Important telephone numbers

Heating installer

Plumbing system installer

Electrical installer

Fuel supplier

Chimney sweep

To be completed by the heating specialist:

Order No.:

Boiler type:

Neutralisation system: yes noCondensate lifting pump: yes no

Set to: Natural gas H Natural gas L Liquid gas

Heating pump type:

Heating controller type:

Mixer type:

Separate calorifier type:Calorifier sensor Thermostat

Outside temperature sensorRoom temperatur sensor

Combustion air supply Room Outside

Heating calculation principles

Lowest outside temperature: °C

Heat requirement: kW

Max. feed temperature: °C

Operating instructionsUltraGas AM condens (50-350)

4 200 191 / 01 Subject to changes

Hoval LTDNorthgateNewarkNottinghamshire NG24 1JNPhone: 01636 672 711Fax: 01636 673 532

4 200 191 / 012Safety instructions

In the case of danger:

• Cut off the fuel immediately (gas) and electricalsupply!

If you smell gas(Operation with a gas blower burner)

Do not smokePrevent the occurrence of open fire andsparks (e.g. do not on lights or electricalappliances)

Open windows and doors

Close the gas cock

Notify the heating specialist/installer

Comply with the safety regulations of thegas supply authority (see gas meter) andthe heating firm!

If you smell flue gas:

• Shut down the system

• Open windows and doors

• Notify the heating specialist

Maintain an air supply in theboiler installation room(windows):Openings for air inlet and outletmust not be closed, or there willbe no combustion air (see page1). Closed air inlets can lead toincomplete combustion andpossible poisoning.

General information

Dear Hoval CustomerWith your Hoval UltraGas AM condens you haveacquired a product manufactured according to thestate-of-the-art and to the very highest qualitystandards.

For the correct installation and operation of your HovalUltraGas AM condens, all applicable laws, regulationsand standards must be complied with; in particular theregulations of the responsible energy supplyauthorities. In the case of queries, please contact yourinstallation specialist or your nearest Hoval after-sales service agent.

Assembly and installation of the boiler is only to becarried out by the trained staff of an approved installer.An installation check is to be carried out beforecommissioning and the system is to be cleared foroperation by the specialist.

To guarantee safe and trouble-free use, operate yourHoval UltraGas AM condens only according to theseoperating instructions.

The Hoval UltraGas AM condens is to be used only forthe purpose and with the fuels for which it is suitableon the basis of its design and construction and forwhich Hoval has given its approval.

Do not carry out any modifications to the appliance, asthis will result in Hoval waiving all its legal obligations.Conversion kits are to be installed and the workaccepted by approved installers or the Hoval after-sales service.

Providing it is handled correctly, your Hoval appliancewill ensure you enjoy comfortable living conditions formany years.

4 200 191 / 01 3General information

Intended purpose:The UltraGas AM condens boiler isonly to be operated with the fuelsdetailed in the technical information/installation instructions. The heatproduced must be carried away onlyby means of the heating water. Allorifices and openings on the boilermust be closed during operation!

Precautionary instructions:Corrosion protectionDo not use any sprays, solvents, chlorine-containingcleaning agents, paints, adhesives etc. in the vicinityof the appliance. These substances can lead tocorrosion in the boiler and the flue gas system.

Filling the heating systemMains water can normally be used for filling theheating system. In exceptional cases, where the waterquality renders it unsuitable for filling the heatingsystem (highly corrosive water or water with a highlime content), contact your approved specialist.

Checking the water levelCheck the system water level at regular intervals(page 8).

GeneralHoval UltraGas AM condens gas boilers are equippedwith automatic control and safety devices. They arenormally in operation from the beginning to the end ofthe heating period. During this time the necessaryboiler temperature is set by means of the automaticheating controller.

If the boiler is also used for water heating it remainsswitched on for the whole year.

Fuel

The boiler is only to be operatedwith the type of gas stated on therating plate. Settings are made bythe installer.

Checking prior to commissioningA new system may only be placed in operation whenclearance to do so has been given by the heatinginstaller.

Filling the heating systemThe heating system is filled with mains water accordingto the specifications of the installer. All air must be bledfrom the system. Check the pressure at the pressuregauge or hydrometer.

Filling the separate calorifierThe calorifier is to be filled on the service water-sideaccording to the specifications of the installer. Theboiler can also be operated when the calorifier is notfilled with water.

Safety valvesThe heating system and the hot water system areeach to be fitted with a safety valve againstimpermissible over-pressures.

Filling pump (boiler with separate calorifier)The speed and flow regulation must be appropriate tothe requirements of the calorifier. Settings are madeby the heating specialist.

Heating pumpsThe speed and flow regulation must be appropriate tothe requirements of the system. Settings are made bythe heating specialist.

Electrical connectionThe electrical connection is to be made by a qualifiedelectrician. The electrical circuit diagram is locatedinside the control cover.

4 200 191 / 014

If you detect a smell of gas, pleaseclose the main gas cock before thegas meter immediately and call theemergency service of your gas supplyauthority.

To ensure that no toxic flue gases occur, the combustionair must flow unobstructed to the gas boiler. Therefore,with room air dependent operation, the air inlet openings(e.g. cellar window) must never be closed. The boileritself must also never be closed off.

Keep the room in which your boiler is installed cleanand before cleaning, switch off the burner as dustladen combustion air can lead to faults.

FaultsFor your safety the burner shuts down automatically inthe case of faults in the burner system, if the gaspressure is too low, if gas is absent or if the maximumpermissible boiler temperature is exceeded. Wait about5 minutes before attempting to place the burner backin operation, by actuating the reset button on the boilercontrol panel. If this is not successful, please close thegas cock and call your after-sales service or heatinginstaller.

Absolutely imperative!

Fault-free function is only guaranteedif the operating instructions arecomplied with and both boiler andburner are regularly maintained by aspecialist.

Faults and damage caused by installing in unsuitablerooms, e.g. hobby rooms, workshops etc., also bycontaminated operating media (gas, water, combustionair), unsuitable chemical additives to the heating water,incorrect handling, faulty installation and damage dueto the exercising of force are not covered by ourguarantee; this also applies to corrosion due to halo-gen compounds, e.g. from spraycans, paints,adhesives, solvents and cleaning agents.

Important information

Important information

Installation and assembly instructions• The installer has handed you the installation and

assembly instructions. Keep these importantdocuments carefully so that where necessary theafter-sales service can obtain technical informationon-site.

4 200 191 / 01 5Commissioning / taking out of operation,boiler cleaning

Preparations for commissioningA newly installed system may only be commissionedby a specialist. A full installation check must be carriedout.

• Place the main SYSTEM switch to ”0”.• Open the cut-off valve in the heating feed and return.• Ensure an air supply (fresh air) by opening the

window of the boiler installation room. Comply withthe boiler installation room guidelines in the case ofboiler outputs from 46 kW.

• Open the gas shut-off cock in the gas supply pipeline.• Switch on the main switch outside the boiler

installation room. Frequently the heating system hasan additional emergency switch which switches offonly the gas burner.

• With the UltraGas AM condens, fill the odour trap(siphon) in the condensate drain pipeline with waterbefore commissioning.

Commissioning

These instructions are accompanied byoperating instructions for the boiler control(pages 6 and 7) with an illustration of theoperating panel and detailed information.These operating instructions for the boilercontrol are to be complied with.

• Place the main SYSTEM switch to ”I” and set thedesired boiler temperature at the boiler temperaturecontroller.

• Please refer to the section ”Faults” on page 4 if faultlamps light.

Placing out of operation• Place the main SYSTEM switch to ”0”.• Close the gas shut-off cock.• In the case of a long break, e.g. vacation, you can

shut down the heating system.• If there is a risk of frost, speak to your heating

installer about suitable preventive measures. Anti-freeze agents are never to be allowed to enter theboiler circuit.

Maintenance and checking

Boiler and burnerHave your burner and boiler checked and servicedregularly; DIN 4756 recommends this is carried outonce a year. In order to achieve optimal yearly efficiency,this maintenance is especially important for a highefficiency boiler such as this Hoval UltraGas AMcondens. You can conclude a maintenance contractwith your heating installer or the responsible after-sales service organisation.

Hot water supplyRegular checks increase the life and cost-effectivenessof any installed calorifier. This work is carried out by themaintenance service.

In the interest of an economic hot water supply, inregions in which the water has a high lime content it isrecommended to have the calorifier periodicallydelimed. Do not delime the storage tank with iron orsteel tools. The installation of a water softener isrecommended if lime deposits are heavy.

4 200 191 / 016 The boiler operating elementsls

0I

ONBoiler in operation

SYSTEMOFFBoiler & burner areinoperative

Attention:No frost protection

SYSTEM

I

Legend Function

2

6 7 5

8

1

3

10

11

4 9

Operating elements

1. Operating modeselectorON/OFF

2. Fuse

3. Basic control

4. Electronic heatingcontroller

5. Setpoint setting ”nor-mal”

Check 6.3A fuse if all displays remain dark.

- Controls the internal boiler functionsSettings and changes are only to be made by the heating specialist.The indication flashes if a fault is present. To reset, fold down thecover and press the reset button.

- Provides for the correct room temperature according to theoutside temperature.

- Controls the heating up of the calorifier etc.Special instructions are supplied with the heatingcontroller.

- Middle setting 20°CHere the room temperature can be changed by ±8°C

4 200 191 / 01 7Legend Function

The boiler operating elements

6. Setpoint setting”reduced”

7. Program switch

8. Interrogation andprogramming level

9. Display field

10.Operating instructions

11.Room station

- The desired room temperature for the night can be set here.Middle setting 14°C ±6°C

The heating program can be selected here:

Heating and hot water filling ”OFF”.Frost protection guaranteed

The room temperature set for the night is also effectiveduring the dayHot water according to clock program 2

Automatic control corresponding to the switching timesentered for the 1st program(interim reduction for the day)

Automatic control corresponding to the switching timesentered for the 2

nd program

(normal setting)

Automatic control corresponding to the switching timesentered for the 3

nd program

(longer operating time)

The room temperature is not reduced in the nightHot water according to clock program 2

Summer operation: Heating ”OFF”Frost protection, hot water filling is effective according toclock program 2

Manual operation for the specialist. Burner andcirculation pump in operation. No supply to the mixervalve, hot water filling in operation

Settings such as time of day and values can be interrogated here.Setting according to special operating instructions.

Displayed here are the current time, boiler temperature and whereapplicable the calorifier temperature.

Quick-reference operating instructions for heating controller only (4)

OptionalPermits operation of the heating controller (4) in the living room. If aroom station is connected, settings 5-6-7 are replaced by the settingsat the room station

3

2

1

4 200 191 / 018

Check the neutralisation system (whereinstalled, see page 1)

Before commissioning the granulatecontainer is to be filled with the neutralisinggranulate NEUTRALAT, as described.

Once a year or after consumption (dissolving) theneutralisation system should be thoroughly cleaned,i.e. rinsed with water. To clean the neutralisationsystem please follow the instruction below.

Maintenance and checks

Maintenance and checks

The work operations described below arenormally carried out by the specialist atthe time of the annual maintenance.However, carry out the following checksin the course of the year and wherenecessary, carry out the work described.

Checking the water levelIf the system water pressure is low (readfrom the pressure gauge), notify yourinstaller or refill with water.

Refilling the heating system• Set the main SYSTEM switch to ”0”.• The shut-off valves for the heating feed and return

must be open.• The boiler filling and draining cock is accessible after

removing the front cover at the front of the boiler.• Connect the filling cock to the water tap by a hose;

unscrew this after filling, to safely break theconnection.

• Note the water quality: Drinking water quality; the pHvalue must not exceed 9.5.

• Fill with water slowly, check the water level at thehydrometer or pressure gauge.

• Keep the bleed valves on the radiators open until air-free water flows out.

• No chemical additives (inhibitors) or anti-freezeagents are to be used in the boiler circuit.

Attention:Never add cold water to the hotheating system.

1. Take off the bottom front boiler cover (remove 2screws) (on the UG-AM-c (200-350) take off thebottom cover at the side.

2. Disconnect any condensate connectors (see page1 for model without condensate lifting pump)

3. Pull out the granulate container.

4. Dispose of any residual granulate with the domesticwaste.

5. Clean the neutralisation system carefully, i.e. flushout with water.

6. Fill up with new granulate.The following quantities are required:- For the UG-AM-c (50-150) – 9 kg of granulate

(3 bags)- For the UG-AM-c (200-350) – 12 kg of granulate

(bags)After removing the first wrapper, shake out the finedust resulting from transport. Then place thegranulate on the grid, respectively on the filter matof the granulate container and distribute it evenly.

7. Push the granulate container back in.8. Reconnect the condensate connection.9. Replace the boiler front cover (UG-AM-c (200-350)

bottom cover at the side).

4 200 191 / 01 9

Please note! In the case of operating faults pleasecarry out the checks according to the listabove.

If you are unable to rectify thefault, please call the heatinginstaller or the Hoval after-salesservice.

Checklist in the case of faults

Fault Check/Cause Rectification See page

Gas boiler - Is current present - Check fuses, switch on main or where applicable,does not start emergency switch

- Is the gas cock open - Open

- Is a number flashing on the basic control - Press reset button- Notify after-sales service

- Is gas present - Enquire at your gas supplier

Radiators - Are the gate valves in the heating feed - Openare not hot and return open

- Is the main switch in the - Changeover 6”OFF” position

- Is the clock of the TopTronic - Carry out check according to the separate operatingcorrectly set instructions for the heating controller

- Check the water level, respectively pressure - Refill and bleed the system 4

- Are the radiator valves open - Open

- The heating circulation pump is not running - Remove sealing screwTurn end of shaft vigorously with a screwdriveruntil resistance ceases.

- The mixer does not open automatically - Open manually, call service

No - The filling pump is not running - Remove sealing screwhot water Turn end of shaft vigorously with a screwdriver

until resistance ceases.

- Is there air in the filling pipeline - Bleed manually where applicable- Actuate automatic bleeding by hand

- Has the temperature limiter been activated - Unscrew nut and unlock by pressing the knob.

4 200 191 / 0110The room temperatures andheating system operatingtimes have a decisiveinfluence on fuelconsumption.

A 1°C lower room temperatureyields a fuel saving of up to 6%. Sonote the following tips:

• Avoid room temperatures ofover 20°C and set your heatingsystem accordingly.

• It is worthwhile closing theradiator valves in unused roomsproviding there is no risk of frostand no damage to the buildingstructure or furnishings isanticipated.

• Heat recycling takes place in themain living rooms through bodyheat, television sets, chimneysand also solar radiation. Thesecannot be compensated with aweather dependent control. It isworthwhile installing individualthermostatic radiator valves inthese rooms.

When there is a draught, it’snot only unpleasant but italso means a loss of heatenergy.

So you’ll save fuel if you . . .

• Keep doors and windowsclosed in the winter

• Close flue flaps when the fire isout

• Use kitchen and bathroom fansonly when steam and odourshave to be extracted

• Ventilate for short periods, butfrequently.

• Seal doors and windows toavoid permanent leakagelosses.

Keep in valuable heat withinsulation.

Utilise these possibilities and . . .

• Close door and window shuttersat night

• Make sure heating and hotwater pipes in unheated roomsare insulated.

The lowest possible radiatortemperature preventsunnecessary heat loss.So radiators must always beable to transfer their heat tothe room unhindered. Avoidtherefore:

• Covered radiators

• Windowsills which allow no heatto pass through because theyare occupied by objects.

Savings are also possiblewith hot water systems.

• Set the calorifier temperature aslow as possible. Find the lowestpossible temperature setting atwhich sufficient hot water is stillavailable.

• If your system includes a hotwater circulation pump, it’sworthwhile switching this off atnight with a timer clock.

How to save energy!

4 200 191 / 01 11Maintenance contract

Maintenance contract

The Hoval After-Sales Maintenance Contract

To ensure fault-free and cost-effective operation ofyour new heating system, we recommend that youtake out a Hoval After-Sales Maintenance Contract.With this agreement the Hoval After-Sales Servicemakes all the timing arrangements for the necessaryannual maintenance.In the period April to October, after prior agreement,your boiler will be thoroughly checked, its valuesmeasured and set up for optimal operation.Any repairs will be carried out at once with youragreement.

A maintenance contract carries a wide rangeof benefits

• Your guarantee period is extended when you takeout a maintenance contract.

• Your heating system is always optimally set, savingheating costs and protecting the environment.

• High level of operating reliability, since any faultsare detected early in the course of maintenanceand can be rectified.

• The optimal setting and regular maintenance extendthe service life of your system.

• The attractive lump sum price. Apart from anynecessary spares, nothing extra has to be paid forthe maintenance.

Date Text:

Enter checks, inspections, fuel purchases etc. here

4 200 191 / 0112

Responsibility for energy and the environment

Hoval LTDNorthgateNewarkNottinghamshire NG24 1JNPhone: 01636 672 711Fax: 01636 673 532

Deutsche Hoval GmbHD-72108 Rottenburg am NeckarFreiherr-vom-Stein-Weg 15Telefon 0180 / 501 63 25Telefax 07472 / 163-50

Carival SAF-91743 Massy Cedex2 route de la BondeTél. 01 69 30 83 00Fax 01 69 30 22 54

Hoval Gesellschaft mbHA-4614 MarchtrenkHovalstrasse 11Telefon 07243 / 550-400Telefax 07243 / 550-17

Hoval Herzog AGCH-8706 FeldmeilenGeneral-Wille-Strasse 201Telefon 01 / 925 61 11Telefax 01/ 923 11 39www.hoval.ch

BaselHauptstrasse 14153 ReinachTel. 061 711 20 70Fax 061 711 26 84kc.basel@hoval.ch

BernAmmenmattstr. 433123 BelpTel. 031 818 66 30Fax 031 818 66 31kc.bern@hoval.ch

ZürichPostfach8706 FeldmeilenTel. 0848 81 19 30Fax 0848 81 19 31kc.zuerich@hoval.ch

ZentralschweizPostfach8706 FeldmeilenTel. 0848 81 19 40Fax 0848 81 19 41kc.zent.schweiz@hoval.ch

OstschweizPostfach8706 FeldmeilenTel. 0848 81 19 20Fax 0848 81 19 21kc.ostschweiz@hoval.ch

VaduzAustrasse 70FL-9490 VaduzTel. +423 39938 66Fax +423 399 38 67kc.vaduz@hoval.ch

TicinoVia Cantonale 34A6928 MannoTel. 091 610 43 60Fax 091 610 43 61kc.ticino@hoval.ch

Suisse romandeAv. de Provence 251000 Lausanne 20Tél. 021 622 01 44Fax 021 622 01 55kc.suisse.romande@hoval.ch

Umwelt-EnergienPostfach8706 FeldmeilenTel. 0848 81 19 50Fax 0848 81 19 51kc.umwelt-energien@hoval.ch

Carival S.r.l.Via Per Azzano S. Paolo, 26/28I-24050 Grassobbio (BG)Tel.: 0039 / 35-525069Fax: 0039 / 35-525858

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