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4.3

Flue gas connection, flue gas conduit

Due to the low flue gas temperature, condensate forms in

the flue gas line and wind protection equipment.

The following directives must be complied

with regarding the flue gas evacuation:

• DVGW (TRGI)

• ÖVGW

• SVGW/VKF

A flue gas temperature limiter as defined in

the aforementioned guidelines is installed in

the boiler.

The flue gas system must meet the following

requirements:

• Gas-tight

• Water-tight

• Acid-resistant

•

Approved for flue gas temperatures of up to

120 °C (T 120)

• Approved for overpressure

WARNING

The flue gas lines must be secured against

unwanted loosening of the plug connections.

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 flow of condensation

water towards the boiler. The whole flue 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 flue gas

conduit manufacturer.

• The values 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 air:

- In the case of room air-independent oper-

a tion (accessories optional) the air pipe

should be of the same dimension as the

flue gas line.

If the flue gas line diameter is greater than

the combustion air connection an individ-

ual calculation must be effected.

The following only applies for countries in

which the wall duct is allowed.

For C53 construction boilers, the air intake

opening for the combustion air must not be on

the opposing wall of the exhaust opening of

the flue gas line.

Guidance values for the flue gas pipe dimensions

can be found in the table below:

Basic rules:

• Height over sea level max. 1000 m.

The first 2 m of the flue gas line must be con

figured with the same dimension as the flue

gas connector, after which the size of the flue

gas system can be selected according to the

table below.

WARNING

Flue gas outlet for oversized flue gas lines.

- For exhaust systems from third-party sup-

pliers (air/flue gas line of versions C63/

C63x), a tolerance of +1/-0.5% of the flue

gas line nominal diameter DN specified in

the table must be upheld for the connection

points.

4 217 215 / 00

INSTALLATION

Содержание UltraGas 1000

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 57: ...57 4 217 215 00...

Страница 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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