UltraGas. Technical Data Output range 15 to 2000 kw. Condensing Gas Boiler /02-07/15 Subject to modifications

Transcription

1 UltraGas Condensing Gas Boiler Technical Data Output range 15 to 2000 kw - 07/15 Subject to modifications

2 UltraGas UltraGas Condensiing D Gas Boiler Contents page Description 3 UltraGas Technical Data 4 Dimensions 6 UltraGas Technical Data 9 Dimensions 12 UltraGas 250D-2000D Technical Data 16 Dimensions 20 Fine gas filter Space requirements, installation and maintenance 23 Flue System / Ventilation Flue design UltraGas ( D) 24 Accessories 25 Typical hydraulic schematics 42 Service 44

3 UltraGas D Description The Hoval UltraGas condensing boiler range features many innovative construction details which ensure market-leading efficiency and cost effective heating performance. Hoval alufer technology The internationally patented alufer tube is a Hoval innovation in advanced heat transfer technology. It is constructed from an inner aluminium finned surface, heat shrunk within an outer stainless steel tube. The exceptional efficiency of the heat transfer is attributed to the following factors: High heat conductivity of aluminium being ten times greater than that of steel A ten times larger heat exchange surface due to the internal finned surface of the aluminium tube Optimised turbulence and heat exchange efficency created by the multiple flow channels on the inner surface of the tube Sophisticated management for your heating system The TopTronic control is the brain of every Hoval system. Innovative microprocessor technology ensures smooth and continuously monitored operation. The touch screen display provides information on operating data and allows setting of the heating systems. If manual intervention is necessary, the required program can be easily found in the self-explanatory user guide. Record level of efficiency of more than 109% Low temperature boilers convert about 93% of the calorific value of gas into usable heat. With the UltraGas, this limit is raised considerably by using condensing technology. One of the main products of combustion gases is water (as steam) and in the conventional boiler the heat within this is lost through the flue. This is not the case with the UltraGas ; in condensing operation the hot steam is cooled back down to C thus releasing the latent heat of vapourisation for use in the heating system. The result is as much as a 15% increase in the amount of usable heat which dramatically increases the boiler efficiency. The UltraClean combustion system: The UltraGas has uniquely low nitrogen oxide and carbon monoxide emission values. The secret of low emission combustion lies in the specially designed and patented UltraClean radiation burner and in the gas/air mixture. On the surface of the UltraClean combustion cylinder, there is an almost flame-free combustion of the gasair mixture. The low, flat flame pattern remains cooler than the gas flames in conventional combustion technology. In this way, substantially lower nitrogen oxide and carbon monoxide emission values can be achieved and as a result the environment is spared a significant amount of harmful waste gases. Natural gas or propane can be used on all models of UltraGas. Optimised stratification with separate high and low temperature returns A key feature of the boiler is that is has two return connections. These can be utilised to raise boiler efficiency and therefore lower fuel consumption. This is achieved by separating any lower temperature (<40 C) system return entering the boiler from system returns that may be at a higher temperature. Even a small volume of water - perhaps 5% of the total - at lower temperatures can positively influence the boiler efficiency in this way allowing the designer to optimise the potential for condensation on the boiler surfaces. Any higher temperature water is introduced into the boiler in such a way that it does not mix with this cooler water and raise the temperature above that which will allow condensation. No minimum flow rate is required other than at start up and pump overrun. Twin UltraGas units are also available Single UltraGas condensing boilers are available in a range of twenty one sizes with outputs ranging between 15 and 1000 kw. For larger outputs or if multiple boilers are required, the UltraGas can be provided as a twin boiler system. This gives a further fourteen sizes with outputs ranging between 250 and 2000 kw. NOx emissions of less than 40 mg/kwh: The twin units are supplied as standard with a flue header. Following additional recent extensive independent emissions testing to DIN EN 676 it is stated by GWI (GasWarme Institut e.v.) that all Ultra- Gas boilers have average NOx emissions of less than 40 mg/kwh. All figures are dry and at 0% excess oxygen. A ErP labelling classification for boilers to 70kW, valid from 26 September To enhance the standard twin unit, optional items are available : Flow header with motorised shut off valves. A return header can be used if the motorised valves are not required. High temperature return header. Low temperature return header. Fine gas filter A gas filter is supplied as standard with the UltraGas and 800D-2000D models to provide long term protection to the boiler against dirt ingress from the gas supply pipework. These filters are supplied to be fitted by the installer adjacent to each boiler. An optional gas filter is available for smaller models. 3

4 UltraGas D Technical Data UltraGas (15-27) Type A (15) A (20) A (27) Nominal output 80/ 60 C with natural gas kw Nominal output 40/ 30 C with natural gas kw Nominal output 80/ 60 C with liquid gas 1 kw Nominal output 40/ 30 C with liquid gas 1 kw Heat input net CV basis with natural gas kw Heat input net CV basis with liquid gas 1 kw Working pressure heating max./min. 2 bar 3.0 / / / 1.2 Working temperature max. C Boiler water capacity l Min. water flow rate 3 l/h Boiler weight (without water, incl. casing) kg Boiler efficiency Part load 30% at 50/30 C (gross) % Boiler efficiency Full load 100% at 80/60 C (gross) % Part L UK Seasonal efficiency % Heat-loss rate at 70 C Watt Standard emission rate Nitrogen oxides 4 mg/kwh Carbon monoxide mg/kwh Content of CO 2 in the exhaust gas max./min. output % 9.0 / / / 8.8 Dimensions See table of dimensions Connections Flow/Return Inches R1" R1" R1" Gas Inches R¾" R¾" R¾" Flue gas/combustion air Ø mm E80 E80 E80 Gas flow pressure min./max. Natural gas E mbar Liquid gas 1 mbar Gas connection value at 0 C / 1013 mbar: Natural gas E - (Wo = 15,0 kwh/m 3 ) H u = 9,97 kwh/m 3 m 3 /h Propane gas (H u = 25,9 kwh/m 3 ) m 3 /h Operation voltage V/Hz 230/50 230/50 230/50 Control voltage V/Hz 24/50 24/50 24/50 Min./max. electrical power consumption Watt 24/46 24/64 24/58 Stand-by electrical consumption Watt IP rating (integral protection) IP Acoustic power level db(a) Acoustic pressure level at 1 metre db(a) Condensate quantity (natural gas ) at 40/ 30 C l/h ph value of the condensate ph ca. 4.2 ca. 4.2 ca. 4.2 Values for flue calculation: Temperature class T120 T120 T120 Flue gas mass flow kg/h Flue gas temperature with operating conditions 80/ 60 C C Flue gas temperature with operating conditions 40/ 30 C C Volume flow rate combustion air Nm 3 /h Usable overpressure for air duct/flue system Pa UltraGas (15-27) can also be operated with propane/butane (liquid gas) mixtures. 2 Boiler test pressure is 1.5 times max. operating pressure. 3 Although generally the UltraGas boilers do not require a minimum water flow, it does not mean that the pump and burner can be switched off together when the unit is operating at full output. There should be a pump overrun to dissipate any residual heat within the boiler to avoid nuisance high temperature lockouts. 4 NOx emissions to EN676 are dry and at 0% excess oxygen. Boiler flow resistance see diagram opposite UltraGas (15-27) [mbar] m 3 /h = Volume flow rate mbar = Flow resistance [m3/h]

5 UltraGas D Technical Data UltraGas (35-100) Type A (35) A (50) A (70) (100) Nominal output 80/ 60 C with natural gas kw Nominal output 40/ 30 C with natural gas kw Nominal output 80/ 60 C with liquid gas 1 kw Nominal output 40/ 30 C with liquid gas 1 kw Heat input net CV basis with natural gas kw Heat input net CV basis with liquid gas 1 kw Working pressure heating max./min. 2 bar 3.0 / / / / 1.2 Working temperature max. C Boiler water content l Min. water flow rate 3 l/h Boiler weight (without water content, incl. casing) kg Boiler efficiency Part load 30% at 50/30 C (gross) % Boiler efficiency Full load 100% at 80/60 C (gross) % Part L Seasonal efficiency % Heat loss rate at 70 C Watt Standard emission rate Nitrogen oxides 4 mg/kwh Carbon monoxide mg/kwh Content of CO 2 in the exhaust gas max./min. output % 9,0 / 8,8 9,0 / 8,8 9,0 / 8,8 9,0 / 8,8 Dimensions See table of dimensions Connections Flow/return Inches R 1¼" R 1¼" R 1½" R 1½" Gas Inches Rp ¾" Rp ¾" R ¾" R ¾" Flue gas/ combustion air Ø mm E80 E80 C100/150 C100/150 Gas flow pressure min./max. Natural gas E mbar Liquid gas mbar Gas connection value at 0 C / 1013 mbar: Natural gas E - (Wo = 15,0 kwh/m 3 ) H u = 9,97 kwh/m 3 m 3 /h Propane gas (H u = 25,9 kwh/m 3 ) m 3 /h Operation voltage V/Hz 230 / / / / 50 Control voltage V/Hz 24 / / / / 50 Min./max. electrical power consumption Watt 26 / / / / 158 Stand-by electrical consumption Watt IP rating (integral protection) IP Acoustic power level max. db(a) Acoustic power level at 1 metre 2 db(a) Condensate quantity (natural gas) at 40 / 30 C l/h ph value of the condensate ca. 4.2 ca. 4.2 ca. 4.2 ca. 4.2 Values for flue calculation Temperature class T120 T120 T120 T120 Flue gas mass flow kg/h Flue gas temperature with operating conditions 80 / 60 C C Flue gas temperature with operating conditions 40 / 30 C C Volume flow rate combustion air Nm 3 /h Usable overpressure for air duct/flue system Pa UltraGas (35-100) can also be operated with propane/butane (liquid gas) mixtures. 2 Boiler test pressure is 1.5 times max. operating pressure. 3 Although generally the UltraGas boilers do not require a minimum water flow, it does not mean that the pump and burner can be switched off together when the unit is operating at full output. There should be a pump overrun to dissipate any residual heat within the boiler to avoid nuisance high temperature lockouts. 4 NOx emissions to EN676 are dry and at 0% excess oxygen. Boiler flow resistance see diagrams below. [mbar] UltraGas (35,50) ,5 1 1,5 2 2,5 3 3,5 4 4,5 5 [m 3 /h] [mbar] UltraGas (70,100) [m 3 /h] m 3 /h = Volume flow rate mbar = Flow resistance 5

6 UltraGas D Dimensions Hoval UltraGas (15-27) with optional connection set AS25-S/NT/ HT and heating circuit set HA25 Hoval UltraGas (35,50) with optional connection set AS32-S/NT/ HT and heating circuit set HA32 (Measurements in mm) The installer must fit a safety valve and automatic air-vent in the flow pipework before any isolation valve or on the second flow connection. A boiler drain connection should be fitted off the low temperature return connection. Type UltraGas (15-27) (35,50) Type A B C D E F G H UltraGas (15-27) UltraGas (35,50) Flow R 1" R 1¼" 2 Low temperature return R 1" R 1¼" 2a High temperature return R 1" R 1¼" 3 Gas connection left or right Rp ¾" Rp ¾" 4 Flue gas outlet DN80 DN80 5 Control panel 6 Condensate drain (left or right) incl. trap (DN25) and 2 m PVC hose D19 x 4 mm 7 Drain 8 Electrical connection 9 Acoustic hood 10 Heating circuit set (optional) versions available for left or right hand side, refer to accessories section 6

7 UltraGas D Dimensions Hoval UltraGas (70, 100) with optional connection set AS40-S/NT/ HT and heating circuit set HA40 (Measurements in mm) The installer must fit a safety valve and automatic air vent in the flow pipework before any isolation valve or on the second flow connection. Type UltraGas (70) (100) 1 Flow R1½" R1½" 2 Low temperature return R1½" R1½" 2a High temperature return R1½" R1½" 3 Gas connection left or right Rp ¾" Rp ¾" 4 Flue gas outlet (concentric) C100/150 C100/150 4a Horizontal flue gas connection (optional) E100 E Control panel 6 +Condensate drain (left or right) incl. trap (DN25) and 2 m PVC hose D19 x 4mm 7 Electrical connection left or right 8 Drain (behind the front casing) ½" ½" 9 Connection set (optional) can be fitted left or right hand side 10 Heating circuit set (optional), versions available for left or right hand side, refer to accessories section 7

8 UltraGas D Dimensions Hoval UltraGas (15-50) (Measurements in mm) A = minimum 150 mm (300mm or more recommended to allow burner to rotate to the left for maintenance). Clearances are without the optional connection sets. Where a condensate pump is used (see Accessories) allow at least 200mm clearance on the side where this will be positioned. Hoval UltraGas (70, 100) (Measurements in mm) A = minimum 150 mm (300mm or more recommended to allow burner to rotate to the left for maintenance). Clearances are without the optional connection sets. *without heating circuit set, 500 mm with heating circuit set Where a condensate pump is used (see Accessories) allow at least 200mm clearance on the side where this will be positioned. 8

9 UltraGas D Technical Data UltraGas ( ) Type (125) (150) (200) (250) (300) Nominal output 80/ 60 C with natural gas kw Nominal output 40/ 30 C with natural gas kw Nominal output 80/ 60 C with liquid gas 1 kw Nominal output 40/ 30 C with liquid gas 1 kw Heat input net CV basis with natural gas kw Heat input net CV basis with liquid gas 1 kw Working pressure heating max./min. 2 bar 5.0 / / / / / 1.2 Working temperature max. C Boiler water capacity l Min. water flow rate 3 l/h Boiler weight (without water content, incl. casing) kg Boiler efficiency Part load 30% at 50/30 C (gross) % Boiler efficiency Full load 100% at 80/60 C (gross) % Part L UK Seasonal efficiency % Heat loss rate at 70 C Watt Standard emission rate Nitrogen oxides 4 mg/kwh Carbon monoxide mg/kwh Content of CO 2 in the exhaust gas max./min. output % 9.0 / / / / / 8.8 Dimensions see table of dimensions Connections Flow/return DN DN65/PN6 DN65/PN6 DN65/PN6 DN65/PN6 DN65/PN6 Gas Inches Rp1" Rp1" Rp1½" Rp1½" Rp1½" Flue gas inside Ø mm Gas flow pressure min./max. Natural gas E mbar Propane gas mbar Gas connection value at 0 C / 1013 mbar: Natural gas E - (Wo = 15,0 kwh/m 3 ) H u = 9,97 h/m 3 m 3 /h 11,6 14,1 18,8 23,5 28,3 Propane gas 3 (H u = 25,9 kwh/m 3 ) m 3 /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 Min./max. electrical power consumption Watt 44/168 44/247 44/143 44/224 46/345 Stand-by Watt IP rating (integral protection) IP Acoustic power level max. db(a) Acoustic pressure level at 1 metre db(a) Condensate quantity (natural gas ) at 40/ 30 C l/h 10,9 13,3 17,7 22,1 26,6 ph value of the condensate ca. 4,2 ca. 4,2 ca. 4,2 ca. 4,2 ca. 4,2 Values for flue calculation: Temperature class T120 T120 T120 T120 T120 Flue gas mass flow kg/h Flue gas temperature with operating conditions 80/ 60 C C Flue gas temperature with operating conditions 40/ 30 C C Volume flow rate combustion air Nm 3 /h Usuable overpressure for air duct/flue system Pa UltraGas ( ) can also be operated with propane/butane (liquid gas) mixtures. 2 Boiler test pressure is 1.5 times max. operating pressure. 3 Although generally the UltraGas boilers do not require a minimum water flow, it does not mean that the pump and burner can be switched off together when the unit is operating at full output. There should be a pump overrun to dissipate any residual heat within the boiler to avoid nuisance high temperature lockouts. 4 NOx emissions to EN676 are dry and at 0% excess oxygen. Boiler flow resistance see diagrams below. [mbar] UltraGas (125,150) UltraGas ( ) [m3/h] [m3/h] [mbar] m 3 /h = Volume flow rate mbar = Flow resistance 9

10 UltraGas D Technical Data UltraGas ( ) Type (350) (400) (450) (500) (575) Nominal output 80/ 60 C with natural gas kw Nominal output 40/ 30 C with natural gas kw Nominal output 80/ 60 C with liquid gas 1 kw Nominal output 40/ 30 C with liquid gas 1 kw Heat input net CV basis with natural gas kw Heat input net CV basis with liquid gas 1 kw Working pressure heating max./min. 2 bar 6.0 / / / / / 1.2 Working temperature max. C Boiler water content l Minimum water flow rate 3 l/h Boiler weight (without water content, incl. casing) kg Boiler efficiency Part load 30% at 50/30 C % Boiler efficiency Full load 100% at 80/60 C % Part L UK Seasonal efficiency % Heat loss rate at 70 C Watt Standard emission rate Nitrogen oxides 4 mg/kwh Carbon monoxide mg/kwh Content of CO 2 in the exhaust gas max./min. output % 9.0 / / / / / 8.8 Dimensions see table of dimensions Connections Flow/return DN [mbar] [mbar] DN100/ PN6 DN100/ PN6 Boiler flow resistance see diagrams below. UltraGas (575) DN100/ PN6 DN100/ PN6 DN125/ PN6 Gas Inches Rp 1½" Rp 2" Rp 2" Rp 2" Rp 2" Flue gas inside Ø mm Gas flow pressure min./max. Natural gas E mbar Propane gas mbar Gas connection value at 0 C / 1013 mbar: Natural gas E - (Wo = 15,0 kwh/m 3 ) H u = 9,97 h/m 3 m 3 /h Propane gas 3 (H u = 25,9 kwh/m 3 ) m 3 /h 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 49/330 60/445 60/582 60/745 62/720 Stand-by Watt IP rating (integral protection) IP Acoustic power level max. db(a) Acoustic pressure level at 1 metre db(a) Condensate quantity (natural gas ) at 40/ 30 C l/h ph value of the condensate ca. 4.2 ca. 4.2 ca. 4.2 ca. 4.2 ca. 4.2 Values for flue calculation: Temperature class T120 T120 T120 T120 T120 Flue gas mass flow kg/h Flue gas temperature with operating conditions 80/ 60 C C Flue gas temperature with operating conditions 40/ 30 C C Volume flow rate combustion air Nm 3 /h Usable overpressure for air duct/flue system Pa UltraGas ( ) can also be operated with propane/butane (liquid gas) mixtures. 2 Boiler test pressure is 1.5 times max. operating pressure. 3 Although generally the UltraGas boilers do not require a minimum water flow, it does not mean that the pump and burner can be switched off together when the unit is operating at full output. There should be a pump overrun to dissipate any residual heat within the boiler to avoid nuisance high temperature lockouts. 4 NOx emissions to EN676 are dry and at 0% excess oxygen. UltraGas ( ) m 3 /h = Volume flow rate mbar = Flow resistance [m3/h] [m3/h]

11 UltraGas D Technical Data UltraGas ( ) Type (650) (720) (850) (1000) Nominal output 80/ 60 C with natural gas kw Nominal output 40/ 30 C with natural gas kw Nominal output 80/ 60 C with liquid gas 1 kw Nominal output 40/ 30 C with liquid gas 1 kw Heat input net CV basis with natural gas kw Heat input net CV basis with liquid gas 1 kw Working pressure heating max./min. 2 bar 6.0 / / / / 1.2 Working temperature max. C Boiler water content l Min. water flow rate 3 l/h Boiler weight (without water content, incl. casing) kg Boiler efficiency Part load 30% at 50/30 C (gross) % Boiler efficiency Full load 100% at 80/60 C (gross) % Part L UK Seasonal efficiency % Heat loss rate at 70 C Watt Standard emission rate Nitrogen oxides 4 mg/kwh Carbon monoxide mg/kwh Content of CO 2 in the exhaust gas max./min. output % 9.0 / / / / 8.8 Dimensions see table of dimensions Connections Flow/return DN DN125/ PN6 DN125/ PN6 DN125/ PN6 Gas Inches Rp 2" Rp 2" Rp 2" Rp 2" Flue gas Ø inside mm Gas flow pressure min./max. Natural gas E mbar Propane gas mbar Gas connection value at 0 C / 1013 mbar: Natural gas E - (Wo = 15,0 kwh/m 3 ) H u = 9,97 h/m 3 m 3 /h Propane gas 3 (H u = 25,9 kwh/m 3 ) m 3 /h Operation voltage V/Hz 230/50 230/50 230/50 1x230/50 3x400/50 Control voltage V/Hz 24/50 24/50 24/50 24/50 Min./max. electrical power consumption Watt 62/ / / /2730 Stand-by Watt IP rating (integral protection) IP Acoustic power level max. db(a) Acoustic pressure level at 1 metre db(a) Condensate quantity (natural gas ) at 40/ 30 C l/h ph value of the condensate ca. 4.2 ca. 4.2 ca. 4.2 ca. 4.2 Values for flue calculation: Temperature class T120 T120 T120 T120 Flue gas mass flow kg/h Flue gas temperature with operating conditions 80/ 60 C C Flue gas temperature with operating conditions 40/ 30 C C Volume flow rate combustion air Nm 3 /h Usable overpressure for air duct/flue system Pa UltraGas ( ) can also be operated with propane/butane (liquid gas) mixtures. 2 Boiler test pressure is 1.5 times max. operating pressure. 3 Although generally the UltraGas boilers do not require a minimum water flow, it does not mean that the pump and burner can be switched off together when the unit is operating at full output. There should be a pump overrun to dissipate any residual heat within the boiler to avoid nuisance high temperature lockouts. 4 NOx emissions to EN676 are dry and at 0% excess oxygen. Boiler flow resistance see diagrams. [mbar] UltraGas ( ) [m3/h] [mbar] UltraGas (850, 1000) [m3/h] DN125 PN6 m 3 /h = Volume flow rate mbar = Flow resistance 11

12 UltraGas D Dimensions UltraGas ( ) (All Measurements in mm) 11a Note: see separate page for installation clearances. The boiler height can be reduced provided clearance is maintained for the condensate discharge trap, item 10 (gravity drain only). For details see page 15. IMPORTANT: A loose Rp 2 fine gas filter is supplied with each UltraGas boiler for fitting by the installer adjacent to the boiler concerned. Suitable isolation should be provided to facilitate routine filter pad replacement. 1 Flow 2 Low temperature return 3 Gas connection left or right 4 Safety valve or calorifier primary 1 5 High temperature return 6 Electrical connection left or right 7 Drain (behind the front casing) 8 Flue gas connection left or right 9 Boiler control panel 10 Condensate discharge with trap 11 Air inlet connector (optional) 11a Motorised air intake shut off damper (optional) 12 Boiler foot adjustable up to 80 mm 13 Flow stool piece (optional) 14 Return stool piece (optional) 15 Expansion Rp 1 16 Pressure limiter Rp ¾ 17 Safety temperature control Rp ½ Type A B C D D1 E F G H I J K L M N O Q R (125,150) ( ) (350) ( ) ( ) (850,1000) Type S T U V W X Y Z 1,2, b (125,150) DN 65 / PN6 / 4 S Rp 1" R 1 ½" Ø155/159 DN25 Ø122/125 DN 110 ( ) DN 65 / PN6 / 4 S Rp 1 ½" R 1 ½" Ø252/256 DN25 Ø197/200 DN 110 (350) DN 100 / PN6 / 4 S Rp 1 ½" R 1 ½" Ø302/306 DN25 Ø197/200 DN 110 ( ) DN 100 / PN6 / 4 S Rp 2" R 1 ½" Ø302/306 DN25 Ø247/250 DN 180 ( ) DN 125 / PN6 / 8 S Rp 2" R 2" Ø302/306 DN40 Ø247/250 DN 180 (850,1000) DN 125 / PN6 / 8 S Rp 2" R 2" Ø402/406 DN40 Ø247/250 DN AAV must be fitted before any isolation valve * DN = nominal diameter, PN = nominal pressure, S = number of bolt holes in flange, example DN65 / PN6 / 4S 8 bar H version available for models 720 and 1000 only (supplied with PN16 connection flanges) 12

13 UltraGas D Dimensions UltraGas ( ) Boiler without casing and insulation (All measurements in mm) UltraGas Type A B C D E F G H I J K (125,150) ( ) (350) ( ) ( ) (850,1000) Required min. width of door and corridor to bring in the boiler The following are minimal dimensions K L B B < 150 K = T = B T B K x L x L B = Boiler width L = max. length of boiler T = Door width K = Corridor width T Calculation example for the necessary corridor width Door width T = 1000 UltraGas and 250D-2000D are delivered with the insulation, casings and control panel packed separately for fitting by the installer. UltraGas ( ) K = 970 x 1531 = corridor width

14 UltraGas D Dimensions UltraGas ( ) with shortened boiler feet (All measurements in mm) UltraGas Type A Cut off 120 mm (125, 150) ( ) ( ) ( ) (850, 1000) Neutralisation box (optional) 2 Condensate pump (optional) 3 Concrete plinth (not by Hoval) 4 Feet adjustable from mm UltraGas ( ) with concrete plinth and adjustable feet UltraGas Type A (125, 150) ( ) ( ) ( ) (850, 1000) UltraGas ( ) with concrete plinth without adjustable feet UltraGas Type A (125, 150) 1721 ( ) 1821 ( ) 1968 ( ) 1994 (850, 1000) 2047 Un-used boiler feet cannot be returned to Hoval for a refund. 14

15 UltraGas D Dimensions Space requirements UltraGas ( ) (All Measurements in mm) For burner door opening and access to top of the boiler this clearance must be provided Install gas line straight to the rear as shown UltraGas Type A A minimum B C D H H minimum (125, 150) ( ) ( ) ( ) (850, 1000) If there is not sufficient room height, dimension A can be reduced to A minimum 2 Attention! With A minimum the burner will no longer swing-open completely. This makes cleaning more difficult! 3 The boiler height can be reduced providing clearance is maintained for the condensate discharge trap. Please see page 14 for details. * If either side of the boiler has 500mm clearance the other side may be reduced to 150mm clearance. 15

16 UltraGas D Technical Data UltraGas (250D-700D) Type (250D) (300D) (400D) (500D) (600D) (700D) Nominal output 80/ 60 C with natural gas kw Nominal output 40/ 30 C with natural gas kw Nominal output 80/ 60 C with liquid gas 1 kw Nominal output 40/ 30 C with liquid gas 1 kw Heat input net CV basis with natural gas kw Heat input net CV basis with liquid gas 1 kw Working pressure heating max./min. 2 bar 5.0 / / / / / / 1.2 Working temperature max. C Boiler water content l Minimum water flow rate 3 l/h Boiler weight (without water content, incl. casing) kg Boiler efficiency Part load 30% at 50/30 C (gross) % Boiler efficiency Full load 100% at 80/60 C (gross) % Part L UK Seasonal efficiency % Stand-by loss at 70 C Watt Standard emission rate Nitrogen oxides 4 mg/kwh Carbon monoxide mg/kwh Content of CO 2 in the exhaust gas maximum/minimum output % 9.0 / / / / / / 8.8 Dimensions See table of dimensions Connections DN125/ Flow/return DN DN80/PN6 DN80/PN6 DN80/PN6 DN80/PN6 DN80/PN6 PN6 Gas x2 Inches 1" 1" 1½" 1½" 1½" 1½" Flue gas Ø inside mm Gas flow pressure min./max. Natural gas E mbar Propane gas mbar Gas connection value at 0 C / 1013 mbar: Natural gas E - (Wo = 15,0 kwh/m 3 ) H u = 9,97 kwh/m 3 m 3 /h Propane gas (H u = 32,7 kwh/m 3 ) m 3 /h Power Supply V/Hz 230/50 230/50 230/50 230/50 230/50 230/50 Control voltage V/Hz 24/50 24/50 24/50 24/50 24/50 24/50 Minimum/maximum electrical power consumption Watt 44/336 44/494 44/286 44/448 46/690 49/660 Stand-by Watt IP rating (integral protection) IP Acoustic power level max. db(a) Acoustic pressure level at 1 metre db(a) Condensate quantity (natural gas ) at 40/ 30 C l/h ph value of the condensate ph ca. 4.2 ca. 4.2 ca. 4.2 ca. 4.2 ca. 4.2 ca. 4.2 Values for flue calculation: Temperature class T120 T120 T120 T120 T120 T120 Flue gas mass flow kg/h Flue gas temperature with operating conditions 80/60 C C Flue gas temperature with operating conditions 40/30 C C Volume flow rate combustion air Nm 3 /h Usable overpressure for air duct/flue system Pa UltraGas (250D-700D) can also be operated with propane/butane (liquid gas) mixtures. 2 Boiler test pressure is 1.5 times max. operating pressure. 3 Although generally the UltraGas boilers do not require a minimum water flow, it does not mean that the pump and burner can be switched off together when the unit is operating at full output. There should be a pump overrun to dissipate any residual heat within the boiler to avoid nuisance high temperature lockouts. 4 NOx emissions to EN676 are dry and at 0% excess oxygen. Boiler flow resistance see separate page. Note, from a controls point of view UltraGas D boilers are seen as two units. This means that each unit will require its own power supply and controls signals. 16

17 UltraGas D Technical Data UltraGas (800D-1300D) Type (800D) (900D) (1000D) (1150D) (1300D) Nominal output 80/ 60 C with natural gas kw Nominal output 40/ 30 C with natural gas kw Nominal output 80/ 60 C with liquid gas 1 kw Nominal output 40/ 30 C with liquid gas 1 kw Heat input net CV basis with natural gas kw Heat input net CV basis with liquid gas 1 kw Working pressure heating max./min. 2 bar 6.0 / / / / / 1.2 Working temperature max. C Boiler water content l Minimum water flow rate 3 l/h Boiler weight (without water content, incl. casing) kg Boiler efficiency Part load 30% at 50/30 C (gross) % Boiler efficiency Full load 100% at 80/60 C (gross) % Part L UK Seasonal efficiency % Stand-by loss at 70 C Watt Standard emission rate Nitrogen oxides 4 mg/kwh Carbon monoxide mg/kwh Content of CO 2 in the exhaust gas maximum/minimum output % 9.0 / / / / / 8.8 Dimensions See table of dimensions Connections Flow/return DN DN125/PN6DN125/PN6DN125/PN6DN150/PN6DN150/PN6 Gas x2 Inches 2" 2" 2" 2" 2" Flue gas Ø inside mm Gas flow pressure minimum/maximum Natural gas E mbar Propane gas mbar Gas connection value at 0 C / 1013 mbar: Natural gas E - (Wo = 15,0 kwh/m 3 ) H u = 9,97 kwh/m 3 m 3 /h Propane gas (H u = 32,7 kwh/m 3 ) m 3 /h 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 Minimum/maximum electrical power consumption Watt 60/890 60/ / / /2060 Stand-by Watt IP rating (integral protection) IP Acoustic power level max db(a) Acoustic pressure level at 1 metre db(a) Condensate quantity (natural gas ) at 40/ 30 C l/h ph value of the condensate ph ca. 4.2 ca. 4.2 ca. 4.2 ca. 4.2 ca. 4.2 Values for flue calculation: Temperature class T120 T120 T120 T120 T120 Flue gas mass flow kg/h Flue gas temperature with operating conditions 80/ 60 C C Flue gas temperature with operating conditions 40/ 30 C C Volume flow rate combustion air Nm 3 /h Usable overpressure for air duct/flue system Pa UltraGas (800D-1300D) can also be operated with propane/butane (liquid gas) mixtures. 2 Boiler test pressure is 1.5 times max. operating pressure. 3 Although generally the UltraGas boilers do not require a minimum water flow, it does not mean that the pump and burner can be switched off together when the unit is operating at full output. There should be a pump overrun to dissipate any residual heat within the boiler to avoid nuisance high temperature lockouts. 4 NOx emissions to EN676 are dry and at 0% excess oxygen. Boiler flow resistance see separate page. Note, from a controls point of view UltraGas D boilers are seen as two units. This means that each unit will require its own power supply and controls signals. 17

18 UltraGas D Technical Data UltraGas (1440D-2000D) Type (1440D) (1700D) (2000D) Nominal output 80/ 60 C with natural gas kw Nominal output 40/ 30 C with natural gas kw Nominal output 80/ 60 C with liquid gas 1 kw Nominal output 40/ 30 C with liquid gas 1 kw Heat input net CV basis with natural gas kw Heat input net CV basis with liquid gas 1 kw Working pressure heating max./min. 2 bar 6.0 / / / 1.2 Working temperature max. C Boiler water content l Minimum water flow rate 3 l/h Boiler weight (without water content, incl. casing) kg Boiler efficiency Part load 30% at 50/30 C (gross) % Boiler efficiency Full load 100% at 80/60 C (gross) % Part L UK Seasonal efficiency % Stand-by loss at 70 C Watt Standard emission rate Nitrogen oxides 4 mg/kwh Carbon monoxide mg/kwh Content of CO 2 in the exhaust gas maximum/minimum output % 9.0 / / / 8.8 Dimensions See table of dimensions Connections Flow/return DN DN150/PN6 DN150/PN6 DN150/PN6 Gas x2 Inches 2" 2" 2" Flue gas Ø inside mm Gas flow pressure minimum/maximum Natural gas E mbar Propane gas mbar Gas connection value at 0 C / 1013 mbar: Natural gas E - (Wo = 15,0 kwh/m 3 ) H u = 9,97 kwh/m 3 m 3 /h Propane gas (H u = 32,7 kwh/m 3 ) m 3 /h Operation voltage V/Hz 230/50 230/50 1x 230/50 3x400/50 Control voltage V/Hz 24/50 24/50 24/50 Minimum/maximum electrical power consumption Watt 65/ / /5460 Stand-by Watt IP rating (integral protection) IP Acoustic power level max. db(a) Acoustic pressure level max. db(a) Condensate quantity (natural gas ) at 40/ 30 C l/h ph value of the condensate ph ca. 4.2 ca. 4.2 ca. 4.2 Values for flue calculation: Temperature class T120 T120 T120 Flue gas mass flow kg/h Flue gas temperature with operating conditions 80/ 60 C C Flue gas temperature with operating conditions 40/ 30 C C Volume flow rate combustion air Nm 3 /h usable overpressure for air duct/flue system Pa UltraGas (1440D-2000D) can also be operated with propane/butane (liquid gas) mixtures. 2 Boiler test pressure is 1.5 times max. operating pressure. 3 Although generally the UltraGas boilers do not require a minimum water flow, it does not mean that the pump and burner can be switched off together when the unit is operating at full output. There should be a pump overrun to dissipate any residual heat within the boiler to avoid nuisance high temperature lockouts. 4 NOx emissions to EN676 are dry and at 0% excess oxygen. Boiler flow resistance see separate page. Note, from a controls point of view UltraGas D boilers are seen as two units. This means that each unit will require its own power supply and controls signals. 18

19 UltraGas D Technical Data Boiler flow resistance UltraGas (250D,300D) [mbar] UltraGas (400D-600D) [mbar] one boiler operating one boiler operating both boilers operating both boilers operating [m 3 /h] [m 3 /h] UltraGas (700D-1000D) [mbar] UltraGas (1150D-1440D) [mbar] one boiler operating both boilers operating one boiler operating both boilers operating [m 3 /h] [m 3 /h] UltraGas (2000D) [mbar] one boiler operating m 3 /h = Volume flow rate mbar = Flow resistance both boilers operating [m 3 /h] 19

20 UltraGas D Dimensions UltraGas (250D-2000D) (All measurements in mm) The boiler height can be reduced provided clearance is maintained for the condensate discharge trap, item 10 (gravity drain only). Optional flow and return stool pieces not shown (two sets required per UltraGas D twin boiler) UltraGas Type (250D, 300D) (400D-600D) (700D) (800D-1000D) (1150D-1440D) (1700D, 2000D) A B C C1 D E F G H I J K L M N O P Q UltraGas Type (250D-300D) 1 Flow (Boiler)... DN65/ PN6/4S* (400D-600D) (700D) (800D-1000D) (1150D-1440D) (1700D-2000D) DN65/ PN6/4S* DN100/ PN6/8S* DN100/ PN6/8S* DN125/ PN6/8S* DN125/ PN6/8S* 1a Flow (Optional header) 1... DN80/ PN6/4S* DN80/ PN6/4S* DN125/ PN6/8S* DN125/ PN6/8S* DN150/ PN6/8S* DN150/ PN6/8S* 2 Low temp return (Boiler)... DN65/ PN6/4S* DN65/ PN6/4S* DN100/ PN6/8S* DN100/ PN6/8S* DN125/ PN6/8S* DN125/ PN6/8S* 2a Low temp return (Optional header) 1.. DN80/ PN6/4S* 3 Gas inlet... Rp 1" R 1½" 4 Safety valve or calorifier primary 3... DN80/ PN6/4S* DN125/ PN6/8S* DN125/ PN6/8S* DN150/ PN6/8S* DN150/ PN6/8S* Rp 1½" Rp 1½" Rp 2" Rp 2" Rp 2" R 1½" R 1½" R 1½" R 2" R 2" 5 High temperature return (Boiler)... DN65/ PN6/4S* DN65/ PN6/4S* DN100/ PN6/8S* DN100/ PN6/8S* DN125/ PN6/8S* DN125/ PN6/8S* 5a High temp return (Optional header) 1.. DN80/ PN6/4S* 6 Hydraulic shut off valve (optional) 7 Motorised air intake shut off damper Ø104/110 8 Flue gas outlet connection left or right possible ID/OD... Ø254/256 9 Flue gas header 10 Condensate discharge with trap... DN25 11 Boiler feet adjustable up to 80 mm 12 Cleaning opening DN80/ PN6/4S* DN125/ PN6/8S* DN125/ PN6/8S* DN150/ PN6/8S* DN150/ PN6/8S* Ø104/110 Ø104/110 Ø180/182 Ø180/182 Ø180/182 Ø306/308 Ø356/358 Ø356/358 Ø356/358 Ø502/506 DN25 DN25 DN25 DN40 DN40 The connection sizes shown on this page are for the optional flow/return headers, see accessories. The UltraGas (D) twin boiler consists of two boilers of half the output example UltraGas 250D = 2 x UltraGas 125. Each of the two boilers requires both an electrical supply and a gas supply. 3 AAV must be fitted before any isolation valve on each of the two boilers. * DN = nominal diameter, PN = nominal pressure, S = number of bolt holes in flange, example DN80/ PN6/4S 1 Notes See UltraGas ( ) Dimensional details page for dimensions and connection sizes1 of individual boilers2 2 8 bar H version available for models 1440D and 2000D only (supplied with PN16 connection flanges) 20 See separate page for installation clearances IMPORTANT: Two loose Rp 2 fine gas filters are supplied with each of the twin UltraGas 800D to 2000D boilers for fitting by the installer adjacent to the two boilers comprising the twin unit. Suitable isolation should be provided to facilitate routine filter pad replacement.

21 UltraGas D Dimensions UltraGas (250D-2000D) with shortened boiler feet (All measurements in mm) UltraGas Type A Cut off 120 mm (250D, 300D) (400D - 600D) (700D D) (1150D D) (1700D, 2000D) UltraGas (250D-2000D) with concrete plinth and adjustable feet 1 Neutralisation box (optional) 2 Condensate pump (optional) 3 Concrete plinth (not by Hoval) 4 Feet adjustable from mm UltraGas Type A (250D, 300D) (400D - 600D) (700D D) (1150D D) (1700D, 2000D) UltraGas with concrete plinth without adjustable feet UltraGas Type A (250D, 300D) 1721 (400D - 600D) 1821 (700D D) 1968 (1150D D) 1994 (1700D, 2000D) 2047 Un-used boiler feet cannot be returned to Hoval for a refund. 21

22 UltraGas D Dimensions Space requirements UltraGas (250D-2000D) (All measurements in mm) For swinging out the burner this clearance must be ensured Install gas line straight to the back with hydraulic connection set UltraGas Type A A minimum B C D H H minimum (250D, 300D) (400D-600D) (700D-1000D) (1150D-1440D) (1700D, 2000D) If there is not sufficient room height, dimension A can be reduced to A minimum 2 Attention! With A minimum the burner will no longer swing-open completely. This makes cleaning more difficult! 3 The boiler height can be reduced providing clearance is maintained for the condensate discharge trap. Please see page 21 for details. 4 If either side of the boiler has 500mm clearance the other side may be reduced to 150mm clearance. 22

23 UltraGas D Dimensions Space requirements UltraGas ( ), UltraGas (250D-2000D) - Gas filter (All Measurements in mm) In addition allowance should be provided for the RP2 fine gas filter(s) supplied with each UltraGas 400 to 1000 or twin UltraGas 800D-2000D boiler (Part No ) as follows: Fine gas filter installation and maintenance: Each filter will be supplied loose for the Installer to fit adjacent to the boiler concerned. It should be possible for the gas filter to be isolated to allow the filter pad to be replaced as required (recommended to be done at least annually or when the pressure drop across the filter reaches 2.5 mbar. This can be measured across the two test points fitted on the filter top cover). The pressure drop through a clean gas filter is as follows and needs to be taken into account by system designers along with an allowance for an increase if the filter becomes dirty: A B C D Gas Filter UltraGas 400 UltraGas 450 UltraGas 500 UltraGas 575 UltraGas 650 UltraGas 720 UltraGas 850 UltraGas 1000 (0.5 mbar) (0.6 mbar) (0.8 mbar) (0.5 mbar) (0.6 mbar) (0.7 mbar) (1.0 mbar) (1.4 mbar) The gas filter also applies for the UltraGas D boiler. Two RP2 gas filters are required in this instance for each twin Ultra- Gas 800D to 2000D boiler (Part No ). The pressure drops across the filters are as follows: UltraGas 800D UltraGas 900D UltraGas 1000D UltraGas 1150D UltraGas 1300D UltraGas 1440D UltraGas 1700D UltraGas 2000D (0.5 mbar) (0.6 mbar) (0.8 mbar) (0.5 mbar) (0.6 mbar) (0.7 mbar) (1.0 mbar) (1.4 mbar) For twin UltraGas boilers the pressure drop is per individual filter. 23

24 UltraGas D Flue System / Ventilation Flue design UltraGas ( D) A minimum temperature class T120 flue can be used if fitted with an over temperature device. The first 2 metres of flue gas pipe must be the same diameter as the boiler flue gas connection. Single wall flues may be used as it is not necessary to keep the flue gas temperature high. The flue gas is very cool and saturated with moisture so there will be very little or no buoyancy to pull the gases up the chimney. The burner fan assists with the evacuation of the flue gases so there may be slight pressurisation of the flue. Flues must be leak proof against condensate and suitable for pressurised flue gases. It is permissible for the condensate from the flue system to drain back through the boiler. Horizontal flue sections must be inclined back to the boiler (3 minimum) to prevent condensate remaining in the flue. If combustion air ducting is used this should be the same size as the flue. Flues must be designed to meet all current regulations / standards. On installations with multiple boilers into a single flue the flue system must be designed to prevent any back circulation of flue gases into the plant room (fitting air shut off dampers enable this criteria to be easily met - see accessories). See Technical data section for flue gas mass flow rates, temperatures and usable fan overpressure. The tables below are for guidance only. Type Boiler Flue size (smooth walled) Number of 90 bends (flue + air supply) Flue gas connection (mm) Dimension Flue (mm) Maximum total length in metres (flue + air supply) UltraGas internal DN outside inside * (125) (150) (125) (150) (200) (250) (125) (150) (200) (250) (200) (250) (300) (350) ( ) ( ) ( ) (850) ( ) (250D) (300D) (250D-300D) (400D) (500D) (400D-600D) (700D) (800D) (900D) (1000D) (700D-900D) (1000D) (1150D) (1300D) (1150D-1300D) (1440D) (1700D-2000D) Figures are based on the flue entering the vertical at 90, for 45 entry or if 45 bends are used longer flue lengths may be possible. * With 5 bends or more the usable overpressure of the fan must be reduced by 30% and a flue calculation done. With flue lengths over 50 metres a seperate calculation must be done. Ventilation For installations not exceeding 70kW total nominal input (net) refer to BS5440-2:current edition. For installations over 70kW total nominal input (net) both high and low level or mechanical ventilation is required, calculate to BS6644:current edition. 24

25 UltraGas D Accessories 100/150PP Concentric flue parts for UltraGas 70, / 500 / / 490 / Connection C100/150 to 2xE100PP For separate routing of flue gases and combustion air. Recommendation: If the air inlet is near a noise sensitive place (window of bedroom, terrace etc.) we recommend the use of a sound absorber on Ø the air inlet Ø152 Ø Ø / 500 / / 490 / / 500 / / / Wall terminal for horizontal discharge mm extension (including support bracket) 500mm extension (including support bracket) 250mm extension Ø102 Ø Ø152 Ø Ø102 Ø Vertical terminal (black) with cap (including support bracket) Ø152 Ø degree bend Wall terminal max 140 Vertical adaptor Complete with 2 sample points Vertical adaptor Ø Ø Wall plate Wall plate 40 Ø degree bend Wall terminal 1220 max degree elbow Vertical adaptor 100 Wall plate Wall plate 40 Ø degree elbow Ø102 Ø Ø152 Ø102 Ø152 Ø Ø Ø152 Ø102 Ø Ø152 Ø Ø152 Ø152 Ø102 Ø Support bracket Ø152 Ø

26 UltraGas D Accessories 100/150PP Concentric flue parts for UltraGas 70, Lead pitched roof flashing (to suit roof angle degrees) Ø Aluminium flat roof flashing max degree bend 195 Vertical Wall terminal Wall plate Wall plate Wall terminal kit (for horizontal discharge) Comprises of vertical adaptor, 93 degree elbow and 2 wall plates. Max dimension can be extended by use of extension pieces adaptor All items finished white RAL Horizontal flue gas connection adaptor E100PP for UltraGas (70, 100) Adaptor to convert horizontal flue gas connection (above) to concentric. Includes air tube for connection to venturi. 75mm dia for UltraGas (70)

27 UltraGas D Accessories Single thermostat with setting in the casing C externally visible setting in the casing, immersion depth 100/150 mm Differential gap 6K, splash proof polymer casing, nickel-plated brass immersion sleeve with thread seal G ½, max. operating pressure 10 bar. 1 changeover contact max. 6 A (ind.) at 230 V Single thermostat - immersion depth 100 mm RAKTW.1000B Single thermostat - immersion depth 150 mm RAKTW.1000S Clamp-on flow temperature controller RAK-TW1000S C, setting (visible from the outside) inside the housing cover, with tensioning band Calorifier thermostat control TW 12 Universal storage tank thermostat controller for calorifier pump starting Setting in casing, visible from outside C Switching differential 6K Capillary length 700 mm Incl. fastening material for Hoval storage tanks Can be used with integrated immersion socket Flue gas thermostat AGT 519 Switching temperature 80 C (switching differential approx. 15K) 1 switchover contact 10A at 230 V/ 50 Hz ohm resistive load Simple screw fastening on flue pipe, with 2 m connecting cable Tested according to DIN Temperature controller LAE LTR-5TSRE Electronic 2 point temperature controller C switching interval 1-25 K 1 switchover contact cable sensor 2 m/ ø 0.7 mm

28 UltraGas D Accessories TopTronic E module expansions for TopTronic E basic module heat generator TopTronic E module expansion heating circuit TTE-FE HK Expansion to the inputs and outputs of the basic module heat generator or the heating circuit/domestic hot water module for implementing the following functions: 1 heating circuit without mixer or 1 heating circuit with mixer OR ODER incl. fitting accessories 1x contact sensor ALF/2P/4/T L = 4.0 m Can be installed in: Boiler control panel, wall housing, separate control panel Note The supplementary plug set may have to be ordered to implement functions differing from the standard! TopTronic E module expansion heat accounting TTE-FE WMZ/EBZ Expansion to the inputs and outputs for the basic module heat generator for implementing the following functions: Calculating total energy consumption Calculating the heat generator energy for heating Calculating the heat generator energy for hot water incl. fitting accessories 3x contact sensor ALF/2P/4/T L = 4.0 m Can be installed in: Boiler control panel, wall housing, separate control panel Note Suitable flow rate sensors (pulse sensors) must be provided on site. TopTronic E module expansion Universal TTE-FE UNI Expansion to the inputs and outputs of a controller module (basic module heat generator, heating circuit/domestic hot water module, solar module, buffer module) for implementing various functions incl. fitting accessories Can be installed in: Boiler control panel, wall housing, separate control panel Note Refer to the Hoval website for suitable hydraulic arrangements. 28

29 UltraGas D Accessories Accessories for TopTronic E Supplementary plug set for basic module heat generator (TTE-WEZ) for controller modules and module expansion TTE-FE HK TopTronic E controller modules TTE-HK/WW TopTronic E heating circuit/ hot water module TTE-SOL TopTronic E solar module TTE-PS TopTronic E buffer module TTE-MWA TopTronic E measuring module TopTronic E room control modules TTE-RBM TopTronic E room control modules easy white comfort white comfort black Enhanced language package TopTronic E one SD card required per control module Consisting of the following languages: HU, CS, SK, RO, PL, TR, ES, HR, SR, PT, NL, DA TopTronic E remote Gateway connection TTE-GW TopTronic E online LAN TTE-GW TopTronic E online WLAN SMS remote control unit System component SMS remote control unit TopTronic E interface modules GLT module 0-10 V Gateway module ModBus TCP/ RS485 Gateway module KNX TopTronic E wall casing WG-190 Wall casing small WG-360 Wall casing medium WG-360 BM Wall casing medium with control module cut-out WG-510 Wall casing large WG-510 BM Wall casing large with control module cut-out TopTronic E sensors AF/2P/K Outdoor sensor TF/2P/5/6T Immersion sensor, L = 5.0 m ALF/2P/4/T Contact sensor, L = 4.0 m TF/1.1P/2.5S/6T Collector sensor, L = 2.5 m System housing System housing 182 mm System housing 254 mm Bivalent switch

30 UltraGas D Accessories Sensors for heating technology Outdoor sensor AF/2P/K for TopTronic E controller modules/module expansions with exception of basic module district heating/fresh water or basic module district heating com Terminal connection Sensor may already be included in scope of delivery of heat generator Dimensions: 80 x 50 x 28 mm (H x W x T) Operating temperature: C Index of protection: IP x4 Incl. fitting accessories Contact sensor ALF / 2P /2 /T /K, L = 2.0 m incl. connection box for TopTronic E controller modules/module expansions with exception of basic module district heating/fresh water or basic module district heating com Cable length: 2 m with connection box Moisture-proof Operating temperature: C Index of protection: IP67 Contact sensor ALF/2P/4/T, L = 4.0 m for TopTronic E controller modules/module expansions with exception of basic module district heating/fresh water or basic module district heating com Cable length: 4 m without plug Moisture-proof Operating temperature: C Index of protection: IP67 Contact sensor ALF / 2P /4 /T /S1, L = 4.0 m with plug for TopTronic E controller modules/module expansions with exception of basic module district heating/fresh water or basic module district heating com Cable length: 4 m with plug Moisture-proof Operating temperature: C Index of protection: IP67 Immersion sensor TF/2P/2.5/6T, L = 2.5 m for TopTronic E controller modules/module expansions with exception of basic module district heating/fresh water or basic module district heating com Cable length: 2.5 m without plug (plug supplied with controller module/ module expansion) Sensor sleeve diameter: 6 x 50 mm Moisture-proof Sensor may already be included in scope of delivery of heat generator/controller module/ module expansion Operating temperature: C Index of protection: IP Immersion sensor TF/2P/2.5/6T /S1, L = 2.5 m, with plug for TopTronic E controller modules/module expansions with exception of basic module district heating/fresh water or basic module district heating com Cable length: 2.5 m with plug Sensor sleeve diameter: 6 x 50 mm Moisture-proof Sensor may already be included in scope of delivery of heat generator/controller module/ module expansion Operating temperature: C Index of protection: IP67 30

31 UltraGas D Accessories Immersion sensor TF / 2P /2.5S /6T, L = 2.5 m silicone for TopTronic E controller modules/module expansions with exception of basic module district heating/fresh water or basic module district heating com For use at high ambient temperatures Cable length: 2.5 m (silicone) without plug (plug supplied with controller module/module expansion) Sensor sleeve diameter: 6 x 50 mm Moisture-proof Operating temperature: C Index of protection: IP Immersion sensor TF / 12N /2.5 /6T, L = 2.5 m for gas boiler with TopTronic RS-OT Cable length: 2.5 m Sensor sleeve diameter: 6x50 mm Moisture-proof Operating temperature: C Index of protection: IP Immersion sensor TF/2P/5/6T, L = 5.0 m for TopTronic E controller modules/module expansions with exception of district heating/fresh water or basic module district heating com Cable length: 5 m without plug Sensor sleeve diameter: 6 x 50 mm Moisture-proof Operating temperature: C Index of protection: IP Immersion sensor TF/2P/5/6T, L = 5.0 m, with plug for TopTronic E controller modules/module expansions with exception of basic module district heating/fresh water or basic module district heating com Cable length: 5 m with plug Sensor sleeve diameter: 6 x 50 mm Moisture-proof Sensor may already be included in scope of delivery of heat generator/controller module/ module expansion Operating temperature: C Index of protection: IP Flue gas temperature sensor TF / 1.1P /5 /4 /B, L = 5.0 m for TopTronic E controller modules/module expansions with exception of basic module district heating/fresh water or basic module district heating com Cable length: 5 m without plug (plug supplied with controller module/module expansion) Sensor sleeve diameter: 4 x 200 mm Moisture-proof Operating temperature: C Index of protection: IP67 Supplied with fastening flange and screws Collector sensor TF/1.1P/2.5S/5.5T, L = 2.5 m for TopTronic E solar module solar controllers ESR and UVR Collector sensor for solar plants Cable length: 2.5 m (silicone) without plug Sensor sleeve diameter: 6 x 50 mm Moisture-proof Operating temperature: C Index of protection: IP

32 UltraGas D Accessories Sensors for district heating Outdoor sensor AF/1.1P/K FW for TopTronic E basic module district heating/ fresh water or basic module district heating com Sensor for district heating applications (PT1000) Terminal connection Sensor may already be included in scope of delivery of heat generator Dimensions:: 80 x 50 x 28 mm (H x W x D) Operating temperature: C Index of protection: IP x4 Incl. fitting accessories Immersion sensor TF/1.1P/2.5/6T, L = 2.5 m FW for TopTronic E basic module district heating/ fresh water, basic module district heating com, fixed setting controller RKP Sensor for district heating applications (PT1000) Cable length: 2.5 m without plug (plug supplied with controller module/module expansion) Sensor sleeve Diameter: 6 x 50 mm Moisture-proof Sensor may already be included in scope of delivery of heat generator/controller module/ module expansion Operating temperature: C Index of protection: IP Contact sensor ALF/1.1P/2.5/T, L = 2.5 m FW for TopTronic E basic module district heating/ fresh water or basic module district heating com Sensor for district heating applications (PT1000) Cable length: 2.5 m without plug (plug supplied with controller module/module expansion) Moisture-proof Sensor may already be included in scope of delivery of heat generator/controller module/ module expansion Operating temperature: C Index of protection: IP Fast temperature sensor KTY with screw connection G ½ Cable length: 2000 mm Clamp connectors for the extension of sensor lines

33 UltraGas D Accessories Bivalent switch for installation in the boiler control panel Can be used with bivalent systems for changing over priorities between heat generators or in other plant-specific switching procedures Can be installed in the TopTronic E heat generator control panel 2-part switch combination of operation interruption heat generator and bivalent switch Max. 1 bivalent switch can be installed Voltage: 230 V

34 UltraGas D Accessories *supplied as standard with UltraGas and UltraGas 800D-2000D Fine gas filter with pressure test point before and after the filter (diameter. 9mm) Pore width of the filter element <50 μm Max. pressure difference 2.5 mbar Max. inlet pressure 100 mbar Type Connection 70612/6B Rp 3/ /6B Rp /6B Rp 1 1/ /6B Rp 1 1/ /6B Rp * Condensate disposal for UltraGas Possible mounting variations for neutralisation: 1 without neutralisation (siphon supplied). 2 with neutralisation box under the boiler. 3 with condensate pump next to the boiler. 4 with neutralisation box under the boiler and with condensate pump next to the boiler. Neutralisation box for UltraGas (15,50) For transporting condensate via gravity. Including condensate neutraliser. To be installed in the boiler base Neutralisation box for UltraGas (70,100) For transporting condensate via gravity. Including condensate neutraliser. To be installed in the boiler base Condensate pump For pumped condensate delivery. Including connecting wiring, cable and plug for connection to the boiler control. Installation on the left or right beside the boiler Neutralisation granulate for neutralisation box Refill set of granulate for neutralisation, volume 3 kg (12 kg required per neutralisation box)

35 UltraGas D Accessories Condensate disposal for UltraGas / 250D-2000D Neutralisation box placed under the boiler (two required per twin D boiler) Type KB 22 For pumped condensate delivery. - condensate pump and float switch included - without neutralisation granulate - from 1200kW, two condensate pumps are required Type KB 23 For condensate drainage via gravity. - with 12 kg neutralisation granulate Type KB 24 For pumped condensate delivery. - condensate pump and float switch included - with 12 kg neutralisation granulate - from 1200kW, two condensate pumps are required Condensate pump For pumped condensate delivery. Including connecting wiring, cable and plug for connection to the boiler control Neutralisation granulate for neutralisation box Refill set of granulate for neutralisation, volume 3 kg (12 kg required per neutralisation box)

36 UltraGas D Accessories Air inlet connection for UltraGas Connection for direct combustion air inlet UltraGas UltraGas UltraGas 350 UltraGas UltraGas UltraGas 850 UltraGas 1000 Recommendation: If the air inlet is near a noise sensitive place (window of bedroom, terrace etc.) we recommend the use of a sound absorber on the air inlet. Not required if air shut off valve fitted tba tba Air shut off damper for UltraGas Motorised air intake shut off damper Connector for direct combustion air supply with motorised flaps. Can also be used for cascading boiler systems with a common flue arrangement. Complete with cabling. UltraGas DN 110 UltraGas DN Fitted as standard on 250D-2000D Twin boiler hydraulic header sets for UltraGas 250D-2000D (not suitable for H1440D & H2000D) Flow/Return Hydraulic header set for twin boiler including motorised shut off valve. UltraGas 250D - 600D UltraGas 700D D UltraGas 1150D D UltraGas 1700D D High temperature return Hydraulic header set for twin boiler (can also be used as flow header if motorised shut off valves not required). UltraGas 250D - 600D UltraGas 700D D UltraGas 1150D D UltraGas 1700D D Hydraulic shut off valves for UltraGas D Hydraulic shut off valve Installed directly onto flow and or return when no flow/return set has been ordered. Complete with plugs and cabling. Two valves required per twin boiler UltraGas piece DN65 UltraGas piece DN100 UltraGas & H720/H piece DN

37 UltraGas D Accessories Boiler connection set for UltraGas Connection set AS25-S/NT/HT for mounting a heating armature group HA25 for UltraGas (15-27) Suitable for left or right connection Low/high temperature Connection set, fully thermally insulated Rigid flow pipe and flexible return flow pipe For mounting an armature group HA20 adapter set DN20 - DN25 necessary. Delivery: Connection set in assembly units, completely packed Connection set AS32-S/NT/HT for mounting a heating armature group HA32 for UltraGas (35,50) Suitable for left or right connection Low/high temperature Rigid flow pipe and flexible return flow pipe, thermally insulated with fastening material adapter set DN25 - DN32 necessary. Delivery Connection set in assembly units, complete packet Connection set AS40-S/NT/HT for mounting a heating armature group HA40 for UltraGas (70,100) Connection set fully thermally insulated Rigid flow pipe and flexible return flow pipe with threaded flange R1½ Suitable for left or right connection Low/high temperature Adapter set DN32 - DN40 necessary. Delivery Connection set in assembly units, complete packet Connection set AS 25-LG for UltraGas (15-27) for mounting a compact charging group LG-2 Suitable for left or right connection, low-temperature return connection set in assemblies, with complete thermal insulation consisting of flexible tubes

38 UltraGas D Accessories Hoval heating armature groups for UltraGas Heating armature group HA-3BM-R with 3-port mixing valve and heat-insulating box. Installation on the right side (flow on the left). HA group type Pump type DN20 (¾ ) Pump with stepless rotation speed control HA20-3BM-R/AX 12-4 AX HA20-3BM-R/AX 13-4 AX DN25 (1 ) Pump with stepless rotation speed control HA25-3BM-R/AX 12-1 AX HA25-3BM-R/AX 13-1 AX HA25-3BM-R without pump Pumps for HA25-3BM-R for heating armature group HA25-3BM-R without pump. Transition pieces and threaded flanges can be ordered separately if necessary. A V A V DN32 (1¼ ) Pump with stepless rotation speed control HA32-3BM-R/AX 13-2 AX HA32-3BM-R/A15-2 A HA32-3BM-R without pump Pumps for HA32-3BM-R for heating armature group HA32-3BM-R without pump. Transition pieces and threaded flanges can be ordered separately if necessary. A V A V DN40 (1½ ) HA40-3M-R without pump Pumps for HA40-3M for heating armature group HA40-3M without pump. Transition pieces and threaded flanges can be ordered separately if necessary. A V Transition piece Z17 Threaded flange Z29 A V Transition piece Z17 Threaded flange Z29 A V ModulA PN V

39 UltraGas D Accessories Hoval heating armature groups for UltraGas Heating armature group HA-3BM-L with 3-port mixing valve, actuator and heatinsulating box. Installation on the left side. HA group type Pump type DN20 (¾ ) Pump with stepless rotation speed control HA20-3BM-L/AX 12-4 AX HA20-3BM-L/AX 13-4 AX DN25 (1 ) Pump with stepless rotation speed control HA25-3BM-L/AX 12-1 AX HA25-3BM-L/AX 13-1 AX DN32 (1¼ ) Pump with stepless rotation speed control HA32-3BM-L/AX 13-2 AX HA32-3BM-L/A 15-2 A Adapter set DN32-DN25 for the installation of the HA group DN32 to a connection set DN Adapter fitting DN32-DN40 for the installation of the HA group DN32 to a wall distributor DN40 or a connection set AS40-S/NT/ HT Adapter set DN20-DN25 for the installation of the HA group DN20 to a wall distributor DN25 or a connection set DN25. Installation height 120 mm Adapter fitting DN25-DN32 for the installation of the HA group DN25 to a wall distributor DN

40 UltraGas D Accessories Loading group LG-2/ Heating armature group HA-2 For connection of a free-standing calorifier, resp. as heating circle without mixing operation, incl. thermal insulation box. Mounting on the right (flow on the left). LG/HA group type Pump type DN20 (¾ ) Pump with stepless rotation speed control LG/HA20-2/AX12-4 AX DN25 (1 ) Pump with stepless rotation speed control LG/HA25-2/AX 12-1 AX LG/HA25-2/AX 13-1 AX DN32 (1¼ ) Pump with stepless rotation speed control LG/HA32-2/AX 13-2 AX Pressure expansion tanks, heating armature groups and wall distributors see separate brochure Wall brackets for mounting a Hoval armature group on the wall. Axle spacing Connection Wall clearance Type mm top bottom mm DN Rp 1 R 1 70,85, DN Rp 1½ R DN Rp 2 R 1½ 142, Installation example Installation example Installation example for UltraGas (15-50) Safety set SG15-1 Suitable up to max. 50 kw complete with safety valve (3 bar) Pressure gauge and automatic air vent with cut off valve Connection: 1 internal thread for UltraGas (70,100) Safety set SG20-1 Range of application to 100 kw complete with safety valve (3 bar) Pressure gauge and autom. aspirator with shut-off valve. Connection: DN20 1 internal thread Safety set Complete with safety valve (3 bar), Pressure gauge and autom. aspirator with shut-off valve. Connection inner thread For UltraGas ( ) DN 25 - Rp 1 to 200 kw For UltraGas ( ) DN32 - Rp 1¼ to 350 kw Boiler plinth for UltraGas (15-50) to elevate the condensate drainage made of steel height 150 mm anthracite painted

41 UltraGas D Accessories Automatic quick release air vent ½ with cut-off valve Accessory for sludge separator (not supplied as standard) Flow and return stool pieces for assembly on flow and high or low temperature return of the Hoval UltraGas boiler. Complete with gasket, nuts and bolts for connection of - an additional safety temperature limiter and a maximum pressure limiter set on the flow - an expansion vessel on the return (not by Hoval) Two sets required per UltraGas D twin boiler Part no below also required Flow stool piece Dimension Suitable for UltraGas Connection DN 65 ( ) flow DN 65 ( ) return DN 100 ( ) flow DN 100 ( ) return DN 125 ( ) flow DN 125 ( ) return Return stool piece Further information see Dimensions Maximum pressure limiter set suitable for use with the above flow and return stool pieces to meet the safety requirements of EN > 300 kw (single boiler) or SWKI 93-1 > 70 kw. Consisting of: - adjustable maximum pressure limiter - safety temperature limiter RAK-ST.131 and cock Two sets required per UltraGas D twin boiler

42 UltraGas D Typical hydraulic schematics UltraGas boiler with - Direct heating circuit SV AAV UltraGas boiler with - Free standing calorifier - Direct heating circuit - 1 or 2 mixed heating circuits TD ATS SV AAV TD ATS TPV Notice : - This hydraulic schematic just shows the RBM Control module ATS Anti-thermal siphon dip to prevent basic principle. The installation must be AF Outdoor sensor gravity circulation in accordance with local regulations. VF1 Flow sensor 1 TPV Temperature and pressure relief VF2 Flow sensor 2 valve - With underfloor heating an over SF Calorifier sensor TD Tundish to drain temperature thermostat has to be installed. B1 Flow temperature thermostat SV Safety Valve (series connection with pump) AAV Automatic air vent - Anti thermal siphon dip has to be installed. MK1 Pump mixed circuit 1 STB Safety temperature limiter MK2 Pump mixed circuit 2 Pmax Pressure limiter - up to eight boilers can be linked together to SLP Calorifier loading pump TTE-GW Gateway provide sequence control YK1 Actuator mixer 1 TTE-WEZ Base module heat generator YK2 Actuator mixer 2 TTE-FEHK Extension module 42 HT High temperature return NT Low temperature return

43 UltraGas D Typical hydraulic schematics UltraGas boilers with - Boiler cascade (2-8 boilers) - Free standing calorifier - a direct heating circuit SV AAV SV AAV SV AAV AAV TD TD TD TPV UltraGas D boiler with - Free standing calorifier - Return flow separation - 1 mixed heating circuit (high temperature return) - 1 mixed heating circuit (low temperature return) SV AAV SV AAV TD TD ATS TPV Notice : - This hydraulic schematic just shows the basic principle. The installation must be in accordance with local regulations. - With underfloor heating an over temperature thermostat has to be installed. - Anti thermal siphon dip has to be installed. - up to eight boilers can be linked together to provide sequence control RBM Control module AF Outdoor sensor VF1 Flow sensor 1 VF2 Flow sensor 2 SF Calorifier sensor B1 Flow temperature thermostat (series connection with pump) MK1 Pump mixed circuit 1 MK2 Pump mixed circuit 2 SLP Calorifier loading pump YK1 Actuator mixer 1 YK2 Actuator mixer 2 HT High temperature return NT Low temperature return ATS TPV TD SV AAV STB Pmax TTE-GW TTE-WEZ Anti-thermal siphon dip to prevent gravity circulation Temperature and pressure relief valve Tundish to drain Safety Valve Automatic air vent Safety temperature limiter Pressure limiter Gateway Base module heat generator 43

44 UltraGas D Hoval Service Notes: All UltraGas boilers are commissioned by our dedicated service team. Service For annual servicing of UltraGas boilers and other equipment please contact our Hoval service department direct dial: or Additional technical and installation information Additional technical and installation information is available to download from our website (please go to the Operating and Maintenance Instructions download page). Information is available on water quality requirements, assembly, operation and servicing. 44

45 An expert partner One-stop shopping With us you can easily incorporate gas, oil, heat pump, solar, CHP, or biomass energy solutions into your heating system. Technical advice We are happy to assist you and your planning partners in developing intelligent systems, allowing you to take advantage of our expertise and the experience of our specialists. After sales For specialist commissioning and maintenance of your Hoval equipment, contact our service and spares department. Hoval Ltd Northgate Newark-on-Trent Nottinghamshire NG24 1JN United Kingdom Phone Fax /15 Responsibilty for energy and environment Hoval follows a policy of continued improvement and reserves the right to change specifications without notice.