Hoval TopGas 35, TopGas 45, TopGas 60 Technical Information Installation Instructions

Subject to modi cations |

Technical information Installation instructions

4 213 893 / 01- 07/15

Hoval products may only be installed and commissioned by appropriately qualied experts. These instructions are intended exclusively for the specialist. Electrical installations may only be carried out by a qualied electrician.

Nominal output ranges at 40/30°C and with natural gas:

41-TopGas

(35) 6,8 - 35,0 kW

41-TopGas® (45) 11,1 - 45,0 kW 41-TopGas® (60) 12,8 - 60,7 kW

Wall-mounted condensing gas boilers TopGas

(35,

45,60) in accordance with DIN 4702, DIN EN 483 und DIN EN 677 are designed and approved for use as heat generators for hot water heating systems with permissible ow temperatures of up to 85 °C. They are designed for continuously controlled reduced operation in heating systems.

TopGas® (35,45,60)

Wall-mounted condensing gas boilers for natural and liquid gas

4 213 893 / 01

TABLE OF CONTENTS

1. Important Information ............................................................................................................................. 4

1.1 On delivery ...........................................................................................................................................................................4

1.2 Guarantee ............................................................................................................................................................................4

1.3 Instructions .........................................................................................................................................................................4

1.4 Regulations, official approvals ...........................................................................................................................................5

1.5 Transport and storage .........................................................................................................................................................5

2. Safety instructions .................................................................................................................................. 6

2.1 Warning levels .....................................................................................................................................................................6

2.2 Warning symbols .................................................................................................................................................................6

2.3 Information ..........................................................................................................................................................................6

3. Technical information ............................................................................................................................. 7

3.1 Technical Data .....................................................................................................................................................................7

3.2 Boiler-flow resistance .........................................................................................................................................................8

3.3 Dimensions ..........................................................................................................................................................................9

3.4 Short description of the automatic firing unit BIC 335 ....................................................................................................10

3.5 Heating system control ..................................................................................................................................................... 11

3.6 Adjustable parameters ......................................................................................................................................................13

4. Installation ............................................................................................................................................. 15

4.1 Description of the Hoval TopGas® .....................................................................................................................................15

4.1.1 Diaphragm expansion tank ..............................................................................................................................................15

4.1.2 Boiler casing ...................................................................................................................................................................15

4.1.3 Gas fittings .....................................................................................................................................................................15

4.1.4 Automatic gas firing unit and heating controller ...............................................................................................................15

4.1.5 Heating circulation pump .................................................................................................................................................15

4.1.6 Hot water supply .............................................................................................................................................................15

4.1.7 Scope of supply ..............................................................................................................................................................15

4.1.8 TopGas® component designation .....................................................................................................................................16

4.2 Boiler installation room .....................................................................................................................................................17

4.3 Installing the boiler............................................................................................................................................................17

4.4 Hydraulic connection ........................................................................................................................................................17

4.4.1 Protection planning guidelines for the hy draulic connection .............................................................................................17

4.4.2 Boil-dry safeguard ...........................................................................................................................................................17

4.4.3 Gravity brake ..................................................................................................................................................................18

4.4.4 Minimum flow rate ...........................................................................................................................................................18

4.4.5 To be provided by customer ............................................................................................................................................18

4.4.6 Examples of hydraulic interconnection ............................................................................................................................18

4.5 Flue gas connection, chimney and condensate pipeline .................................................................................................20

4.5.1 Waste gas pipelines in compliance with building construction law ...................................................................................20

4.5.2 Project planning information for the TopGas® ..................................................................................................................20

4.5.3 Installation examples for room-air-dependent operation ..................................................................................................21

4.5.4 Exhaust gas system for room-air-independent operation .................................................................................................21

4.5.5 Roof heating centre concentric flue (vertical exhaust gas conduit installation) .................................................................22

4.5.6 Wall penetration (permitted only in Austria) ..................................................................................................................... 22

4.5.7 Connection of the pipes ..................................................................................................................................................23

4.5.8 Condensate draining and neutralisation ..........................................................................................................................23

4.5.9 Gas connection ...............................................................................................................................................................23

4.6 Electrical connection .........................................................................................................................................................23

4.6.1 Regulations for electrical connections .............................................................................................................................24

4.6.2 Electrical connection (mains) 230 V, 50 Hz ......................................................................................................................24

4.6.3 Boiler control / electrical connection diagram ..................................................................................................................24

4.6.4 Connection of the heating controller ................................................................................................................................24

4.6.4.1 TopTronic® RS-OT ..........................................................................................................................................................................24

4.6.4.2 TopTronic® E ................................................................................................................................................................................... 24

4 213 893 / 01

TABLE OF CONTENTS

5. Commissioning ..................................................................................................................................... 25

5.1 Setting the control .............................................................................................................................................................25

5.2 Water quality ......................................................................................................................................................................25

5.2.1 Heating water..................................................................................................................................................................25

5.3 Filling and replacement water:..........................................................................................................................................25

5.3.1 Filling up the system .......................................................................................................................................................26

5.4 Gas adjustment ..................................................................................................................................................................26

5.4.1 Bleeding the gas pipeline ................................................................................................................................................26

5.4.2 Commissioning ...............................................................................................................................................................26

5.4.3 Gas inlet pressure ...........................................................................................................................................................26

5.4.4 Gas fitting .......................................................................................................................................................................26

5.4.5 Setting the gas flow rate CO2 (O2) and measurement of NOx/CO content in the flue gas (flue gas measurement) ...........27

5.5 Changing to a different kind of gas ..................................................................................................................................28

5.6 Handing over to the user ...................................................................................................................................................28

5.6.1 Instruction the user .........................................................................................................................................................28

5.6.2 Checking the water level .................................................................................................................................................28

5.6.3 Maintenance ...................................................................................................................................................................28

6. Decommissioning ................................................................................................................................. 29

7. Maintenance .......................................................................................................................................... 29

7.1 Checking the water connections for leakage ...................................................................................................................29

7.2 Refilling ..............................................................................................................................................................................29

7.3 Maintenance includes ........................................................................................................................................................29

7.4 Cleaning the heat exchanger ............................................................................................................................................29

7.5 Function check ..................................................................................................................................................................30

7.6 Emission measurement .....................................................................................................................................................30

8. Faults ..................................................................................................................................................... 31

9. Automatic firing unit BIC 335-Parameter list ....................................................................................... 33

4 213 893 / 01

IMPORTANT INFORMATION

1. Important Information

BThe following points must be observed when performing work on the TopGas®:

CAUTION

• If you smell ue gas or gas,

• avoid naked ames and

the occurrence of sparks,

• do not smoke,

• take the system out of operation,

• close the gas shut-off valve,

• open windows and doors

• The system may only be placed in operation if all the relevant standards and safety regulations have been

complied with. However, for trial operation, the following are the minimum conditions requiring fullment:

- Safety valve installed (closed system)

- Control in operation (connected to the mains current supply system)

- System lled with water

- Expansion tank connected

- Boiler connected to a ue gas conduit installed in compliance with the relevant regulations

- Burner preset

• When performing maintenance and repairs:

- Allow the gas condensing boiler to cool down

- Switch off the gas condensing boiler and disconnect it from the power supply

- Close the gas shut-off valve

- Close all cut-off valves on the unit

(cold water, heating ow and return)

- If work on the components of the gas condensing

boiler which carry water is not performed correctly,

the heating medium may escape and lead to scalding.

- After performing repair and maintenance work, reattach all cover plates which were removed.

- Do not exceed the maximum operating pressure and operating temperature (see type label) for the gas condensing boiler.

- Open all cut-off valves on the unit

(cold water, heating ow and return)

- Open gas shut-off valve

WARNING

The heat generator can only be de-energised by disconnection from the mains (e.g. allpole switch).

WARNING

All electric power supply circuits must be

switched off before accessing the terminals.

1.1 On delivery

Carry out a visual inspection immediately on receiving the

boiler. If any damage is found, take the necessary steps as dened in the delivery contract. The respective risk

carrier bears the cost of repairs.

1.2 Guarantee

The warranty does not cover defects attributable to:

- Failure to comply with these instructions

- Failure to comply with the operating instructions

- Incorrect installation

- Impermissible modications

- Incorrect handling

- Contaminated operating materials

(gas, water, combustion air)

- Unsuitable chemical additives to the heating water

- Damage caused by the application of force

- Corrosion by halogen compounds

(e.g. paints, adhesives, solvents)

- Corrosion caused by not observing the required water quality

1.3 Instructions

All instructions relevant to your system can be found in the Hoval system manual! In exceptional cases, the instructions can be found with the components!

Further sources of information:

- Hoval catalogue

- Standards, regulations

4 213 893 / 01

IMPORTANT INFORMATION

1.4 Regulations, official approvals

The following regulations are to be complied with for

installation and operation, in addition to the recognised

rules of the art:

Germany

• DIN EN 12831 Heating systems in buildings

- Methods for calculating the design heat load

• DIN EN 13384 Flue gas systems

- Heat and ow calculation methods

• DIN EN 12828 Heating systems in buildings

- Planning of hot water heating systems.

• VDI 2035 Prevention of damage through corrosion and scale formation in hot water heating systems.

• Firing regulation for the Federal regions

• DVGW-TRGI 86-96

• Technical regulations of gas supply enterprises

• VDE 0100 for electrical installations and the TAB (technical connection conditions of the responsible energy supplier)

• ATV data sheet M251

• Accident prevention regulations

- VBG 1 General regulations

- VBG 4 Electric systems and equipment

Austria

• OENORM 12831 Heating systems in buildings

- Methods for calculating the design heat load

• OENORM 13384 Flue gas systems

- Heat and ow calculation methods

• OENORM 12828 Heating systems in buildings

- Planning of hot water heating systems.

• OENORM H5152 Gas condensation for furnace installations

• OENORM H5195-1 Prevention of damage through corrosion

• M 7443, (Part 2,3,7) Gas appliances with atmospheric burners

• M 7446, Heat output appliances for gaseous fuels

• M 7457, Heat output appliances with mechanically supported premix batwing burners

• M 7444, Special gas boilers with burners without fan

• M 7459, Gas appliances with gas-air compound controller

• ÖVGW TR- Gas (Austrian Gas and Water Confederation - Technical Guidelines)

• Technical provisions of the gas suppliers

Switzerland

• SN EN 12831 Heating systems in buildings

- Methods for calculating the design heat load

• SN EN 13384 Flue gas systems

- Heat and ow calculation methods

• SN EN 12828 Heating systems in buildings

- Planning of hot water heating systems.

• Requirements of the VKF Cantonal Fire Insurance Association

• Fire service regulations

• SVGW directives, gas guiding standard G1

• SNV271020 Aeration and ventilation of the boiler installation room

• SWKI 88-4 Water treatment for heating, steam and air conditioning systems

• SWKI 80-2 Technical safety regulations for heating systems

• KRW Corrosion through halogen compounds

• Procal/FKR Plug-in electrical connections on heating boiler and burner

• Technical tank regulations TTV 1990

• EKAS - Guideline for liquid gas part 2

and further regulations and standards prescribed by the

CEN, CEN ELEC, DIN, VDE, DVGW, TRD and by law.

The regulations of the local building authorities, insur-

ance companies and chimney inspectors must also be taken into account. The regulations of the responsible gas supply company are also to be complied with and

any necessary ofcial approval obtained if using gas.

Regulations governing the discharge and treat ment of condensate are subject to the

spe cications of the local water authorities

and may deviate from waste water guideline

ATVM251. Please contact your water author

ity for details of the applicable local regula

tions.

1.5 Transport and storage

Please remove the packing materials and examine the

consignment for correctness, completeness and possible

transport damage. The appliance is only to be transported and stored only in its original packing. Interim storage of Hoval gas boilers is only to take place in weather protected rooms and only in the original packing. The ambient conditions for storage must be within the following limits:

- Air temperature: -10 °C - +50 °C

- Air humidity: 50 - 85 % relative humidity

- no condensation

4 213 893 / 01

SAFETY

2. Safety instructions

2.1 Warning levels

DANGER

... indicates a situation of immediate danger

which will lead to serious or fatal injuries if

not avoided.

WARNING

... indicates a situation of possible danger

which can lead to serious or fatal injuries if not avoided.

CAUTION

... indicates a situation of possible danger which can lead to minor or slight injuries if

not avoided.

NOTICE

... indicates a situation of possible danger

which can lead to damage to property if not avoided.

2.2 Warning symbols

General warning of a danger zone.

«Warning: dangerous electrical voltage» as a

warning for accident prevention.

Ensures that people do not come into contact with electrical voltage. The danger sign with the black lighting symbol warns against the

danger of electrical voltage.

2.3 Information

Information: Provides important information.

4 213 893 / 01

TECHNICAL INFORMATION

3. Technical information

3.1 Technical Data

Type (35) (45) (60)

• Nominal heat output 80/60 °C with natural gas

kW 6,0-31,8 10,0-41,0 11,7-55,3

• Nominal heat output 40/30 °C with natural gas

kW 6,8-35,0 11,1-45,0 12,8-60,7

• Nominal heat output 80/60 °C propane gas

kW 6,6-31,9 10,8-41,0 13,1-54,9

• Nominal heat output 40/30 °C propane gas

kW 7,3-35,2 11,9-45,0 14,1-60,3

• Nominal load with natural gas

kW 6,4-33,0 10,6-42,5 12,2-57,3

• Nominal load with propane gas

kW 7,0-33,2 11,4-42,5 13,6-56,9

• Working pressure heating maximum/minimum. bar 3,0/1,0 3,0/1,0 3,0/1,0

• Working temperature maximum °C 85 85 85

• Boiler water content l 4,5 4,5 6,0

• Minimum water ow l/h 300 350 470

• Boiler weight (without water content, incl. body) kg 83 83 89

•

Boiler efciency at full load at 80/60 °C (related to net/gross caloric value)

% 96,4/86,8 96,5/86,9 96,5/86,9

•

Boiler efciency at 30 % partial load (in acc. with EN 303) (related to net/ gross caloric value)

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

• Normal degree of efciency (in accordance with DIN 4702 Part 8) 40/30 °C % 109,1/98,3 109,0/98,2 109,0/98,2 (related to net/gross caloric value) 75/60 °C % 106,1/95,6 106,0/95,5 106,0/95,5

• Standby losses at 70 °C Watt 95 95 120

• Norm emission factors Nitrogen oxide NOx mg/kWh 30,0 30,0 35,0

Carbon monoxide CO mg/kWh 9,0 11,0 13,0

• CO

content in ue gas max./min. output % 9,0/8,8 9,0/8,8 9,0/8,8

• Dimensions see table of dimensions

• Connections Flow/Return Inches Rp 1¼″ Rp 1¼″ Rp 1¼″

Gas Inches R ¾″ R ¾″ R ¾″ Air/ue gas Ø mm C80/125 C80/125 C80/125

• Gas ow pressure min./max.

Natural gas E/LL mbar 18-50 18-50 18-50 Liquid gas mbar 37-50 37-50 37-50

• Gas connection value at 0 °C/1013 mbar:

Natural gas E - (Wo = 15,0 kWh/m

) Hu = 9,97 kWh/m

m3/h 3,3 4,3 5,8

Natural gas LL- (Wo = 12,4 kWh/m

) Hu = 8,57 kWh/m

m3/h 3,9 5,0 6,7

Propane gas

(Hu = 25,9 kWh/m3) m3/h 1,27 1,64 2,21

• Operation voltage V/Hz 230/50 230/50 230/50

• Control voltage V/Hz 24/50 24/50 24/50

• Minimum/maximum electrical power consumption Watt 29/62 29/66 30/102

• Standby Watt 13 13 13

• Protection rating IP 40 40 40

• Sound power level

- Heating noise (EN 15036 part 1) (room air dependent) dB(A) 61 63 63

- Exhaust noise is radiated from the mouth (DIN 45635 part 47) (room air dependent/room air independent

dB(A) 63 66 66

• Sound pressure level (depending on installation conditions)

dB(A) 49 51 51

• Condensate quantity (natural gas) at 40/30 °C l/h 3,1 4,0 5,4

• pH-value of the condensate ca. 4,2 ca. 4,2 ca. 4,2

• Flue gas system: requirements, values Temperature class T120 T120 T120 Type of connection B23, C13(x), C33(x), C53(x), C63(x) Flue gas mass ow kg/h 54,8 70,6 95,1 Flue gas temperature at nominal output and operation 80/60 °C °C 69 75 79 Flue gas temperature at nominal output and operation 40/30 °C °C 47 52 49 Volume ow rate combustion air Nm

/h 41,3 53,1 71,6

Feed pressure total at the combustion air/ue gas pipe Pa 95 115 140 Maximum draught/depression at ue gas outlet Pa - 50 - 50 - 50

Data related to Hu. The boiler series is tested for EE/H-settings. With a factory setting of the Wobbe coefcient of 15,0 kWh/m3 operation at a Wobbe coefcient of 12,0 up to 15,7 kWh/m3 is possible without new settings.

Hoval TopGas 35, TopGas 45, TopGas 60 Technical Information Installation Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual