Technical information Installation instructions UltraGas ... · 4 210 264 / 04 Important notes 5 2.4.1 Germany § • DIN EN 12831 Heating systems in buildings - Methods for calculating

The floor standing gas condensing boiler UltraGas® are designed and approved for use as heat generators for hot water heating systems with a permissible flow tem-perature 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 40/30ºCand for natural gas30-UltraGas® (15) 3,1 - 15,5 kW30-UltraGas® (20) 4,0 - 20,2 kW30-UltraGas® (27) 5,0 - 27,2 kW30-UltraGas® (35) 5,8 - 35,7 kW30-UltraGas® (50) 8,3 - 50,1 kW

UltraGas® (15-50)Condensing gas heating boilersfor natural gas and liquid gasfor modulating operation

Hoval products must be installed and commissioned only by appropriately qualified experts. These instruc-tions are intended exclusively for the specialist. Electri-cal installations may only be carried out by a qualified electrician.

Subject to modifi cations | EN

Technical informationInstallation instructions

4 210 264 / 04 - 08/13

4 210 264 / 04 2 Table of contents

1. Safety instructions1.1 Key to symbols used .............................................................................................................................. 4

2. Important notes2.1 Acceptance of delivery ........................................................................................................................... 42.2 Scope of guarantee ................................................................................................................................. 42.3 Instruction manuals ................................................................................................................................ 42.4 Regulations, official permits .................................................................................................................. 42.4.1 Germany § ................................................................................................................................................ 52.4.2 Austria § .................................................................................................................................................... 52.4.3 Switzerland § ............................................................................................................................................. 5

3. Assembly3.1 Set-up, levelling ....................................................................................................................................... 6

4. Technical data4.1 Description of the boiler ......................................................................................................................... 74.2 Technical data ......................................................................................................................................... 84.3 Dimensions .............................................................................................................................................. 94.4 Space requirements .............................................................................................................................. 104.5 Boiler-Flow resistance .......................................................................................................................... 114.6 Brief description of the automatic firing device ................................................................................ 11

5. Installation5.1 Safety information ................................................................................................................................. 125.2 Boiler room requirements .................................................................................................................... 125.2.1 Room air dependent installation .............................................................................................................. 125.2.2 Room sealed installation ......................................................................................................................... 125.3 Flue gas connection and flue ............................................................................................................... 135.4 Condensate drainage ............................................................................................................................ 145.5 Design variants ..................................................................................................................................... 145.6 Fitting the condensate drain (standard design with siphon) ............................................................ 155.7 Fitting the neutralisation box (if fitted) ............................................................................................... 165.8 Fitting the condensate delivery pump ................................................................................................ 175.9 Fitting the neutralisation box and the condensate delivery pump ................................................... 185.10 Hydraulic connection ............................................................................................................................ 205.10.1 Customer-side requirements ................................................................................................................... 205.10.2 Hydraulic interconnection ........................................................................................................................ 205.11 Electrical connection ............................................................................................................................ 21

6. Commissioning6.1 Safety information ................................................................................................................................ 226.2 Filling with water ................................................................................................................................... 226.3 Water quality .......................................................................................................................................... 236.4 Bleeding the air from the gas line ....................................................................................................... 246.5 Switching on the system ...................................................................................................................... 246.6 Gas inlet pressure ................................................................................................................................. 246.7 Setting the gas flow rate CO2(O2) and measurement of NOx/CO content in the flue gas

(flue gas measurement) ........................................................................................................................ 256.8 Changing over to a different gas type ................................................................................................. 266.9 Handover to the user ............................................................................................................................ 266.10 Record - Activation of screed function ............................................................................................... 27

4 210 264 / 04 3Table of contents

7. Maintenance7.1 Safety information ................................................................................................................................ 297.2 Bleeding ................................................................................................................................................ 297.3 Water refilling ....................................................................................................................................... 297.4 Information for combustion controller/chimney sweep regarding emission monitor key ............. 307.5 Cleaning ................................................................................................................................................. 317.5.1 Cleaning the burner cylinder ................................................................................................................... 317.5.2 Cleaning the exterior of the combustion chamber and burner cylinder ................................................... 327.5.3 Cleaning/adjusting the ignition and ionisation device .............................................................................. 337.6 Setting the gas flow rate CO2(O2) and measurement of NOx/CO content in the flue gas (flue gas

measuring according to point 6.7) ..................................................................................................... 337.7 Clean siphon or neutralisation box .................................................................................................... 347.8 Maintenance of the Neutralisation equipment (if available) .............................................................. 357.8.1 Procedure for servicing the neutralisation installation ............................................................................. 35

8. Overview of settings8.1 Table of parameters .............................................................................................................................. 368.2 FIRING DEVICE UltraGas® (15-50) ....................................................................................................... 438.3 Fault Reporting overview TopTronic®T ................................................................................................ 488.4 Automatic firing device (Warning, Blocking, Lock-out) ..................................................................... 50

4 210 264 / 04 4 Safety instructions

1. Safety instructions

i The system shall not be put into opera-tion until all relevant standards and safe-ty 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 connect-ed to flue.

- Burner is preset (see point 6.7).

1.1 Key to symbols used

Tools:Shows the tools required for the following work.

Result:Shows the expected reaction to your ac-tion.

i Note:Provides important information.

Safety information:Indicates an immediate hazard to per-sons.

Safety information:Warning of dangerous electrical voltage.

Warning information:Indicates danger to machines and Instal-lations.

§ Provides important information.Reference to standards and regulations.

2. Important notes2.1 Acceptance of delivery

i 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 cor-recting the damage shall be taken over by the individual risk bearer.

2.2 Scope of guarantee

i The guarantee does not cover defects caused by: - non-observance of these instructions - non-observance of the operating in-structions

- 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 wa-ter quality

2.3 Instruction manuals

i A summary of all the instruction manuals relevant to this system can be found in the Hoval System User Guide! In excep-tional cases the instructions are kept with the respective components!

Additional sources of information: - Hoval catalogue - Standards and regulations

2.4 Regulations, official permits

i When installing and operating the sys-tem, the standards and regulations spec-i fied in point 2.4.1 to 2.4.3 must be com-plied with at all times.

4 210 264 / 04 5Important 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. Con-

struction, design, safety requirements, design and execution (for gas burner operation).

• DIN 18160 Domestic chimneys, requirements, de-sign 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 ap-plicable 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 boil-

er 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 au-thority, 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.

4 210 264 / 04 6 Assembly

3. Assembly3.1 Set-up, levellingThe boiler is fixed to wooden transport chocks. For transport up and down stairs, it is wise to leave these timbers in place under the boiler.

A special foundation plate for the boiler is not an es-sential, but it is recommended.

Space requirementFor further information on space requirements, see chapter 4.4.

The cleaning apertures must be easily accessible.

Installing and levelling the boilerRemove transport chocks. Store nuts and washers. Lift the boiler on one side and put grub screws of boiler base from the bottom through the slot of the boiler sockets. Fix boiler feet using hexagonal nuts (figure 01).

Using a spirit level, set the boiler in longitudinal and transverse direction and position it with a slight forward tilt. This is done by adjusting the nuts on the boiler feet. After this adjustment, the upper (locking) nuts on the boiler feet must be tightened.

Fig. 01

4 210 264 / 04 7Technical data

4. Technical data4.1 Description of the boiler

The Hoval UltraGas® is a low 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.

Feed tube on left and/or right side

High temperature returnon left and/or right side

Low temperature returnon left and/or right side

Gas safety and control devices

Combustion air fan

Electrode for ignitionand flame monitoring

TopTronic®T controller

aluFer® heat exchanger

Condensate collection tray

Flue gas connection

4 210 264 / 04 8 Technical data

4.2 Technical dataUltraGas® (15-50)

Type (15) (20) (27) (35) (50)

• Nominal output 80/60°C with natural gas 1 kW 3,0-14,0 3,8-18,2 4,5-24,5 5,2-32,2 7,5-45,2• Nominal output 40/30°C with natural gas 1 kW 3,3-15,5 4,3-20,3 5,0-27,2 5,8-35,7 8,3-50,1• Nominal output 80/60°C with liquid gas 2 kW 4,5-13,8 4,9-18,6 6,6-24,3 6,9-32,2 9,9-45,5• Nominal output 40/30°C with liquid gas 2 kW 5,0-15,3 5,5-20,7 7,3-27,0 7,7-35,7 10,9-50,5• Nominal load with natural gas 1 kW 3,1-14,5 4,0-19,0 4,7-25,4 5,4-33,3 7,7-46,9• Nominal load with liquid gas 2 kW 4,7-14,3 5,1-19,3 6,8-25,2 7,2-33,4 10,2-47,2

• Working pressure heating max./min. bar 3,0 / 1,0 3,0 / 1,0 3,0 / 1,0 3,0 / 1,0 3,0 / 1,0• Working temperature max.. °C 85 85 85 85 85• Boiler water capacity l 57 55 51 81 75• Flow resistance boiler 3 z-value 3,5 3,5 3,5 1,1 1,1• Min. water circulation l/h 0 0 0 0 0• Boiler Weight (without water content, incl. casing) kg 131 135 143 161 174

• Boiler efficiency at partial load 30% (according to EN 303) (related to net / gross calorific value)

107,1/96,5 106,9/96,3 106,7/96,1 106,7/96,1 106,9/96,3

• Standard efficiency 40/30°C % 109,5/98,6 109,5/98,6 109,5/98,6 109,5/98,6 109,5/98,6(net calorific value / gross calorific value) 75/60°C % 107/96,4 107/96,4 107/96,4 107,0/96,4 107,0/96,4

• Heat loss rate at 70°C Watt 160 160 160 220 220• Standard emission rate NOx. mg/kWh 25 26 28 31 29

CO. mg/kWh 11 11 10 11 4• Content of CO2 in the exhaust gas max./min. power % 9,0 / 8,8 9,0 / 8,8 9,0 / 8,8 9,0 / 8,8 9,0 / 8,8

• Dimensions See table of dimensions

• Connections Flow /ReturnInches R 1" R 1" R 1" R 1¼" R 1¼"Gas Inches Rp ¾" Rp ¾" Rp ¾" Rp ¾" Rp ¾"Flue gas Ø mm E80 E80 E80 E80 E80

• Gas flow pressure min./ max.Natural gas E/LL mbar 18-50 18-50 18-50 18-50 18-50Liquid gas mbar 37-50 37-50 37-50 37-50 37-50

• Gas connection value at 0°C / 1013 mbar:Natural gas E - (Wo = 15,0 kWh/m3) Hu = 9,97 kWh/m3 m3/h 1,5 1,9 2,6 3,3 4,7Natural gas LL- (Wo = 12,4 kWh/m3) Hu = 8,57 kWh/m3 m3/h 1,7 2,2 3,0 3,9 5,5Propane gas (Hu = 25,9 kWh/m3) m3/h 0,6 0,8 1,0 1,3 1,8

• 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• Min./Max. electrical power consumption Watt 24/46 24/64 24/58 29/98 30/122• Standby Watt 12 12 12 12 12• IP rating (integral protection) IP 20 20 20 20 20

• Acoustic capacity- Heating noise (EN 15036 part 1) (room air-dependent) dB(A) 57 61 66 62 60- Exhaust noise is radiated from the mouth

(DIN 45635 part 47) (room air-dependent/room air-independent)dB(A) 43 49 55 55 58

• Acoustic pressure level (depending on installation) 4 dB(A) 50 56 59 55 53

• Condensate quantity (Natural gas ) at 40/30°C l/h 1,3 1,8 2,4 3,1 4,4• pH value of the condensate pH ca. 4,2 ca. 4,2 ca. 4,2 ca. 4,2 ca. 4,2

• Value for flue calculationTemperature class T120 T120 T120 T120 T120

Flue gas mass flow kg/h 23 31 42 55,0 78,0Flue gas temperature at nominal output and operation 80/60°C °C 62 63 64 65 68Flue gas temperature at nominal output and operation 40/30°C °C 45 45 45 46 46Mass flow combustion air Nm3/h 17 23 31 41 58Feed pressure for combustion air/ flue gas system Pa 100 100 100 120 120Maximal Draft / negative pressure flue gas outlet Pa - 50 - 50 - 50 - 50 - 50

1 Data related to Hu. The boiler series is tested for EE/H-settings. With a factory setting of the Wobbe coefficient of 15,0 kWH/m3 operation at a Wobbe coefficient of 12,0 up to 15,7 kWh/m3 is possible (a readjustment may be necessary).

2 Data related to Hu.3 Flow resistance boiler in mbar = volume flow (m3/h)2 x z4 See also notes at „Engineering“.

• Boiler flow resistence see diagram.


4.3 Dimensions

(Dimensions in mm)

Type A B C D E F G H

UltraGas® (15-27) 1400 655 333 1320 1220 852 1184 144UltraGas® (35,50) 1640 895 573 1560 1460 930 1340 222

Type UltraGas® (15-27) (35,50)

1 Heating flow / safety flow R 1" R 1¼"2 Low temperature-return R 1" R 1¼"2a High temperature-return R 1" R 1¼"3 Gas connection Rp ¾" Rp ¾"4 Flue gas outlet DN80 DN805 Boiler control6 Condensate drain (left or right) incl.

siphon DN25 and 2 m PVC continuous-flow tube inner Ø 19 x 4 mm

7 Draining8 Electric cable entry point9 Sound absorber hood10 Heating armature group

or loading group (Option)

4 210 264 / 04 10 Technical data

4.4 Space requirements

(Dimensions in mm)

Boiler door incl. burner swings upward and to the left or outward.

A = minimum 150 mm *Burner service position front - boiler cleaning from the right

A = optimum 300 mm *- Burner service position left - boiler cleaning

from the front- Boiler can be placed with the right side di-

rectly against the wall- however, a minimum gap of 160 mm is re-

quired.

* without armature group, 500 mm with armature group

- The cleaning aperture must be easily accessible. - Ensure access to the area behind the boiler.


4.5 Boiler-Flow resistance

UltraGas® (15-27)

UltraGas® (35,50)

0

5

10

15

20

25

30

0 0,5 1 1,5 2 2,5 3 3,5 4 4,5 5

[m3/h]

[mbar]

m3/h = Volume flowmbar = Flow resistance

0

5

10

15

20

25

30

35

0 1 2 3

[m3/h]

[mbar]

4.6 Brief description of the automatic fir-ing device

The automatic firing device BIC960 of the UltraGas® only operates in conjunction with the heating controller TopTronic®T/UG. For this rea-son, the automatic firing device only needs to take care of the last remaining functions to ensure the correct operation of a modulating gas boiler.

The automatic firing device comprises the following functions: - PWM fan control (230V AC) - Modulating operation - Common electrode for ignition and flame monitor-ing (ionisation)

- LPG valve and boiler room fan controllable - Inputs forflow sensor 1flow sensor 2flue gas sensorwater pressure sensorsafety temperature limiter (not used)air pressure switch (not used)gas pressure switch

- Status outputs “fault” and “flame signal” - Allows connection of additional (external) ignition device

- RS 485 connection to TopTronic®T/UG - RS 232 connection to PC - Start attempts: maximum 4 - Safety period: 5 sec - Pre-ignition period: 5 sec - Pre-purging period: 50 sec - Follow-on time pump (230V AC): 5 min after heat demand

Fuses:The BIC 960 is fitted with 3 fuses:2AT Mains4AT Pump4AT Burner fan

Blowing of one of the two 4AT fuses securing the pump or the burner fan, respectively, will prevent the affected device from starting. A failure of the mains fuse of the automatic firing device is displayed on the TopTronic®T/UG by the failure message „DATABUS ERROR 70-6“. The failure appears when there is no communication between automatic firing device and TopTronic®T/UG.

4 210 264 / 04 12 Installation

5. Installation5.1 Safety information

Caution! Sharp edges pose a cutting hazard. Handle the cladding parts with care and avoid contact with sharp edges.

5.2 Boiler room requirements

§ - The boiler room must satisfy the ap-plicable local building regulations.

- The boiler room ventilation must satisfy the applicable local regulations in this regard.

- Boilers may not be installed in rooms containing halogen compounds which can be carried into the combustion air (e.g. wash rooms, drying rooms, DIY rooms, hair dresser rooms).

- Halogen compounds can originate, for example, from cleaning and degreas-ing agents, solvents, glue, and bleach-ing lyes.

Ensure that the required combustion air can flow un-hindered at all times. This is important for the correct operation of all the boilers installed therein and to protect the users from an oxygen depleted atmos-phere. An adequate fresh air supply meeting the lo-cal regulations must be provided.

5.2.1 Room air dependent installation• The applicable regulations do not normally provide

any specific data on the size of air intakes. They only require the pressure in the boiler room not to be below 3 N/m2.

• This means that for a rated thermal output of up to 50 kW an air intake with a cross section of at least 300 cm2 must be available.

• For rectangular apertures the aspect ratio should not exceed 1.5:1. If a grid is fitted on the air intake, a suitable allowance must be made to obtain an air intake cross section of 300 cm2.

5.2.2 Room sealed installationConfiguration based on a concentric flue system: • The suction air is supplied through a double-wall

flue system.• Ensure the boiler room is sufficiently ventilated.

Configuration using a separating piece (optional):

i The following must be observed when laying out the intake pipe: - If the intake opening is installed on the house facade near to a noise-sensitive area (e.g. bedroom windows, garden seating area, etc.) we recommend in-stalling a noise damper in the direct fresh air suction line.

- The intake opening must be easily ac-cessible.

- No chemicals or poisonous substances may be stored close to the intake open-ing

- The intake opening may not be installed beside fume extraction outlets or other venting outlets.

- Ensure that the intake aperture is free from any obstructions at all times (leaves, snow, ...)

- A safety grid must be installed on the suction opening on the outside wall.

4 210 264 / 04 13Installation

5.3 Flue gas connection and flueDue to the low flue gas temperatures, condensate forms within the flue. For this reason, Hoval gas heating boilers can not be connected to convention-al house chimneys.

i

§

The flue gas extraction system must comply with the following directives: - DVGW (TRGI) - ÖVGW - SVGW/VKF

Pursuant to the abovementioned regula-tions, a flue gas temperature limiter must be installed in the boiler.

i The flue gas system must meet the following requirements: - Gastight - Watertight - Acid-proof - Approved for flue gas temperatures of up to 120ºC (T 120)

- Approved for overpressure

i Unhindered back flow of condensate into the boiler can only be ensured if:The gradient of the horizontal connection elements is at least 50 mm/m..

i

§

Only one heat generator may be con-nected to the same chimney.If two heat generators are to be con-nected to the same chimney, the relevant regulations must be complied with.

i Cross sections and maximum lengths are calculated on the basis of graphs or tables. The tables can be obtained from the chimney or flue system manufacturer. The calculation values can be obtained from the table under point 4.2.

The flue gas conduit cross sections and lengths are calculated following the tech-nical data for the boiler.

The concentric supply air/exhaust sys-tem of the boiler can also be conducted horizontally backwards. The Hoval remo-delling set allows a remodelling on site.


Possibility 3 - see chapter 5.8• Siphon and condensate delivery pump• Without neutralisation, condensate discharge into

higher drain line.

Fig. 04

Possibility 4 - see chapter 5.9• Neutralisation box and condensate delivery pump• With condensate neutralisation - condensate dis-

charge into higher drain line.

Fig. 05

5.4 Condensate drainage

i The condensate drainage pipes on the boiler must be made of corro-sion resistant material. The following materials are suitable for condensate drainage:

PVC, PE, PP, ABS

The local regulations regarding con-densate drainage must be observed.

5.5 Design variantsPossibility 1 - see chapter 5.6• Execution with siphon• Condensate discharge into lower drain line.

Fig. 02

Possibility 2 - see chapter 5.7• Execution with neutralisation box• For condensate discharge in lower drain line, incl.

condensate neutralisation.

Fig. 03


5.6 Fitting the condensate drain (stand-ard design with siphon)

1. Remove front cover (1a, fig. 06). Release lateral locking bolt (1, fig. 06) (approx. ¼ turn to the left). Lift the front cover straight upwards and remove towards the front.

2. Remove base plate (2, fig. 06). Lift base plate straight upwards and remove.

3. Screw siphon (3) on the condensate tray (4) and tighten securely (connection must be sealed)!

4. Slide the siphon support (3a) un-der the siphon.

6. Fit drain (5) on siphon (3) and lead it outwards (optionally left or right side) through the aperture (5a).

7. Fit connecting line (5) to the drain line (2m hose enclosed with the boiler).

8. Reattach front cover (1a, fig. 06) and base plate (2, fig. 06).

Before commissioning, the siphon mustbe filled with water in order to preventflue gas leakage..

The condensate drain must be madeof corrosion-resistant material.

1

1a

Fig. 06

2

3

5

5a

4

3a

i If a neutralisation box is to be fitted, youwill find the further installation steps onthe next page.


5.7 Fitting the neutralisation box (if fitted)

1. Remove the neutralisation box from its pa-ckaging. Remove the front and rear cover of the neutralisation box.

2. Empty the neutralisation granulate (Neutroxid) into the neutralisation box and distribute evenly.

Neutralisation granulate (Neutroxide)

front

6

Fig. 07

3. Remove front cover (1a, fig. 08). Release lateral locking bolt (1, fig. 08) (approx. ¼ turn to the left). Lift the front cover straight upwards and remove it towards the front.

4. Remove base plate (2, fig. 08). Lift the base plate straight upwards and remove it.

1

1a

2

Fig. 08

5. Fit rear cover (9, fig. 09) of the neutralisation box.6. Fit jubilee clip (10, fig. 09) approx. 20mm from

the upper end of the hose and tighten slightly. The hose (10a, fig. 09) of the connection eccen-tric (10b, fig. 09) must be aligned towards the left.

109

10a

10b Fig. 09

7. Slide the neutralisation box (11, fig. 10) into the boiler until the hose of the siphon (6, fig. 07) is directly beneath the drain connection.

11Fig. 10


8. The hose of the siphon (11, fig. 11) can be easi-ly pushed onto the drain connection of the con-densate drip tray by lifting the neutralisation box (10a, fig. 9).

11Fig. 11

9. Slightly loosen the jubilee clip (10, fig. 12) and push it upwards. Firmly tighten the jubilee clip (connection must be sealed).

10Fig. 12

10. Fill the neutralisation box with water.11. Fit the front cover (13, fig. 13) of the neutralisa-

tion box.12. Fit base plate (2, fig. 13) and front cover

(1a, fig. 08).

2 13Fig. 13


Before commissioning the neutralisati-on box must be filled with water in order to prevent flue gas leakage.

5.8 Fitting the condensate delivery pump

1. Install the condensate delivery pump (14, fig. 14) as shown in the drawing.

14

Fig. 14


5.9 Fitting the neutralisation box and the condensate delivery pump

1. Fit condensate delivery pump. (14, fig. 15).

14

Fig. 15

2. Remove the neutralisation box from its pa-ckaging. Vorderen und hinteren Remove the front and rear cover of the neutralisation box.

3. Empty the neutralisation granulate (Neutroxide) into the neutralisation box and distribute evenly.

Neutralisation granules (Neutroxide)

front

6

Fig. 16

4. Remove front cover (1a, fig. 17). Release lateral locking bolt (1, fig. 17) (approx. ¼ turn to the left). Lift the front cover straight upwards and remove towards the front.

5. Remove base plate (2, fig. 17). Lift base plate straight upwards and remove.

1

1a

2

Fig. 17

6. Fit rear cover (9, fig. 18) of the neutralisation box.7. Fit jubilee clip (10, fig. 18) approx. 20mm from

the upper end of the hose and tighten slightly. The hose (10a fig. 18) of the connection eccen-tric (10b fig. 18) must be aligned towards the left.

109

10a

10bFig. 18


8. Slide the neutralisation box (11, fig. 19) into the boiler until the hose of the siphon (10a, fig. 18) is directly beneath the drain connection.

11Fig. 19

9. The hose of the siphon (10a, fig. 18) can be eas-ily pushed onto the drain connection of the con-densate drip tray by lifting the neutralisation box (11, fig. 20).

11Fig. 20

10. Slightly loosen the jubilee clip (10, fig. 21) and push it upwards. Firmly tighten the jubilee clip (connection must be sealed).

10Fig. 21

11. Fill the neutralisation box with water.12. Fit the front cover (13, fig. 22) of the neutralisa-

tion.13. Fit base plate (2, fig. 22) and front cover

(1a, fig. 17).

2 13Fig. 22


Before commissioning the neutralisati-on box must be filled with water in order to prevent flue gas leakage.


5.10.2 Hydraulic interconnectionWhen combining a calorifier with floor heating, a mixer needs to be installed. A minimum amount of circulating water is not required.

Regarding suitable hydraulic connections, please observe the notes in the planning documentation of the relevant Hoval sales company!

Example: UltraGas® (15-50) with calorifier and direct heating circuit

RS-T

AF

TopTronic T

WW

Dies ist einunerlaubterWeg!Gehen Sieeinen Schrittzurück oderlöschen Siedieses Shape!Sie haben dieMöglichkeit einneues Shapezu nehmen!!!hovhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalhovalh

T

KW

SFSLP

Dies ist einunerlaubter Weg!Gehen Sie einenSchritt zurück oderlöschen Sie diesesShape!Sie haben dieMöglichkeit einneues Shape zunehmen!!!hovhovalhhovalhovaalhovalho

UltraGas(35-90)

P

NT

HT

NT

HT

TT

MK1

MYK1

B1VF1

5.10 Hydraulic connection

The boiler comprises the following safety equip-ment, in accordance with EN 12828:2003: - Minimum pressure limiter DBmin - Safety maximum pressure limiter DBmax - Hydraulic pressure monitor DBmax + 50% - Thermostat - Temperature monitor TBmax + 20% - Safety temperature limiter

i To achieve an optimal efficiency, ensure that the return pipe is properly connect-ed.

1

2

Fig. 23

1 High temperature return (e.g. venting group or calorifier)

2 Low temperature return (e.g. underfloor heating)

5.10.1 Customer-side requirementsA pressure expansion tank adapted to the heating system, water volume and static height. Make sure to close off unused connec-

tors tightly.

AF Outside sensor 1VF1 Flow sensor 1SF Calorifier sensorB1 Flow temperature monitor (optional)

MK1 Pump mixing circuit 1SLP Calorifier - loading pump

YK1 Actuator mixer 1


5.11 Electrical connection

i - The electrical connection must be car-ried out by an approved electrician.

- The connection diagram is located within the boiler control box.

- The electrical circuit diagram is sup-plied separately.

The following applies to Austria and Germany:A connection diagram is provided with the boiler control unit.The power supply must be fitted with an omnipolar isolation switch with a contact gap of at least 3 mm.

The following applies to Switzerland:The electrical connections must comply with the system-specific electrical circuit diagram!

Safety measures for EMC installation Control units with their own mains connection re-quire the mains, sensor and bus cables to be routed separately.

i Cable trunking with dividing parti-tions should be used.

The mains connection for the heating system (boil-er-control panel-control unit) must be configured in form of an independent electric circuit.No other electrical loads (light, power outlets, ...) may be connected to that electric circuit.The external sensor may not be installed close to transmitters or receivers (garage door openers, am-ateur radio aerials, radio alarm systems,...).

Recommended conductor cross sections:

Conductor type Cross section Length

Mains voltage cables min. 1,0 mm² unlimited m

Extra-low voltage cables(sensors)

min. 0,5 mm² max. 50 m

Data bus cables (screened) 2 x 0,6 mm² max. 100 m

Procedure to remove the front covering panel1. Remove front cover (1, fig. 23a), after first releas-

ing the lateral locking bolt (1a) (turn approx. ¼ turn to the left and pull out as far as the stop). Lift the front cover (1) straight upwards and remove towards the front.

2. Remove lower front cover (2), after first releasing the lateral locking bolt (2a) (turn approx. ¼ turn to the left and pull out as far as the stop). Slightly raise the lower front cover (2) and remove to-wards the front.

3. Remove the locking screw (3a) on the right.4. Lift the switch control box (3) and fold it out.5. Cable entry refer to the Technical Datasheet (Di-

mensions, point 4.3, item 8).

The electrical connection is to be made in accordance with the diagram supplied.

1

1a

2

2a

3a

3

Bild 23a

Fig. 24

4 210 264 / 04 22 Commissioning

6.2 Filling with water

Filling of the heating system may only be carried out by qualified personnel.

The European Standard EN 14868 and the Directive VDI 2035 must be observed (see point 6.3).

1. Open the isolating valves in the flow and return lines.

2. Connect the water hose to the filling tap.3. Fill the heating system slowly.

i Monitor the water level on the manometer.

i - Use only chemical additives with sup-pliers’ confirmation of their safe usage.

- Anti-freeze additive may be filled up to a maximum of 40% and to a minimum according to the manufacturer’s infor-mation.

- The anti-freeze or anti-corrosion agent concentration must be checked at least once per year.

- The identical product must be used when replenishing the anti-freeze or anti-corrosion agents.

- When transferring to operation without anti-freeze or anti-corrosion agents, the system is to be thoroughly flushed through several times before refilling with water.

6. Commissioning

i - After filling the system with water, bleed any air and check for water leaks.

- Before putting the boiler into opera-tion, the siphon and neutralisation tank needs to be filled with water.

- When starting up the system for the first time, the correct operation of all the safety and control devices must be verified.

- The operation and maintenance of the system must be explained to the user in detail.

- he combustion air needs to be filtered in very dusty environments.

- The gas flow pressure must be checked and the CO2 value set correctly.

6.1 Safety information

Caution! - Sharp edges pose a cutting hazard. - Handle the cladding parts with care and avoid contact with sharp edges!

- Danger of injury for unqualified person-nel.

- Maintenance and cleaning work may only be performed by trained person-nel or by the Hoval Customer Service.

i Vorsicht! - Danger of damaging the system by fill-ing it with incorrect liquids.

- Water filled into the system must have drinking quality.

4 210 264 / 04 23Commissioning

6.3 Water quality

Heating Water

The European Standard EN 14868 and the directive VDI 2035 must be observed.

In particular, attention must be paid to the following stipu-lations:• Hoval boilers and calorifi ers are designed for heating

plants without signifi cant oxygen intake (plant type I ac-cording to EN 14868).

• Plants with - continuous oxygen intake (e.g. underfloor heating systems without diffusion proof plastic piping) or

- intermittent oxygen intake (e.g. where frequent refill-ing is necessary)

must be equipped with separate circuits.

• Treated fi lling and replacement water must be tested at least 1x yearly. According to the inhibitor manufacturer‘s instructions, more frequent testing may be necessary.

• A refi lling is not necessary if the quality of the heating water in existing installations (e.g. exchange of boiler) conforms to VDI 2035.The Directive VDI 2035 applies equally to the replace-ment water.

• New and if applicable existing installations need to be adequately cleaned and fl ushed befor being fi lled. The boiler may only be fi lled after the heating system has been fl ushed!

• Parts of the boiler / calorifi er which have contact with water are made of ferrous materials and stainless steel.

• On account of the danger of stress cracking corrosion in the stainless steel section of the boiler the chloride, nitrate and sulphate content of the heating water must not exceed 50 mg/l.

• The pH value of the heating water should 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 fi ll-ing and replacement water. However, as not all drinking water is suitable for use as as fi lling and replacement water the water quality must fulfi l the standard set in VDI 2035. Should the mains water available not be suited for use then it must be desalinated and/ or be treated with inhibitors. The stipulations of EN 14868 must be observed.

• In order to maintain a high level of boiler effi ciency and to avoid overheating of the heating surfaces the values given in the table should not be exceeded (dependent on boiler performance ratings - for multi-boiler plants rating of smallest boiler applies - and on the water con-tent of the plant).

• The total amount of fi lling and replacement water which is used throughout the total service life of the boiler must not exceed three times the water capacity of the plant.

Maximum filling capacity based on VDI 2035Total hardness of the fi lling water up to ...

[mol/m3] 1 <0,1 0,5 1 1,5 2 2,5 3 >3,0f°H <1 5 10 15 20 25 30 >30d°H <0,56 2,8 5,6 8,4 11,2 14,0 16,8 >16,8e°H <0,71 3,6 7,1 10,7 14,2 17,8 21,3 >21,3~mg/l <10 50,0 100,0 150,0 200,0 250,0 300,0 >300Conductance 2 <20 100,0 200,0 300,0 400,0 500,0 600,0 >600Boiler size of the individual boiler maximum fi lling quantity without desalination

to 50 kW NO REQUIREMENT 20 l/kW

1 Sum of alkaline earths2 If the conductance in µS/cm exceeds the tabular value an analysis of the water is necessary.


6.4 Bleeding the air from the gas line

§ Observe the relevant regulations when bleeding the gas line

1. Open the gas shut-off valve.2. Bleed the air up to the gas armature.

6.5 Switching on the system

1. Switch on the main switch on the boiler.

6.6 Gas inlet pressure

i The gas flow may only be adjusted and the heating system therefore started up, if the minimum flow pressure values are achieved (see point 6.7 Adjusting the gas flow).

The minimum flow pressure in the con-nector pipe must reach the following val-ues:Natural Gas 18 to 50 mbar Liquid gas 37 to 50 mbar


7. Measurement of NOx and CO content. The measured values must meet the limiting values prescribed by the regulations. Values exceeding these reference values are an indication of faulty burner setting, gas burner or heat exchanger contamination or gas burner defect.

If the limiting values prescribed by the re-gulations are exceeded, the boiler must be put out of operation and the corre-sponding measures for repair work must be initiated. .

8. Press the emission monitoring key.

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

TorxT40, screwdriver, size 5 and/or allen key 4 mm

The Honeywell multiple actuator allows measuring the inlet pressure on meas uring nipple A.

A Measuring nipple gas inlet pressure B Measuring nipple gas outlet pressure C Gas choke D Offset screw

AB

C

D

Fig. 25

Flow setting operation:

i To set the flow on the venturi, both flue gas values need to be controlled. e.g.: Set upper value - control lower value - value incorrect - set lower value - control upper value - ...

1. Press the emission monitoring key. i After 20 min. the controller switches over to

normal operation automatically.2. Position the emission monitor in the flue gas

duct.3. Set the boiler to maximum output (100%).4. Set the CO2 (O2) value by turning the choke-

screw C. . i The content in the flue gas must be be-tween CO2 = 8.5 - 8.8 (O2 = 5,9 - 5,5) vol% (dry).

5. Set the boiler to minimum output (1%)6. Set the CO2 (O2) value by turning the choke screw D.

i The content in the flue gas must be between CO2 = 8.5 - 8.8 (O2 = 5,9 - 5,5) vol% (dry).


5. Set the CO2 (O2) content to CO2 = 9.9 - 10.2 (O2 = 5,9 - 5,5) vol% (dry). (flow setting operation as described in section 6.7)

6. Install the boiler hood.

6.9 Handover to the user

i The manufacturer of the unit is respon-sible for providing operating instructions for the complete system.

The following must be carried out during handover to the user: - Provide instructions in the operation and mainte-nance of the system.

- Handover of all the instruction manuals and docu-ments.

- Explain to the user that these instructions must be kept with the system at all times.

- Written confirmation of receipt of instruction. - Handover protocol see page 52.

6.8 Changing over to a different gas type

i This changeover may only be carried out by an authorised specialist or by the Hov-al Customer Service.

Changeover from natural gas H to natural gas LAn emission check is required when changing to a natural gas of lower calorific value; a correction of the CO2 (O2) value may be necessary (see point 6.7 Setting the gas flow rate)

Changeover from natural gas to liquid gasThe applicable local provisions for operating a boiler with liquid gas are to be complied with.VKF, DVGW, ÖVGW

i Changeover only possible by means of a conversion kit.

Ensure that the fuel type in the measur-ing device has been set correctly

The conversion kit contains: - gas pressure switch. - yellow sticker.

Removing the gas pressure switch:1. Close the gas shut-off valve.2. Set the main system switch to “0”.3. Take off the boiler hood.4. Remove the gas pressure switch.

Install the liquid gas pressure switch:

Ensure that the liquid gas line is free of any air. Any air in the liquid gas line can have a negative influence on the flue gas values.

1. Install the liquid gas pressure switch. i Set the AMP flat pin to position 1 and 3.

2. Affix the yellow sticker on the boiler name plate.3. Open the gas valve.4. Set the main system switch to “1”.

Adjust fan speed of rotation according to the list of parameters “Liquid gas adapta-tions“.


6.10 Record - Activation of screed function

Required parameter settings:Parameter level Par. No Setting Description

- Key DK ............... Activate heating characteristic curve, above 0 = OFF, e.g. ~ 0.8 for FBH

UNMIXED CIRC. 13 ...............°C Maximum fl ow temperature to be set

UNMIXED CIRC. 161 2 3

Screed program to be set (for description see following page)1 Function heating (duration: Starting day + 7 days)2 Surface-ready heating (duration: Starting day + 18 days)3 Function and surface-ready heating (duration: Starting day + 25 days)

HEAT GENER. 4 ...............°C Max. H-Gen temperature to be set, set as for max. fl ow temperature (after termination of screed function reset max. temperature to the value required).

If the screed function is activated for the unmixed circuit, all the other circuits (MC, DHW) are switched off.

In alternation with the basic display of the controller, the activated screed heating is displayed giving some information about the remaining term in days „screed - 18“.

RecordScreed heating activated by: ............................................Screed heating activated on: ............................................Screed heating ends on: ..................................................

..........................................................................................Date and signature

Required parameter settings:Parameter level Par. No Setting Description

MIX.VALVE (1 or 2) 13 ...............°C Maximum fl ow temperature to be set

MIX.VALVE (1 or 2) 161 2 3

Screed program to be set (for description see following page)1 Function heating (duration: Starting day + 7 days)2 Surface-ready heating (duration: Starting day + 18 days)3 Function and surface-ready heating (duration: Starting day + 25 days)

Direct heating circuit (possible only with H-Gen without minimum H-Gen temperature - e.g. condensing boiler)

Start

PRESS

HC level Parameters 13,16

H-GEN level Parameter 4

Characteristic heating curve

Enable HC

Activate Installer level (Code entry)

> 3 sec: Access to

level

Select / Confi rm Set Confi rm End / Exit

Heating circuit selection for screed function and necessary parameter settings Mixing circuit 1 Mixing circuit 1

Start

PRESS

MC1/MC2 level Parameters 13,16

Activate Installer level (Code entry)

> 3 sec: Access to

level

Select / Confi rm Set Confi rm End / Exit

Cross where applicable;cut out record and fasten to the control during the active screed function.

Minimum requirements for the activation of the screed function: Minimum age cement screed 21 days Minimum age calcium sulphate screed 7 days Flow temperature monitor installed and connected

For newly laid screed - see „Recommendation of the Federal Association of Radiant Panel Heating“.


Parameter 16 „Screed function“(Parameter HC, MC1 or MC2)

Example:Maximum fl ow temperature 40°C

1 Function heating

- On the starting day and on the 1st day constantly at 25°C, on each further day the demand value rises by 5°C until the maximum fl ow temperature is reached. Subsequently the temperature is lowered again in the same gradations until the low point of 25°C is reached.

Example: Set fl ow maximum temp.: 40°C Starting day + 1st day: 25°C 5th - 15th day: constant heating with the max. fl ow temperature 2nd day: 30°C 16th day: 35°C 3rd day: 35°C 17th day: 30°C 4th day: 40°C 18th day: 25°C

2 Surface-ready heatingStarting day + 18 days

- Combination of 1 function heating and subsequently 2 surface-ready heating

3 Function heating and surface-ready heatingStarting day + 25 days

START 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 t [TAGE]

55

45

35

25

Funktionsheizen und Belegreifheizen

START 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 [TAGE]

55

45

35

25

3=Funktionsheizen und Belegreifheizen

T [°C]VLSol

3 = Function heating and surface-ready heating

START DAYS

- On the starting day and for the three following days at 25°C constantly- Subsequently for 4 days at the set fl ow maximum temp., but limited to a maximum of 55°C

Starting day + 7 days

START 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 t [TAGE]

55

45

35

25

Funktionsheizen

START 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 TAGE]

55

45

35

25

1=Funktionsheizen

maximal 55°C einstellbar!

T [°C]VLSol

1 = Function heating

START DAYS

START 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 t [TAGE]

55

45

35

25

Belegreifheizen

START 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 [TAGE]

55

45

35

25

2=Belegreifheizen

T [°C]VLSol

2 = Surface-ready heating

DAYSSTART

55°C maximum set level!

4 210 264 / 04 29Maintenance

7. Maintenance

Missing or faulty cleaning and main-tenance may cause damage to the in-stallation. - The heating installation must be sur-veyed and cleaned once a year.

- If required, installation maintenance must be carried out. Defects must be remedied immediately in order to pre-vent damages to the installation!

7.1 Safety information

Sharp edges pose a cutting hazard.Handle the cladding parts with care and avoid contact with sharp edges.

Danger of injury for unqualified per-sonnel.Maintenance and cleaning work may only be performed by trained personnel or by the Hoval Customer Service.

After repair work respectively exchang-ing boiler parts, a flue gas measurement according to point 6.7 must be carried out imperatively.

7.2 Bleeding

1. Open all radiator valves.2. Heat up the system for at least half a day with a

high flow temperature.3. Turn off the boiler and wait 5 minutes.4. Bleed all the air form the system.

7.3 Water refilling

The European Standard EN 14868 and the Directive VDI 2035 must be ob-served (see point 6.3).

i The systems warns when the water pres-sure falls below 1 bar and the boiler out-put is reduced to 50%. If the water pres-sure falls below 0.5 bar, the boiler is set automatically to a fault state.

The system must be refilled with water when the pressure falls below the minimum system pressure:

1. Connect the filling hose to the water supply2. Remove the air from the filling hose3. Connect the filling hose to the filling and draining

cock4. Top up with water (see point 6.2)

4 210 264 / 04 30 Maintenance

All other control elements of the control unit are described in the operating instructions.The emission monitor key can also be used to change over to manual operating mode.

Emission monitor key / Manual operation To protect under fl oor heating systems against invalid overheating during emission monitoring / manual opera-tion it is necessary to implement ap-propriate safety measures (e.g. safety temperature limiter with pump switch-off). The duration of the emission moni-toring is limited to 20 minutes and shall be restarted, if necessary.

Scalding hazard due to hot water tem-perature, since the hot water tempera-ture can exceed the temperature set-point!

Emissions metering

%%

Immediate end

PRESSSHORTLY

Output reference / actual valueModulation display

REACTIONS for emissions metering- Time unit automatically 20 min. – thereafter reverts- Boiler temperature - > maximum temperature restriction- The heating circuits and the calorifi ers regulate to their maximum temperature

(at the direct heating circle only, if the warm water mode of operation is adjusted to parallel operation)

Manual operation

Immediate end

PRESS> 5 seconds

REACTIONS for manual operation- Set reference boiler temperature with button!- All heating pumps ON- Mixer without current - manual setting necessary!- Note the maximum permissible temperature of the fl oor heating!- The hot water temperature reaches the set DHW maximum temperature

(expert level standard 65°C).

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

4 210 264 / 04 31Maintenance

7.5 Cleaning

i The boiler may only be cleaned by an au-thorised technician or by the Hoval Cus-tomer Service.

i The Hoval gas heating boiler should be cleaned and maintained once every year.

If the Hoval gas heating boiler was in operation dur-ing the building phase, it will be necessary to carry out a check for cleanliness. If the boiler is dirty, clean it.

7.5.1 Cleaning the burner cylinder

i The burner cylinder must be cleaned if visible contamination exists (such as de-posits, e.g. builder’s dust)

Adjustable spanner, screw driver, open end spanner SW 8, vacuum cleaner, compressed air, water.

Preparation:1. Set the main switch on the boiler control unit

to “0”.2. Close the main gas valve.3. Remove the sound insulation covers.4. Disconnect all the burner connector plugs.5. Pull the corrugated hose (1, fig. 26) off the ven-

turi tube on the burner (if present).6. Disconnect the earthing cable (2, fig. 27) from

the burner cylinder.7. Disconnect the gas connection from the gas ar-

matures.8. Unscrew the fan with the gas mixing unit in place

(3, fig. 27).

Removal and cleaning: Caution, burn hazard

9. Safety gloves must be worn when removing the burner cylinder.

10. Lift the burner cylinder out (4, fig. 28).11. Clean the premix burner with compressed air in-

side and out, or rinse thoroughly with water.12. Remove dust and dirt particles with a vacuum

cleaner (fig. 29).

Reassembly:13. Replace the gasket on the gas connection14. Reassemble the burner in reverse order.

15. Check for leaks16. Carry out a flue gas measuring according to

point 6.7.

1

Fig. 26

2

3

Fig. 27

4

Fig. 28

Fig. 29

4 210 264 / 04 32 Maintenance

7.5.2 Cleaning the exterior of the combustion chamber and burner cylinder

Warnung!Chemical burn hazard through cleaning agents. - Safety gloves and eye protection must be worn when using cleaning agents.

- Observe the information on the original packaging.

Caution! - The system can be damaged when us-ing incorrect cleaning agents.

- Use only cleaning agents approved for gas boilers with aluminium compo-nents.

i Spray on the cleaning agent undiluted.

Open end spanner SW 17, adjustable spanner, screw driver, spray gun

Preparation:1. Set the main switch on the boiler control unit

to “0”.2. Close the main gas valve.3. Remove the sound insulation cover.4. Disconnect all the burner connector plugs.5. Pull the corrugated hose off the venturi tube on

the burner (if present).

Opening the combustion chamber:6. Loosen the cap nut SW177. Lift and turn the burner with the boiler door side-

ways (8, fig. 30)8. Remove the neutralisation box and siphon

i (For maintenance of the neutralisation unit see point 7.7 Neutralisation unit)

8

Fig. 30

Cleaning:9. Spray the combustion chamber and aluFer

tubes (10, fig. 31). i The best results are obtained with a spray

gun with a suitable wide jet nozzle (fan or coni-cal jet). We recommend, e.g.: Desoxin

10. Leave the applied cleaning agent to react as in-structed by the manufacturer.

11. Then remove the contamination on the combus-tion chamber and aluFer® tubes by spraying them with clean water. i Use a powerful jet.

12. Repeat the procedure in case of stubborn dirt.13. Flush clean the bottom tube plate.

i Use an angled spray lance.14. Clean and dry the boiler tray.

15. i Clean the siphon see point 7.7:

- screw it off - clean it - screw it back on - fill it with water

16. Clean the fabric material in the burner cylinder with compressed air.

17. Reconnect the gas and electrical connections.18. Place the boiler into operation19. Carry out a flue gas measuring according to point

6.7. Correct the settings, if necessary. Complete a measurement record.

10

Fig. 31

4 210 264 / 04 33Maintenance

7.5.3 Cleaning/adjusting the ignition and ioni-sation device

iThe distance between the ignition elec-trode and the burner cylinder must be approx. 4 mm.

Fine sanding paper, long-nosed pliers, blowtorch, compressed air.

Preparation:1. Set the main system switch of the boiler con-

trol to “0”.2. Open the combustion chamber as described un-

der point 7.5.2.

Cleaning:3. Sand the ignition and ionisation device with fine

sanding paper.4. Clear the sanding dust.

Adjustment:5. Heat the ignition electrode at the kink with the

blowtorch until it glows red (5, fig. 32).6. Bend the ignition electrode with the long-nosed

pliers (6, fig. 33). i Distance to the burner cylinder 4 mm

Reassembly:7. Replace the gasket at the gas connection.8. Reassemble the burner in reverse order.9. Check for leaks

5

Fig. 32

6

Fig. 33

7.6 Setting the gas flow rate CO2(O2) and measurement of NOx/CO content in the flue gas (flue gas measuring ac-cording to point 6.7)

i

Maintenance should be carried out at least every second year or after con-sumption of the neutralisation granulate (check pH value with litmus paper, if nec-essary).

4 210 264 / 04 34 Maintenance

7.7 Clean siphon or neutralisation box

1. Set the main system switch to “0”.2. Remove the front panel (1, fig. 34).3. Unscrew resp. remove (according to execution)

siphon (Fig. 34, pos. 3), siphon bottom part (2) , siphon support (2a) or neutralisation box (Fig. 35, pos. 4).

4. Rinse siphon.5. Check if siphon gaskets (3) are not damaged,

replace if necessary.

Danger: flue gas escaping through the siphon can endanger lives (poi-soning).The siphon (fig. 34, pos. 2) must always be filled with water. The condensate drain line must not be soiled or blocked. • Before replacing the siphon, fill it with

water.• Check whether the condensate drain

line is soiled/blocked.

1

2

3

Mount hose forwet cleaning

Design with condensate discharge

2a

Fig. 34

Design with neutralisation box (if fitted)

1. Set the main system switch to “0”.2. Remove the front panel (1, fig. 35).3. Clean the neutralisation box (4 - if fitted) ac-

courding to chapter Kapitel 7.8.

1

4

Mount hose forwet cleaning

Fig. 35

4 210 264 / 04 35Maintenance

i Maintenance should be undertaken at least every second year, or after the neu-tralisation granules are exhausted (check the ph-value if appropriate with litmus pa-per test).

Neutralisation granulate for refi lling can be ordered from Hoval under the following item no.:

• 1 pack (3 kg) neutralisation granulesPart no. 2028 906

Procedure for servicing the neutralisation installation• Set the main control switch to "0".• Remove the front cover.• Undo the bolts and withdraw the neutralisation box.• Remove the neutralisation granules and any deposits

from the neutralisation box. Any remaining neutralisa-tion granulate, since it is harmless, can be disposed of as domestic waste.

• Refi ll the neutralisation box with new granules.

Attach the neutralisation box cover mak-ing sure that it is tight-closing.

• Push the neutralisation box back in.

Before putting back into service, the si-phon and the neutralisation box must be fi lled together with water.

The water can be poured through the cleaning aperture into the neutralisation box and the siphon.

Neutralisation granulesSiphon7.8 Maintenance of the Neutralisation

equipment (if available)

4 210 264 / 04 36 Overview of settings

Designation FactoryRegulator Setting range /

Setting values10 20 30 40 50

Type of device:

DHW:

SW:

Address:

Surface operation Key :

Heating curve HC OFF OFF, 0,20 .... 3,5

Heating curve MC1 1,0 OFF, 0,20 .... 3,5

Heating curve MC2 1,0 OFF, 0,20 .... 3,5

Daytime target temperature HC *) 20°C 5 .... 30°C *)

Daytime target temperature MC1 *) 20°C 5 .... 30°C *)

Daytime target temperature MC2 *) 20°C 5 .... 30°C *)

Night-time target temperature HC *) 16°C 5 .... 30°C *)

Night-time target temperature MC1 *) 16°C 5 .... 30°C *)

Night-time target temperature MC2 *) 16°C 5 .... 30°C *)

DHW target temperature 50°C 5 ... DHW-Max.

*) Depending on the setting of system parameters 03 OPERATING MODE

Remote operation/room stationsType Heating circuit Address HW SW

8. Overview of settings8.1 Table of parameters

4 210 264 / 04 37Overview of settings

Table for Time programs

DHW circuitTime program P1 Time program P2 Time program P3

Tag Cycle 1 Cycle 2 Cycle 3 Cycle 1 Cycle 2 Cycle 3 Cycle 1 Cycle 2 Cycle 3

from to from to from to from to from to from to from to from to from to

Mo

Tu

We

Th

Fr

Sa

Su

Direct circuitTime program P1 Time program P2 Time program P3



Mo

Tu

We

Th

Fr

Sa

Su

Mixer Circuit 1Time program P1 Time program P2 Time program P3



Mo

Tu

We

Th

Fr

Sa

Su

Mixer Circuit 2Time program P1 Time program P2 Time program P3



Mo

Tu

We

Th

Fr

Sa

Su


HYDRAULICPar. Designation Factory 10 20 30 40 50 Lev.

2 Function allocation of the output DHW charging pump 1 HF

3 Function allocation of the output Mixer circuit 1 3 HF

4 Function allocation of the output Mixer circuit 2 3 HF

5 Function allocation of the output Direct circuit Pump 2 HF

6 Function allocation of the variable output 1 OFF HF

7 Function allocation of the variable output 2 OFF/ 4/ 43 HF

8 Function allocation of the variable input 1 OFF HF

9 Function allocation of the variable input 2 OFF HF

10 Function allocation of the variable input 3 OFF/ 2/ 33 HF

11 Indirect return increase OFF HF

12 Maximum limit energy management 80 °C HF

13 Activation cooling buffer OFF HF

14 Release contact cooling to KVLF OFF HF

SYSTEMPar. Designation Factory 10 20 30 40 50 Lev.

LANGUAGE Selection of the style-language EN BE

2 Number of cleared switching time programs P1 HF

3 Clearing for separate operating mode 1 HF

4 Limit temperature for summer disconnection 22 °C HF

5 System frost protection 3 °C HF

6 Demand contact module for VE1 1 HF



9 Air conditioning zone -12 °C HF

10 Building type 2 HF

11 Automatic reversion time (surface end user level, except info. level) 5 min HF

12 Pump and mixer compulsory operation ON HF

13 Logical fault signal OFF HF

14 Automatic SET function(after 24:00, is automatically set to OFF) ON/ OFF HF

15 Blocking code for heating Installer OEM

18 Release cycle temperature OFF HF

19 Frost protection mode 30 min HF

21 RTC adjustment 0 HF

23 Blocking code operator level OFF HF

24 Temperature display in Fahrenheit OFF OEM

26 First commissioning date (after 24:00) - OEM

27 Fault report (only TTT/UG) 2 HF

28 Fault stack 2 ON HF

29 Characteristic curve emergency operation 0 °C HF

30 Thermostat function sensor allocation AF HF

31 Thermostat function reference value 1 °C HF

32 Thermostat function switching difference 3K HF

33 Thermostat function anti-blocking protection ON HFTop: ArtNo - HW IndexBottom: Code:REV - Software version ----- OEM

RESET Reset parameter values BE


DHWPar. Designation Factory 10 20 30 40 50 Lev.

DHW-NIGHT DHW - economy temperature 40/ 45 °C BE

2 DHW-legionella protection-day OFF HF

3 DHW-egionella protection-time 2:00 HF

4 DHW-legionella protection-temperature 50/ 55/ 65/ 70 °C HF

5 DHW-temperature recording 1 HF

6 DHW-maximum temperature limit 50/ 55/ 65/ 70 °C HF

7 DHW-mode of operation 1 HF

8 DHW-tank discharge protection ON/ OFF HF

9 DHW-charging temperature excess 7/ 20 K HF

10 DHW-switching difference 5 K OEM

11 DHW-charging pump follow-on 0.5/ 1/ 2/ 5 min OEM

12 ZKP-switching time program AUTO HF

13 ZKP-economy interval (pause) 0 min HF

14 ZKP-economy interval (period duration) 20 min HF

17 H-GEN behaviour during SLP follow-on time AUTO/ OFF HF

18 DHW-parallel loading OFF HF

19 DHW-time-out OFF/30 min HF

20 PI-reference value control OFF HF

21 PI-amplifi cation factor, P-portion Xp 0,1 %/ K OEM

22 PI-scanning time Ta 20 s OEM

23 PI -reset time Tn 600 s/ °C OEM

UNMIXED CIRCPar. Designation Factory 10 20 30 40 50 Lev.

1 Type of reduced operation ECO/ ABS HF

2 Heating system (exponent) DK= 1,30 HF

3 Room override (in connection with room sensor) 3 HF

4 Room factor OFF HF

5 Adaptation heating curve OFF HF

6 Switch-on optimisation 1 HF

7 Heating limit 0,5 OEM

8 Room frost protection limit 10 °C HF

9 Room thermostat function OFF HF

10 Outside temperature allocation 0 HF

11 Constant temperature reference value 20 °C HF

12 Minimum temperature limit 10 °C HF

13 Maximum temperature limit 55/ 75 °C HF

14 Temperature elevation Heating circuit DK=0 HF

15 Pump follow-on 5 min HF

16 Screed function OFF HF

23 Room control K-factor 8 HF

24 Room control Tn-factor 35 min HF

25 Vacation mode STBY HF

36 Minimum value override OFF HF

Name heating circuit (max. 5 letters) XXXXX HF


MIX. VALVE-1Par. Designation Factory 10 20 30 40 50 Lev.


2 Heating system (exponent) MK= 1,10 HF


4 Room factor 100 % HF

5 Adaptation heating curve ON HF









14 Temperature elevation/ abatement heating circuit 0/ 8 K HF



18 P-portion Xp 2,0 %/ K OEM

19 Scanning time Ta 20 s OEM

20 I-portion Tn 270 s OEM

21 Running time servomotor 150 s HF

22 End position function, valve 1 OEM





37 Mixer lead time OFF HF

38 Regulation offset 0 HF

50 Cooling switch-on point, OT OFF HF

51 Cooling max. point, OT 35 °C HF

52 Cooling reference fl ow temp. at switch-on point 18 °C HF

53 Cooling reference fl ow temp. at max. point 24 °C HF

54 Cooling reference room temp. at switch-on point 23 °C HF

55 Cooling reference room temp. at max. point 28 °C HF

56 Min. temp. cooling 18 °C OEM



MIX. VALVE-2Par. Designation Factory 10 20 30 40 50 Lev.


2 Heating system (exponent) MK= 1,10 HF


4 Room factor 100 % HF

5 Adaptation heating curve ON HF









14 Temperature elevation/ abatement heating circuit 0/ 8 K HF



18 P-portion Xp 2,0 %/ K OEM

19 Scanning time Ta 20 s OEM

20 I-portion Tn 270 s OEM

21 Running time servomotor 150 s HF

22 End position function, valve 1 OEM





37 Mixer lead time OFF HF

38 Regulation offset 0 HF

50 Cooling switch-on point, OT OFF HF

51 Cooling max. point, OT 35 °C HF

52 Cooling reference fl ow temp. at switch-on point 18 °C HF

53 Cooling reference fl ow temp. at max. point 24 °C HF

54 Cooling reference room temp. at switch-on point 23 °C HF

55 Cooling reference room temp. at max. point 28 °C HF

56 Min. temp. cooling 18 °C OEM



HEAT GENER.Par. Designation Factory 10 20 30 40 50 Lev.

1 H-GEN model 1/ 2/ 5 HF

2 Start-up protection H-GEN OFF/ 3 HF

3 Minimum temperature limit H-GEN 5/ 48/ 65/ 75 °C HF

4 Maximum temperature limit H-GEN 75/ 85 °C HF

5 Mode of action minimum temperature limit H-GEN 1 HF

6 Sensor mode operation for H-GEN 1 OEM

7 Minimum burner running time 2 min HF

8 Burner switching difference I 6 K HF

9 Burner switching difference II 12 K HF

10 Time-out stage II 10 HF

11 Release mode stage II 1 HF

12 DHW charging mode 1-2 stage 2 HF

13 Lead time, boiler circuit pump 1 min HF

14 Follow-on time, boiler circuit pump or parallel boiler release 5 min HF

15 Search time feed pump, primary pump 5 min HF

16 Exhaust gas temperature monitoring OFF HF

17 Exhaust gas limit value 200 °C HF

18 Boiler gradient OFF OEM

19 Modulation P-portion Xp 5 %/ K OEM

20 Modulation scanning time Ta 20 s OEM

21 Modulation adjustment time Tn 180 s/ °C OEM

22 Modulation running time 12 s HF

23 Modulation starting time 200 s HF

24 Modulation start-up output 70 HF

25 Outside temperature block OFF OEM

26 Basic charge elevation 0 K/ 10K OEM

27 Minimum temperature limit, heating circuits 5/ 38/ 65 °C HF

28 Switching difference, minimum temperature limit Heating circuits 2 K OEM

29 H-GEN forced discharge OFF HF

30 OEM Maximum limit 110 °C OEM

31 Minimum load control OFF OEM

34 Output limitation heating 100 % HF

35 Output limitation hot water 100 % HF

36 ET blocking 2.burner stage OFF HF

37 Running time meter 1 HF

38 DHW release regulator (CD) ON HF

39 Emergency operation temperature H-Gen (e.g. for 70-8) 70 °C HF

40 Heat balance (from V3.2) ON HF

41 Reset heat balance HF

42 Volumetric fl ow rate0,0 l/ min

HF0,0 l/ IMP

43 Density, medium 1,00 kg/ l HF44 Specifi c thermal capacity, medium 4,2 HF

RESET ST-1 Reset counters starts and running time, stage 1 OEMRESET ST-2 Reset counters starts and running time, stage 2 OEM


AUTOMATIC FIRING DEVICE UltraGas® (15-50)P

aram

eter

Description Un

it

Lev

el

Pla

nt

sett

ing

s

30-U

G (

15)

30-U

G (

20)

30-U

G (

27)

30-U

G (

35)

30-U

G (

50)

1 2AA Blocking temperature °C OEM 90 90 90 90 90

2 2AC Maximum setpoint °C BE 80 80 80 80 80

3 2AD Switch-off hysteresis via setpoint °C OEM 5 5 5 5 5

4 2AE Switching difference to switch-off point °C HF 10 10 10 10 10

5 2AF Proportional range °C OEM 10 10 10 10 10

6 2AG Integral part sec OEM 180 180 180 180 180

7 2AH Differential part sec OEM 10 10 10 10 10

8 2AI Setpoint for bus interrupt °C HF 75 75 75 75 75

9 2AJ Maximum temperature rise for low flow temperature °C/s OEM 1 1 1 1 1

10 2AK Maximum temperature rise for high flow temperature °C/s OEM 0.5 0.5 0.5 0.5 0.5

11 2AL “low” flow temperature °C OEM 60 60 60 60 60

12 2AM “high” flow temperature °C OEM 80 80 80 80 80

13 2BC Flue gas temperature lock °C OEM 110 110 110 110 110

14 2BD Flue gas temperature block °C OEM 100 100 100 100 100

15 2CA Gas pressure switch available OEM ON ON ON ON ON

16 2DA Hydrau. pressure sensor available OEM ON ON ON ON ON

17 2DB Pressure warning bar OEM 1 1 1 1 1

18 2DC Pressure warning hysteresis bar OEM 0.2 0.2 0.2 0.2 0.2

19 2DD Blocking pressure min bar OEM 0.5 0.5 0.5 0.5 0.5

20 2DE Blocking pressure min - hysteresis bar OEM 0.2 0.2 0.2 0.2 0.2

21 2DF Blocking pressure max bar OEM 2.8 2.8 2.8 2.8 2.8

22 2DG Blocking pressure max - hysteresis bar OEM 0.2 0.2 0.2 0.2 0.2

23 2DH Lock-out pressure max bar OEM 3 3 3 3 3

24 2DI Max boiler output for pressure warning % OEM 50 50 50 50 50

25 2EC Ionisation warning µA OEM 3 3 3 3 3

26 2FA Number of Hall pulses per rotation OEM 2 2 2 2 2

27 2FF Fan speed first phase pre-vent min–1 OEM 5000 6300 5500 6500 6800

28 2FG Start rpm min–1 OEM 3500 2500 2200 2500 2500

29 2FH Maximum fan speed min–1 OEM 5000 6300 5500 6500 6800

30 2FI Minimum fan speed min–1 OEM 1000 1300 1100 1100 1200

31 2FJ Fan ramp-up during purge min–1/s OEM 500 500 500 500 500

32 2FK Fan ramp-down during purge min–1/s OEM 200 200 200 200 200

33 2FL Fan ramp-up during operation min–1/s OEM 100 100 100 100 100

34 2FM Fan ramp-down during operation min–1/s OEM 100 100 100 100 100

35 2FN Fan follow-on time after a lock-out sec OEM 180 180 180 180 180

36 2FO Fan speed after shut-down during normal operation or lock-out min–1 OEM 1000 1300 1100 1100 1200

37 2FR Fan follow-on time after operation or block min OEM 3 3 3 3 3

38 2FU Fan speed for boiler operation in frost protection mode min–1 OEM 1500 1500 1500 1500 1500

39 2GA Waiting period after opening of main gas valve or activation of boiler room fan

min OEM 0 0 0 0 0

40 2GB External main gas valve / boiler room fan available OEM ON ON ON ON ON

41 2HA Follow-on time for heating pump or shut-off device after heat demand min HF 5 5 5 5 5

42 2HD Summer operation (“summer kick”) sec OEM 10 10 10 10 10


Par

amet

er

Description Un

it

Lev

el

Pla

nt

sett

ing

s

30-U

G (

15)

30-U

G (

20)

30-U

G (

27)

30-U

G (

35)

30-U

G (

50)

43 2IA Ignition (0-> internal, 1-> internal + external, 2-> external) OEM 0 0 0 0 0

44 2KM Stepped modulation (0-> off, 1-> rising, 2-> rising and falling) HF 1 1 1 1 1

45 2LA Action mode fault relays HF 2 2 2 2 2

46 2NA ADC/4 value at 0 bar OEM 25 25 25 25 25

47 2NB *ADC/4 value at 6/10 bar (V3) OEM145/225

145/225

145/225

145/225

145/225

48 2IB Extended external ignition time sek OEM 8 8 8 8 8

49 2QA Reserve % OEM 70 70 70 70 70

*With automatic firing device: BIC960_V2 parameter 47: must be 145 (6bar) With automatic firing device: BIC960_V3 parameter 47: must be 225 (10bar)

Liquid gas adaptations

27 2FF Fan speed first phase pre-vent min–1 OEM 4300 5800 5100 6100 6300

28 2FG Start rpm min–1 OEM 3500 2500 2500 3000 3000

29 2FH Maximum fan speed min–1 OEM 4300 5800 5100 6100 6300

30 2FI Minimum fan speed min–1 OEM 1400 1500 1400 1300 1400

36 2FO Fan speed after shut-down during normal operation or lock-out min–1 OEM 1400 1500 1400 1300 1400

AUTOMATIC FIRING DEVICE UltraGas® (15-50)

i


RETURN CONTRPar. Designation Factory 10 20 30 40 50 Lev.

1 Minimum limit return temperature / reference value return temperature 38 °C HF

2 Switch-off difference 2 K HF

3 Pump follow-on time 1 min HF

SOLARPar. Designation Factory 10 20 30 40 50 Lev.

1 Switch-on difference 10 K HF


3 Minimum running time SOP 3 min HF

4 Solar collector maximum temperature 100 °C HF

5 Solar tank maximum limit (KSPF) 65 °C HF

6 Solar mode of operation 2 HF

7 Heat generator cycle lock (only when parameter 06=1,3,4) 0,5 h HF

8 Solar priority parallel changeover 10 K HF

9 Solar heat balance OFF HFSOLAR RESET Reset heat balance HF

11 Volumetric fl ow rate 0,0 l/ min HF0,0 l/ IMP12 Density, medium 1,05 kg/ l HF

13 Specifi c thermal capacity, medium 3,6 KJ/ kgK HF

14 Final switching-off temperature 120 °C HF

15 Test cycle solar charging switch-over 10 min HF

16 Switch-over temperature (SLVF) 60 °C HF

17 Solar minimum temperature OFF HF

SOLID FUELPar. Designation Factory 10 20 30 40 50 Lev.

1 Minimum temperature 60 °C HF

2 Maximum temperature 95 °C HF

3 Switch-on difference 10 K HF


5 Clock block, heat generator 15 HF


MAIN SUPPLYPar. Designation Factory 10 Lev.

1 PI-amplifi cation factor, P-portion Xp 0 %/ K HF

2 PI-scanning time Ta 20 s HF

3 PI -reset time Tn 600 s/ °C HF

CASCADEPar. Designation Factory 10 Lev.

1 Switch-off difference 3 K OEM

2 Connecting delay 20 OEM

3 Switch-off delay 5 OEM

4 Switching output stage sequence 65 OEM

5 Stage reversal OFF OEM

6 Control stage 1 BE

7 Peak load stage OFF OEM

8 Group switch-over OFF OEM

9 DHW fast activation OFF OEM

10 Peak load elevation 10 K OEM

BUSPar. Designation Factory 10 20 30 40 50 Lev.

1 Bus address central device 10 HF

2 Bus right RS direct circuit 1 HF

3 Bus right RS mixer circuit 1 1 HF

4 Bus right RS mixer circuit 2 1 HF

BUFFERPar. Designation Factory 10 20 30 40 50 Lev.

1 Minimum temperature 5/ 20 °C HF

2 Maximum temperature 95 °C HF

3 Temperature elevation, H-GEN 8/ 10/ 12K HF

4 Switching difference 2/ 5/ 10K HF

5 Forced discharge OFF HF

6 Skimming function switch-on difference 10 K HF

7 Skimming function switch-off difference 5 K HF

8 Start-up protection OFF HF

9 Discharge protection OFF HF

10 Buffer mode of operation 2/ 3 HF

11 Pump follow-on time 3 min HF

12 Switch-off reference value temp. 70 °C HF

13 H-GEN release temp. skimming function 60 °C HF


SERVICEPar. Designation Factory 10 20 30 40 50 Lev.

Service 1 (Cleaning ST1 )

1 Suspend message «CLEANING ST-1» for X days 7 BE

2 Cleaning according to fi xed date OFF BE

3 Cleaning according to fi xed interval OFF BE

4 Cleaning according to cleaning counter OFF BE

5 Reset cleaning display 1 BE

Service 2 (Cleaning ST2)

6 Suspend message «CLEANING ST-2» for X days 7 BE

7 Cleaning according to fi xed date OFF BE

8 Cleaning according to fi xed interval OFF BE

9 Cleaning according to cleaning counter OFF BE

10 Reset cleaning display 2 BE

Service 3 (maintenance ST1 )

11 Suspend message «MAINTENANCE ST-1» for X days 7 HF

12 Maintenance according to fi xed date OFF HF

13 Maintenance according to fi xed interval OFF HF

14 Maintenance according to maintenance counter OFF HF

15 Reset maintenance display 1 HF

Service 2 (maintenance ST2 )

16 Suspend message «MAINTENANCE ST-2» for X days 7 HF

17 Maintenance according to fi xed date OFF HF

18 Maintenance according to fi xed interval OFF HF

19 Maintenance according to maintenance counter OFF HF

20 Reset maintenance display 2 HF

ALARM 1Par. Designation 10 20 30 40 50 Lev.

1 Alarm 1 OEM

2 Alarm 2 OEM

3 Alarm 3 OEM

4 Alarm 4 OEM

5 ... 20 Alarm 5 - 20 OEM

21 Reset fault signals OEM

ALARM 2 (can ony be activated with H-Gen 5)Par. Designation 10 20 30 40 50 Lev.

1 Alarm 1 OEM

2 Alarm 2 OEM

3 Alarm 3 OEM

4 Alarm 4 OEM

5 ... 20 Alarm 5 - 20 OEM

21 Reset fault signals OEM


FAULT REPORTING OVERVIEW TopTronic®TStatus Designation Fault type Code Remark

System External sensor Interruption 10-0

System External sensor Short-circuit 10-1

System Boiler sensor Interruption 11-0

System Boiler sensor Short-circuit 11-1

System Flow sensor 1 Interruption 12-0 MC1=off, YK1=no current

System Flow sensor 1 Short-circuit 12-1 MC1=off, YK1=no current

System Storage sensor Interruption 13-0

System Storage sensor Short-circuit 13-1

System VE 2 Interruption 14-0

System VE 2 Short-circuit 14-1

System VE 2 Alarm 14-7







System Solar tank sensor Interruption (KSPF) 17-0

System Solar tank sensor Short-circuit (KSPF) 17-1

System Flow sensor 2 Interruption 18-0 MC2=off, YK2=no current

System Flow sensor 2 Short-circuit 18-1 MC2=off, YK2=no current

System Collector sensor Interruption (KVLF) 19-0

System Collector sensor Short-circuit (KVLF) 19-1

System Room sensor (RS) Interruption 20-0

System Room sensor (RS) Short-circuit 20-1

System Burner 1 No switching off (1 min) 30-2 With par. log. alarm can be switched off

System Burner 1 No switching on (10 min) 30-3 With par. log. alarm can be switched off

System Burner 2 No switching off (1 min) 31-2 With par. log. alarm can be switched off

System Burner 2 No switching on (10 min) 31-3 With par. log. alarm can be switched off

System Exhaust gas temperature Exceeding 33-5

System Exhaust gas temperature SLT triggered 33-8

System Cleaning stage 1 Triggering by date 40-1

System Cleaning stage 1 Triggering by interval 40-2

System Cleaning stage 1 Triggering by counter 40-4

System Maintenance stage 1 Triggering by date 41-1

System Maintenance stage 1 Triggering by interval 41-2

System Maintenance stage 1 Triggering by counter 41-4

System Cleaning stage 2 Triggering by date 42-1

System Cleaning stage 2 Triggering by interval 42-2

System Cleaning stage 2 Triggering by counter 42-4

System Maintenance stage 2 Triggering by date 43-1

System Maintenance stage 2 Triggering by interval 43-2

System Maintenance stage 2 Triggering by counter 43-4


FAULT REPORTING OVERVIEW TopTronic®TStatus Designation Fault type Code Remark

Logical Boiler temperature Not reached (90 min) 50-4

Logical Tank temperature Not reached (4 h) 51-4

Logical Flow temperature MC1 Not reached (1 h) 52-4

Logical Flow temperature MC2 Not reached (1 h) 53-4

Logical Room temperature HC Not reached (3 h) 54-4

Logical Room temperature MC1 Not reached (3 h) 55-4

Logical Room temperature MC2 Not reached (3 h) 56-4

System Lock by energy supply company ST 2 Address collision 70-0

System Activity No T2B signal 70-1

System Activity No FA signal 70-6

System Activity Regulator with address 10 is missing 70-8

System Activity Data bus error 70-9 No Hoval regulatorSystem HP return sensor Return min. temp. below setpoint 85-4System HP return sensor Return max. temp. exceeded 85-5

System QF Heat source min. temp. below setpoint 86-4

System QF Heat source max. temp. exceeded (cooling operation) 86-5

System QF Fault heat source sensor -- Standard signal «VE-x»System WPS Variable input HP fault 87-7System Pulse counter No pulse (5 min) 90-0System Fault Warning W:XX Warning in automatic fi ring deviceSystem Fault Lock-out E:XX Fault in automatic fi ring deviceSystem Fault Blocking B:XX Fault in automatic fi ring device

SENSOR ALLOC.Par. Designation Factory 10 20 30 40 50 Lev.

1 Balancing external sensor 0 OEM

RS-T Balancing room sensor (only adjustable with RS-T) 0 HF

2 Balancing heat generator 0 OEM

3 Balancing tank sensor 0 OEM

4 Balancing fl ow sensor 1 0 OEM

5 Balancing fl ow sensor 2 0 OEM

6 Balancing solar collector sensor 0 OEM

7 Balancing solar buffer sensor 0 OEM

8 Balancing variable input 1 0 OEM




Code Failure Type Description

W:01W:02

WarningWarning

Water pressure too lowIonisation too low

B:03B:04B:05B:06B:07B:08

BlockingBlockingBlockingBlockingBlockingBlocking

Gas pressure too low/ Gas pressure switch defective/ external blockings*Main gas valve (possibly LPG- valve)/ Heating room fanWater pressure outside of limitsSafety limit thermostat activatedFlue gas temperature too highBoiler temperature too high

E:01E:02E:05E:06E:07E:08E:09E:10E:11E:12E:13E:14E:15E:16E:17E:18E:19E:20E:21E:22E:23E:24E:25E:26E:27E:28

Lock-outLock-outLock-outLock-outLock-outLock-outLock-outLock-outLock-outLock-outLock-outLock-outLock-outLock-outLock-outLock-outLock-outLock-outLock-outLock-outLock-outLock-outLock-outLock-outLock-outLock-out

Flue gas sensor shortedFlue gas sensor interruptedFlow temperature sensor 2 shortedFlow temperature sensor 2 interruptedFlow temperature sensor 2 lock-out temperature exceededFlow temperature sensor 1 lock-out temperature exceededDifference between flow sensors 1+2 too highFlow temperature sensor 1 shortedFlow temperature sensor 1 interruptedInternal error in automatic firing deviceParameter loadedParameter loading errorInternal error in automatic firing deviceWater pressure too highInternal error in automatic firing deviceFan rotation below limitFan rotation above limitFlame interruption during operationNo flame after ignitionAir pressure switch does not openAir pressure switch does not closeFlame detected without reasonFlue gas temperature too highSafety limit thermostat activatedInternal error in automatic firing deviceSeveral gas pressure drops during start-up

i *Block B:04 is no longer displayed from BIC 969_V3.Waiting period parameter 39 is still observed.

Automatic firing device (Warning, Blocking, Lock-out)

4 210 264 / 04 51

Confirmation

The user (owner) of the system herewith confi rms that• he has received adequate instruction in the operating and maintenance of the installation,• received and taken note of the operating and maintenance instructions and, where applicable other documents con-

cerning the heat generator and any further components.• and is consequently suffi ciently familiar with the installation.

Installation address: Type:

Serial number:

Year of manufacture:

Place, Date:

System installer: System user:

Confirmation

The user (owner) of the system herewith confi rms that• he has received adequate instruction in the operating and maintenance of the installation,• received and taken note of the operating and maintenance instructions and, where applicable other documents con-

cerning the heat generator and any further components.• and is consequently suffi ciently familiar with the installation.

Installation address: Type:

Serial number:

Year of manufacture:

Place, Date:

System installer: System user:

COPY FOR PLANT USER

COPY OF SYSTEM INSTALLER

Documents

Technical information Installation instructions UltraGas ... · 4 210 264 / 04 Important notes 5 2.4.1 Germany § • DIN EN 12831 Heating systems in buildings - Methods for calculating