Hoval TopGas 35 Technical Information Installation Instructions
Wall-mounted condensing gas boilers
for natural and liquid gas
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- Technical information installation instructions (34 pages) ,
- Operating instructions manual (17 pages)
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Technical information
Installation instructions
TopGas
(35,45,60)
®
Wall-mounted condensing gas boilers
for natural and liquid gas
Hoval products may only be installed and commis-
sioned by appropriately qualified experts. These in-
structions are intended exclusively for the specialist.
Electrical installations may only be carried out by a
qualified electrician.
Subject to modifi cations
|
4 213 893 / 01- 07/15
Nominal output ranges at 40/30°C
and with natural gas:
41-TopGas
®
41-TopGas
®
41-TopGas
®
Wall-mounted condensing gas boilers TopGas
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 flow temperatures of up to 85 °C. They are
designed for continuously controlled reduced operation
in heating systems.
(35)
6,8 - 35,0 kW
(45)
11,1 - 45,0 kW
(60)
12,8 - 60,7 kW
EN
(35,
®
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Table of Contents
Related Manuals for Hoval TopGas 35
Summary of Contents for Hoval TopGas 35
- Page 1 11,1 - 45,0 kW ® 41-TopGas (60) 12,8 - 60,7 kW ® Hoval products may only be installed and commis- Wall-mounted condensing gas boilers TopGas (35, ® sioned by appropriately qualified experts. These in- 45,60) in accordance with DIN 4702, DIN EN 483 structions are intended exclusively for the specialist.
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Page 2: Table Of Contents
Boiler-flow resistance .................................8 Dimensions ..................................9 Short description of the automatic firing unit BIC 335 ....................10 Heating system control ..............................11 Adjustable parameters ..............................13 Installation ............................. 15 Description of the Hoval TopGas .............................15 ® 4.1.1 Diaphragm expansion tank ..............................15 4.1.2 Boiler casing ...................................15 4.1.3... - Page 3 TABLE OF CONTENTS Commissioning ............................. 25 Setting the control ................................25 Water quality ..................................25 5.2.1 Heating water..................................25 Filling and replacement water:............................25 5.3.1 Filling up the system ...............................26 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...
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Page 4: Important Information
All instructions relevant to your system can be found in - Burner preset the Hoval system manual! In exceptional cases, the in- structions can be found with the components! • When performing maintenance and repairs:... -
Page 5: Regulations, Official Approvals
The appliance is only to be transported and stored only in • Technical provisions of the gas suppliers 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... -
Page 6: Safety Instructions
SAFETY Safety instructions Warning levels Warning symbols General warning of a danger zone. DANGER ... indicates a situation of immediate danger which will lead to serious or fatal injuries if «Warning: dangerous electrical voltage» as a not avoided. warning for accident prevention. Ensures that people do not come into contact WARNING with electrical voltage. -
Page 7: Technical Information
TECHNICAL INFORMATION Technical information Technical Data Type (35) (45) (60) • Nominal heat output 80/60 °C with natural gas 6,0-31,8 10,0-41,0 11,7-55,3 • Nominal heat output 40/30 °C with natural gas 6,8-35,0 11,1-45,0 12,8-60,7 • Nominal heat output 80/60 °C propane gas 6,6-31,9 10,8-41,0 13,1-54,9... -
Page 8: Boiler-Flow Resistance
TECHNICAL INFORMATION Boiler-flow resistance Boiler incl. connection set /h = Volume flow mbar = Flow resistance Boiler only 5,5 m Maximum residual overpressure TopGas (35-60) ® with connection set AS32-TG/UPM2 32-60 TopGas® (30-60) mit AS32-TG/UPM2 32-60 Maximum residual overpressure TopGas (35-60) ®... -
Page 9: Dimensions
TECHNICAL INFORMATION Dimensions Minimum clearances Dimensions in mm • Lateral clearance 50 mm • Distance from ceiling depending on exhaust flue system used • Front 500 mm Ansicht von unten View from bottom Ansicht von oben View from top Fig. 01 Gas connection R ¾″... -
Page 10: Short Description Of The Automatic Firing Unit Bic 335
TECHNICAL INFORMATION Short description of the automatic firing unit BIC 335 - The automatic firing unit operates both without control- ler (TTE) and also without room station (RS-OT). The automatic firing unit comprises the following functions - PWM- fan (230V~) - Modulating operation - Inputs for Flow sensor... -
Page 11: Heating System Control
TECHNICAL INFORMATION Heating system control Boiler control Normally, the user does not need to set the basic controller. All settings have been made by the installer or the manufacturer. Display: Mode Display: temperature RESET Fault-clearance (display is blinking, if there is a failure) Changing of Saving of Options, to change settings... - Page 12 TECHNICAL INFORMATION Function Meaning, Description Current flow temperature e.g. 45° (Heating water temperature) e.g. 40° Current return temperature e.g. 60° Current temperature in water heater e.g. 3° Current outdoor temerature It is possible to read monetary e.g. 55° Current flue gas temperature values from here e.g.
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Page 13: Adjustable Parameters
TECHNICAL INFORMATION Adjustable parameters Parameter 21 (2BK) – Maximum outside temperature – Parameter 7 (2AH) – Set point DHW charging temperature – If the outside temperature exceeds the values set using Using this parameter the reference value for the DHW this parameter, the heating demand is cancelled. - Page 14 TECHNICAL INFORMATION Parameter 62 (2GG) – DHW charging (switch / pump) – This parameter is used to indicate whether a separate pump is present for DHW charging or there is simply a switch for accessing the main pump in use. The setting «0»...
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Page 15: Installation
Depending on the hydraulic situation of the system an ad- Description of the Hoval TopGas ® equately dimensioned diaphragm expansion tank with an The heat exchanger of the Hoval TopGas (35,45,60) com- ® inlet pressure of at least 0.3 bar above the static pressure prises a corrosion-resistant aluminum casting, through must be installed by the customer. -
Page 16: Topgas ® Component Designation
MONTAGE 4.1.8 TopGas component designation ® Fig. 02 1. Burner viewing window 2. Fan 3. Flue gas air inlet 4. Water pressure deflector 5. Flue gas temperature sensor 6. Flow temperature sensor 7. Return temperature sensor 8. Ignition/ionisation electrode 9. Heat exchanger 10. -
Page 17: Boiler Installation Room
For suitable hydraulic connections, please note the in- b) extract the combustion air from the outside via a structions in the Hoval project planning documentation. closed system (room air independent gas firing) The boiler installation rooms must satisfy the locally ap-... -
Page 18: Gravity Brake
MONTAGE 4.4.3 Gravity brake 4.4.4 Minimum flow rate It is recommended to install a gravity brake, to avoid heat During the burner operation a circulation pump must al- losses due to gravity circulation (particularly important ways be in operation too. The minimum flow rate indicat- when changing existing, open installations). - Page 19 MONTAGE Gas boiler with - Free-standing calorifier - 1 direct circuit - 1 direct circuit + 1-... mixer circuit(s) Hydraulic schematic BDDE030 TTE-GW TTE- TTE-WEZ HK/WW B1.1 B1.2 TopGas >35 Fig. 05 Option / Opzione Optional TTE-WEZ TopTronic E basic module heat generator (installed) ®...
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Page 20: Flue Gas Connection, Chimney And Condensate Pipeline
There are two possibilities of flue gas removal with heat output gas boilers: Your Hoval agent can supply a suitable and approved flue a) The use of specially approved flue gas pipelines, gas system for your TopGas ®... -
Page 21: Installation Examples For Room-Air-Dependent Operation
MONTAGE 4.5.3 Installation examples for 4.5.4 Exhaust gas system for room-air-dependent operation room-air-independent operation Combustion air Verbrennungsluft Falls erforderlich ist Falls erforderlich ist ein Inspektions-T- If necessary, an inspection If necessary, an inspection ein Inspektions-T- T-piece has to be inserted Stück einzusetzen Stück einzusetzen T-piece has to be inserted... -
Page 22: Roof Heating Centre Concentric Flue (Vertical Exhaust Gas Conduit Installation)
MONTAGE 4.5.5 Roof heating centre concentric flue 4.5.6 Wall penetration (permitted only in Austria) (vertical exhaust gas conduit installation) Combustion air Verbrennungsluft TopGas Fig. 09 Falls erforderlich ist If necessary, an inspection ein Inspektions-T- T-piece has to be inserted Stück einzusetzen TopGas Fig. -
Page 23: Connection Of The Pipes
MONTAGE 4.5.7 Connection of the pipes 4.5.9 Gas connection On of the boiler installation the pipelines are connected directly to the feed and the return connectors. Please WARNING note the designations for the pipeline connectors in chap- The installation of the gas pipeline and first ter 3.3. -
Page 24: Regulations For Electrical Connections
0100 and the regulations imposed by the responsible en- TopTronic RS-OT controller for external mounting. Your ® ergy company must be complied with. Hoval agent will provide you with a detailed description of the scope of supply. Accident prevention regulations «General regulations (VBG1)» «Electrical installations and equipment (VBG4)»... -
Page 25: Commissioning
Filling and replacement water: • Hoval boilers and calorifiers are designed for heating For a plant using Hoval boilers untreated drink ing wa ter plants without significant oxygen intake (plant ty pe I ac- is generally best suited as fil ling and replacement water. -
Page 26: Filling Up The System
WARNING 5.4.4 Gas fitting Before commissioning, the siphon must be The Hoval TopGas is equipped with a Honeywell pneu- ® filled with water to prevent flue gas leakage. matic modulating multiple setting device. scope of supply includes two solenoid valves (B+B), a screen filter plus an - Minimum system pressure at the boiler: installed pressure balance (1:1) - gas/air servo controller. -
Page 27: Setting The Gas Flow Rate Co ) And Measurement Of Nox/Co Content In The Flue Gas (Flue Gas Measurement)
COMMISSIONING b) Connect the boiler at the gas side and electrically. To get into the service mode, press the „MODE“ and „+“ keys! - Indication on the display during service mode: The current level shows „SEr“ on the display! - after entering into this mode an efficiency of 50 % is achieved. -
Page 28: Changing To A Different Kind Of Gas
COMMISSIONING d) Measurement of NOx and CO content. The measured C) Remove the gas pressure deflector „Natural gas“ and values must meet the limiting values prescribed by install the new gas pressure deflector „Liquid gas“. the regulations. Values exceeding these reference Wire up the gas pressure deflector (AMP connector values are an indication of faulty burner setting, gas at position 1 and 3). -
Page 29: Decommissioning
DECOMMISSIONING / MAINTENANCE Decommissioning Cleaning the heat exchanger - Disconnect the boiler from the electrical supply The following steps are to be taken if the compact (pull out the plug) heat ing controller is to be placed out of operation for - Close the gas appliance cock several weeks: - Remove the front boiler panel (open the control flap lid,... -
Page 30: Function Check
MAINTENANCE After cleaning, assemble in reverse order. The entire gas way / gas route tightness check up (with leak detection spray) is necessary after the assembly. Function check - Set the gas boiler according to chapter 5.4 - Check all gas boiler connections for leaks - Check the system pressure, replenish where necessary (at least 1,5 bar) - Bleed the gas boiler... -
Page 31: Faults
FAULTS Faults If a fault occurs the boiler will be shut down immediately. P 30 Temperature difference flow - return too large There is a differentiation between blocking and locking. As soon as the difference between flow and return tem- Blocking means that the boiler can restart itself when perature is higher than the value of the parameter 59 plus there is no more failure. - Page 32 FAULTS E 10 Flame stop during a heating demand A locking will occur, when the ionisation flow sinks more than 3 times under 1.5mA during a single heating de- mand. E 11 Flame message without reason A locking will occur, when there is a flame without an open gas valve.
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Page 33: Automatic Firing Unit Bic 335-Parameter List
Automatic firing unit BIC 335-Parameter list Adjustment on the BIC 335 may only be executed by author- ised Hoval after-sales service personnel. The following data- sheet is only for information for the Hoval after sales service personnel! Description DHW Operation... - Page 34 AUTOMATIC FIRING UNIT BIC 335-PARAMETER LIST Description P2EB fan decrement value 5(00) –1 P2EC maximum fan speed 60(00) 58(00) 59(00) 58(00) –1 P2ED fan speed – second phase of pre-ventilation 30(00) 29(00) 29(00) 29(00) –1 P2EE fan speed following false start 60(00) 58(00) 59(00)
- Page 35 4 213 893 / 01...
- Page 36 COPY FOR PLANT USER Confirmation The user (owner) of the system herewith confi rms that • he has received adequate instruction in the operating and maintenance of the installation, • received and taken note of the operating and maintenance instructions and, where applicable other documents con- cerning the heat generator and any further components.
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