 6 6 2 Cleaning the combustion chamber and burner cylinder on the outside 40 6 6 3 Cleaning adjusting ignition and ionisation devices 41 6 7 Setting the gas quantity measuring the CO2 O2 and NOx...

Page 4: ...suspend it 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 p...

Page 5: ...spective 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 instruct...

Page 6: ...ensate from condensing boilers The regulations of the local water authorities could deviate from the rules in this worksheet Accident prevention regulations DGUV Regulation 1 Accident prevention regul...

Page 7: ...table Fig 01 UltraGas Type A A minimum B C D H H minimum 1550 450 1 1550 2 2090 200 2560 2455 3 1 If the room height is too low the dimension can be reduced See A minimum 2 Caution At A minimum the bu...

Page 8: ...destal and adjustable feet UltraGas 1550 with walled in pedestal without adjustable feet 1 Neutraliser condensate box 2 Condensate pump 3 Walled base 4 Adjustable feet 30 80 mm No refunds for pedestal...

Page 9: ...o the front and side see Fig 02 4 Push in front feet 3 and mount both front cover brackets 4 5 Using a winch raise the rear of the boiler 6 Remove both side beams 2 7 Push in the rear and centre feet...

Page 10: ...n Place the insulation mat 1 Fig 03 around the UltraGas 1550 boiler and attach with plastic straps 1a Fig 03 and strap fasteners 1b Fig 03 Tension springs 1c Fig 03 are used for additional fixing Do n...

Page 11: ...in detail the individual work steps of the mounting process for attaching the casings 1 Cable duct 2 Side wall front with special screws 3 Side wall back with long slot for suspension 4 Rear wall bot...

Page 12: ...box at the bottom on the side of the stud 6 Hold the electrical box 7 horizontal and tighten with the second stud 5 on the opposite side Fasten the safety cord 8 8a on the right and left Fold the ele...

Page 13: ...tting the pedestal ca sing 10 Fig 06 11 13 14 12 12 14 a 16 17 13 13 a 23 a Exhaust gas sensor b Mains cable c Condensate box if fitted d Water pressure sensor e Pressure switch B17 B18 f Flame monito...

Page 14: ...t condensate drain pipe 18 Fig 07 supplied with the boiler 18 a 18 19 Fig 07 12 Screw the right and left side walls 20 21 Fig 08 using the cap nuts already mounted on the boiler foot 13 Hook in the fr...

Page 15: ...ater side aluminium on the exhaust gas side The secondary heating surface is designed so that part of the water vapour contained in the exhaust gas conden ses and the heat of evaporation is utilised f...

Page 16: ...E CY MT DE l 1550 328 1550 kW PT 9 0 Erdgas H 18 mbar 37 PL II2ELw3P 20 25 20 37 IE IS LT NO 6 SVGW Nr SVGW No N SVGW N SVGW 11 013 4 max 4070 400V 41 230V W C kW TS 110 20 20 37 20 37 20 50 336 1685...

Page 17: ...ge V Hz 1x230 50 3x400 50 Electrical power consumption min max Watts 271 4111 Standby Watts 9 Type of protection IP 20 Permitted ambient temperature during operation C 5 40 Sound power level Heating n...

Page 18: ...0 528 284 345 205 205 12 1829 1480 316 1290 1800 1442 834 608 202 554 284 367 367 110 86 1847 1790 313 895 1550 1854 1494 858 636 204 578 294 417 417 218 198 1888 X y z 1 2 5 3 4 8 10 11 473 195 138 O...

Page 19: ...Fig 12 UltraGas peak load boiler Dimensions for partial load installation Type A B C D E F G H I Y K 1550 2244 1410 2032 1916 1780 Required minimum width of door and corridor for bringing in the boil...

Page 20: ...external ignition device can be connected RS 485 connection to TopTronic E UG RS 232 connection to the PC Number of start attempts maximum 4 Safety time 5 sec Pre ignition 5 sec Pre ventilation perio...

Page 21: ...e g washrooms drying rooms hobby rooms hairdressers CAUTION Halogen compounds can be created for ex ample by cleansing and degreasing agents solvents glue and bleaches Always make sure there is an ad...

Page 22: ...in the table under chapter 3 3 The exhaust gas conduit cross sections and lengths are calculated according to the spe cified technical data of the boilers Combustion air For airtight operation option...

Page 23: ...to the syphon via the cleaning hole Fig 13 Option 2 With neutralisation neutraliser box type KB 23 The syphon must be fitted and filled with water before commissioning The water can be filled into the...

Page 24: ...ure limiter DBmax Water pressure measuring device DBmax 50 Temperature regulator Temperature measurement device TBmax 20 Safety temperature limiter Additional safety equipment may be required dependin...

Page 25: ...enerator installed VF1 Flow temperature sensor 1 MK1 Pump mixer circuit 1 YK1 Actuator mixer 1 AF Outdoor sensor SF Calorifier sensor HCP Pump for heating circuit without mixer SLP Calorifier charging...

Page 26: ...heat generator the cir cuit diagram is supplied separately The country specific regulations must be adhered to WARNING The heat generator can only be de energised by disconnection from the mains e g a...

Page 27: ...be taken in the building 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 independe...

Page 28: ...AN bus line in parallel in adjacent buildings overbuildings or through under ground car parks If this cannot be avoided one or more of the following options should be selected to im prove the decoupli...

Page 29: ...heat generator 230 V min 2 5 mm2 with 16 A fuse unlimited m Electrical supply of the heat generator 400 V min 2 5 mm2 with 16 A fuse unlimited m Cables with line voltage from actuators min 1 0 mm2 unl...

Page 30: ...ng carefully and avo id contact with sharp edges Risk of injury for non expert personnel Initial start up maintenance and cleaning work are only allowed to be performed by trained specialist personnel...

Page 31: ...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 fill ing and replacement water Howe...

Page 32: ...f the deviation between the measured value and the nominal value 10 cor rect setting of pressure switch B17 and B18 Ensure that combustion air is supplied and exhaust gas is discharged In order to ens...

Page 33: ...s Compare measured value with the nominal measu red value in the following table the difference bet ween the measured value and the nominal measured value must be no more than 10 UltraGas Type Nominal...

Page 34: ...he exhaust gas line 3 Set the boiler to maximum output 100 4 Set the CO2 O2 value by turning throttle screw A The exhaust gas value must lie in the following range CO2 8 5 8 8 O2 5 9 5 5 by vol dry 5...

Page 35: ...eed 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 discussed with the screed layer othe...

Page 36: ...the active 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...

Page 37: ...orm reset See operating manual 6 2 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 Thoroughl...

Page 38: ...information see operating instructions Emission chapter Power limitation with 2 stage burner 0 to 50 1st stage 51 to 100 2nd stage REACTION to emission metering Go back after expiry of the time unit t...

Page 39: ...leaner compressed air water Preparation 1 Remove cover plate 2 Fold out step board s WARNING The heat generator must be de energised for maintenance Set the blocking switch to 0 and disconnect the hea...

Page 40: ...hat are appro ved for gas boilers having aluminium com ponents Spray the cleansing agent on undiluted Ring spanner screwdriver spray gun Preparation WARNING The heat generator must be de energised for...

Page 41: ...ect gas and electrical connections Put the boiler into operation Carry out exhaust gas measurement according to chap ter 5 8 If necessary adjust the setting Make a record of the measurement 9 3 Fig 30...

Page 42: ...the gas quantity measuring the CO2 O2 and NOx CO content in the exhaust gas see chapter 5 8 6 8 Cleaning the syphon Release the syphon and remove it from the boiler Rinse the syphon Check syphon seal...

Page 43: ...y de posits from the neutraliser box Any remaining neu tralisation granulate since it is harmless can be disposed of as domestic waste Refill the neutraliser box with new granules Neutraliser box KB 2...

Page 44: ...on pressure switch B18 Torque 25 Nm Position 2 and 3 Serto connecting nuts of connec ting cable on the double nipples Tightened by hand and then tightened by another 1 4 revolution with a spanner hold...

Page 45: ...C sec OEM 0 5 11 2AL 32779 Low flow temperature C OEM 60 12 2AM 32780 High flow temperature C OEM 80 13 2BC 32781 Exhaust gas temperature lock C OEM 110 14 2BD 32782 Exhaust gas temperature block C OE...

Page 46: ...shut off device after heat demand min HF 5 42 2HD 32810 Summer operation summer kick sec OEM 10 43 2IA 32811 Ignition 0 internal 1 internal external 2 external OEM 2 44 2KM 32812 Stepped modulation 0...

Page 47: ...47 4 217 901 02...

Page 48: ...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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