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A condensing boiler achieves its high efficiency precisely by cooling the flue gases enough for the water vapour they contain to condense and release its latent heat. The by-product is condensate, which is produced continuously throughout the heating season – in a family house this means litres per day, and therefore hundreds of litres over a season. With air conditioning, it is the opposite: condensate is produced mainly in summer, when moisture from the air condenses on the cold evaporator of the indoor unit, and on a hot day the amount is far from negligible. Dehumidifiers and refrigeration equipment produce condensate all year round.
What is more, flue gas condensate is not just ordinary water. Oxides from the flue gases dissolve in it, making it acidic – which is why everything that comes into contact with it must be made of resistant plastics or stainless steel. Ordinary metal pipework or an unsuitable pump would gradually be destroyed by acidic condensate. Condensate from oil-fired boilers is more aggressive than that from gas boilers, which is why a neutralisation unit is additionally required for them (more on this below).
What happens if condensate has nowhere to drain? First, it starts to build up in the trap and collection tray of the appliance. Modern boilers and air conditioning units respond with a fault message and shutdown – so in winter the boiler stops heating, and in summer the air conditioning stops cooling. The worse scenario is when the appliance has no such protection or it fails: then the condensate overflows and damages the floor, wall or room furnishings, and with air conditioning units typically even the suspended ceiling. Manufacturers of condensing boilers therefore specify proper condensate drainage as a condition of operation, and relying on a bucket under the boiler is simply not an option.
The principle is simple and similar for all units of this type. The basis is a small collection tank into which condensate from one or more sources flows by gravity – which is why the lifting unit is always installed below the condensate source, or next to it in such a way that the inlet has a fall. Inside the tank is a float switch: as soon as the level rises to the switching point, the float automatically starts the pump. It then forces the contents of the tank through a thin discharge hose upwards and, if necessary, sideways to the nearest waste pipe. When the level drops to the switch-off point, the pump stops and waits for the next filling cycle. A non-return valve on the discharge side prevents condensate that has already been pumped out from flowing back from the hose into the tank.
The entire cycle repeats fully automatically, without any user intervention. Because condensate flows in gradually, the pump only ever runs briefly and remains idle most of the time – which corresponds to intermittent duty operation (NovaCON S3 15%) and low energy consumption. Due to the low flow rates involved, a discharge hose with an internal diameter of around 10 mm is sufficient, and it can be routed discreetly along a wall or inside trunking.
An important part of the unit is the alarm. Quality lifting units have a second float that monitors an excessive liquid level – if the pump cannot keep up for any reason (blocked hose, power failure), the alarm contact can shut down the connected condensate source (for example switch off the boiler) or trigger a warning signal. Without this safeguard, a pump fault would mean the tank overflowing.
Wilo-NovaCON is an automatic condensate lifting unit designed for condensing boilers (including connection of the safety valve), air conditioning and refrigeration equipment (refrigerators, refrigerated display cabinets, evaporators) and dehumidifiers. According to the manufacturer, it is suitable for boilers up to 50 kW (gas) or 30 kW (oil). It is a “plug & play” solution – everything needed for installation is included in the package, and the unit can be put into operation immediately after connecting the hoses and plugging it in.
NovaCON has two inlet openings with a diameter of 28 mm – the left one is open, while the right one is factory-sealed with a perforated blanking plug that can be cut off if required. This allows condensate from two sources to be fed in at the same time, for example from the boiler and the safety valve. The unit can be placed on the floor or screwed to the wall; the top surface is designed for placing a spirit level on it, because the pump must stand level – the correct operation of the float switch depends on it.
Important note for oil-fired boilers: for boilers burning heating oil, a neutralisation unit must be installed upstream of the pump (provided by the customer) – oil condensate is more aggressive and would damage the pump without neutralisation. Manufacturers of gas boilers may also require neutralisation on the inlet side, so always follow the boiler manufacturer’s instructions.
The unit does not require any special maintenance. The tank has a removable lid, so any cleaning that may be needed (deposits, float inspection) only takes a moment. If the pump does not switch on, check the most common causes: mains connection, a blocked float, a clogged inlet hose, the transport lock not having been removed, or the unit not standing level. If the pump runs but does not pump, the cause is usually a blocked non-return valve or a clogged discharge hose. The manufacturer provides a 2-year warranty on NovaCON, provided it is professionally installed and used correctly.
NovaCON is intended for flats, family houses and smaller commercial premises – anywhere condensate needs to be removed from a wall-mounted condensing boiler, air conditioning unit, refrigeration equipment or dehumidifier and gravity drainage is not available. A delivery head of 4.5 m is sufficient for pumping from a basement up to the level of the sewer connection, while noise levels below 45 dB(A) and compact dimensions allow installation even in living areas. For larger condensate sources (boilers above 50 kW), a more powerful unit is required.
No. If the condensate can be drained into the sewer by gravity (the drain is lower than the boiler trap), you do not need a pump. A lifting unit is only necessary when the drain is higher than the condensate outlet or too far away.
The maximum delivery head is 4.5 m at a maximum flow rate of 380 l/h. As the height increases, the flow rate decreases (see the pump curve in the manual). Horizontal sections of the discharge line reduce the delivery head further, so route the hose as vertically as possible first.
Yes, the materials in contact with the medium are resistant to condensate down to pH 2.5. However, for oil-fired boilers a neutralisation unit upstream of the pump is mandatory, and for gas boilers you should also follow the boiler manufacturer’s instructions – neutralisation may be required to protect the drainage system.
Yes. The manufacturer requires the alarm to be integrated into the safety circuit of the condensate source (typically shutting down the boiler if the tank overfills). Without the alarm connected, there is a risk of overflow in the event of a fault, and any resulting damage is not covered by the warranty. Have the connection carried out by a qualified person.
The noise level is below 45 dB(A), which corresponds to quiet operation comparable to a standard fridge. In addition, the pump only runs briefly (S3 15% duty), so it is also suitable for living spaces.
Only in the termination of the power cable: the EF version has a Schuko plug for a socket outlet, while the O version has a free cable end for fixed electrical connection. The technical parameters are identical.
Up to +80 °C for short periods, with an average operating medium temperature of 35 °C. This covers normal operation of condensing boilers and air conditioning units.
The power supply, a blocked float in the tank, a clogged inlet hose, whether the unit is level, and whether the transport lock on the rear has been removed (a common mistake during first start-up). If the pump runs but does not pump, check the non-return valve and that the discharge hose is clear.
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