Hoval topgas 80 Installation Instructions Manual
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Hoval topgas 80 Installation Instructions Manual

Gas condensing boiler for natural and liquid gas
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Technical information
Installation instructions
TopGas
(80)
®
Gas condensing boiler
for natural and liquid gas
Hoval products must be installed and commissioned
only by appropriately qualified experts. These instruc-
tions are intended exclusively for the specialist. Elec-
trical installations may only be carried out by a qualified
electrician.
Subject to modifi cations
|
4 213 894 / 01 - 07/15
These instructions apply to the following ty-
pes:
41-TopGas
®
TopGas
(80) wall-hung gas condensing boilers in ac-
®
cordance with DIN 4702, DIN EN 483 and 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.
(80)
17,3 - 80,0 kW
EN

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Summary of Contents for Hoval topgas 80

  • Page 1 41-TopGas (80) 17,3 - 80,0 kW ® Hoval products must be installed and commissioned TopGas (80) wall-hung gas condensing boilers in ac- ® only by appropriately qualified experts. These instruc- cordance with DIN 4702, DIN EN 483 and DIN EN 677 tions are intended exclusively for the specialist.

  • Page 2: Table Of Contents

    Dimensions ..................................9 Short description of the automatic firing unit BIC 335 ..................................10 Control of the boiler ................................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 5.2.2 Filling and replacement water ............................25 5.2.3 Filling up the system ...............................26 Gas adjustment ..................................26 5.3.1 Bleeding the gas pipeline ..............................26 5.3.2 Commissioning ................................26 5.3.3 Gas inlet pressure ................................26 5.3.4...

  • Page 4: Important Notes

    - Boiler connected to a flue gas conduit installed in All instructions relevant to your system can be found in compliance with the relevant regulations. the Hoval system manual! In exceptional cases, the inst- - Burner preset. ructions can be found with the components! •...

  • Page 5: Regulations, Official Approvals

    The appliance is only to be transported and stored only in rosion its original packing. Interim storage of Hoval gas boilers is • M 7443, (Part 2,3,7) Gas appliances with atmospheric only to take place in weather protected rooms and only in burners the original packing.

  • Page 6: Safety Instructions

    SAFETY Safety instructions Warning symbols Warning levels General warning of a danger zone. DANGER ... indicates a situation of immediate danger «Warning: dangerous electrical voltage» as a which will lead to serious or fatal injuries if warning for accident prevention. not avoided.

  • Page 7: Technical Information

    TECHNICAL INFORMATION Technical information Technical Data Type (80) • Nominal heat output 80/60°C with natural gas 15,8-72,4 • Nominal heat output 40/30 °C with natural gas 17,3-80,0 • Nominal heat output 80/60 °C propane gas 19,5-72,4 • Nominal heat output 40/30 °C propane gas 21,6-80,0 •...

  • Page 8: Boiler-Flow Resistance

    TECHNICAL INFORMATION Boiler-flow resistance Boiler incl. connection set Boiler only Maximum residual overpressure TopGas (80) ® with connection set AS32-TG/UPM2 32-60 TopGas® (80) mit AS32 und UPM2 32-60 Maximum residual overpressure TopGas (80) ® with connection set AS32-TG/UPM GEO 32-85 TopGas®...

  • Page 9: Dimensions

    TECHNICAL INFORMATION Dimensions Dimensions in mm • Sideways 50 mm • Space to ceiling dependent on the flue gas system • Front 500 mm View from bottom View from botton 6 2 0 2 7 0 2 7 0 5 2 0 1 0 0 2 1 6 4 1 3...

  • 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 controller (TTE) and also without room station (RS-OT). The auto- matic firing unit comprises the following functions - PWM- fan (230V~) - Modulating operation - Inputs for Flow sensor Return sensor...

  • Page 11: Control Of The Boiler

    TECHNICAL INFORMATION Control of the boiler Control elements on the boiler control panel / Basic control G04.4 The basic controller can be upgraded with an RS-OT (G04.4) or a TopTronic E ZE1 heating controller set. ® Normally, the user does not need to set the basic controller. All settings have been made by the installer or the manufacturer.
  • 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.

  • Page 13: Adjustable Parameters

    TECHNICAL INFORMATION Adjustable parameters Parameter 22 (2BL) –Restart delay following temperature blocking in heating operation mode – Parameter 7 (2AH) – Set point DHW charging temperature – When the boiler is shut down on account of a temperature Using this parameter the reference value for the DHW limit being exceeded, i.e.
  • Page 14 TECHNICAL INFORMATION Parameter 64 (2GI) – Pump – maximum PWM value – This parameter is used to determine the maximum per- mitted capacity of the PWM pump in %. The maximum PWM value is effective when the boiler output is at a ma- ximum.

  • Page 15: Installation

    4.1.4 Automatic gas firing unit and heating controller Automatic firing unit BIC 335 Description of the Hoval TopGas ® (see 7.3 for short description). The heat exchanger of the Hoval TopGas (80) com- ® prises a corrosion-resistant aluminum casting, through 4.1.5 Heating circulation pump...
  • Page 16 ASSEMBLY 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. Gas fitting 11.

  • Page 17: Boiler Installation Room

    (room temperature control or weather-supported boiler and heating control) temperature limiting. For suitable hydraulic connections, please note the inst- ructions in the Hoval project planning documentation. NOTE When modernising an old heating system with an open expansion tank, this is to be converted to a “closed”...

  • Page 18: Gravity Brake

    ASSEMBLY 4.3.3 Gravity brake 4.3.4 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 indica- when changing existing, open installations).
  • Page 19 ASSEMBLY 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 Option / Opzione fig. 05 Achtung ! Für die Installation muss das anlagenbezogene Schema verwendet werden! Verbindungshinweise / Hydr.

  • Page 20: Flue Gas Connection, Chimney And Condensate Pipeline

    The use of specially approved flue gas pipelines, Your Hoval agent can supply a suitable and approved flue Use of damp-insensitive flues, approved for flue gas system for your TopGas ®...

  • Page 21: Natural Ventilation Flue Example

    ASSEMBLY 4.4.3 Natural ventilation flue example 4.4.4 Flue gas system for room sealed operation 9 HU EU HQ Q XQ JV Ł O XIW 9 HU EU HQ Q XQ JV Ł combustion air O XIW ) DO O V˜HU IRU G HU O L FK˜L VW ˜ if necessary an HL Q ˜,Q VSHN W L RQ VŁ...

  • Page 22: Roof Heating Centre Concentric Flue (Room Sealed)

    ASSEMBLY 4.4.5 Roof heating centre concentric flue (room 4.4.6 Wall outlet sealed) combustion air Verbrennungsluft TopGas if necessary an inspection-T-piece is to Falls erforderlich ist ein Inspektions-T- attach Stück einzusetzen fig. 09 TopGas fig. 08 NOTE The condensate from the exhaust gas sys- tem must not be discharged through the boi- ler.

  • Page 23: Connection Of The Pipes

    ASSEMBLY 4.4.7 Connection of the pipes 4.4.9 Gas connection On of the boiler installation the pipelines are connected WARNING directly to the feed and the return connectors. Please note the designations for the pipeline connectors in sec- The installation of the gas pipeline and first placing in operation must be carried out by a tion 2.2.

  • Page 24: Regulations For Electrical Connections

    Your Hoval agent will provide you with a detailed descrip- 4.5.2 Electrical connection (mains) 230 V, 50 Hz tion of the power outputs of this type of controller. The...

  • Page 25: Commissioning

    5.2.2 Filling and replacement water The European Standard EN 14868 and the Directive VDI For a plant using Hoval boilers untreated drink ing wa ter 2035 must be observed. In par ticular, attention must be is generally best suited as fil ling and replacement water.

  • Page 26: Filling Up The System

    Installation of a strainer in the boiler return is 5.3.4 Gas fitting recommended. The Hoval TopGas is equipped with a Honeywell pneu- ® matic modulating multiple setting device. scope of supply includes two solenoid valves (B+B), a screen filter plus an installed pressure balance (1:1) - gas/air servo controller.

  • Page 27: Setting The Gas Flow Rate

    COMMISSIONING Measuring nipple for inlet pressure The gas flow rate is corrected by changing the fan speed: Measuring nipple for outlet pressure - Decrease the max. fan speed at the automatic firing Choke screw for max. output (Inbus 4mm) unit: -> gas flow increases (with constant CO (O2) Offset-screw min.

  • Page 28: Changing To A Different Kind Of Gas

    COMMISSIONING Changing to a different kind of gas E) Affix the yellow sticker „change to the set gas type: Liquid gas“ to the boiler rating plate. WARNING F) with boiler already connected: - open the gas valve Changes are only to be carried out by a re- - place the system deflector to „I“...

  • Page 29: Decommissioning

    DECOMMISSIONING Decommissioning The following steps are to be taken if the compact hea- ting controller is to be placed out of operation for several weeks: Clean the boiler heating surfaces and have your boiler servicing agent apply a conservation agent. Your chim- ney-sweep technician will eagerly consult you.

  • Page 30: Maintenance

    MAINTENANCE Maintenance Function check - Set the gas boiler according to 5.3 Checking the water connections for leakage - Check all gas boiler connections for leaks Tighten screw connections on the water side while the - Check the system pressure, replenish where necessary boiler is still at operating temperature.
  • Page 31 MAINTENANCE Mounting opening Plug connections Gas screw connection Burner plate Bolting burner plate fig. 15 fig. 16 fig. 18 - Fan must be remove first (fig. 16) - The cleaning cover below is for visual control only and must be closed during cleaning process (Bfig. 17). fig.

  • Page 32: Faults

    FAULTS Faults P 30 Temperature difference flow - return too large As soon as the difference between flow and return tem- If a fault occurs the boiler will be shut down immediately. perature is higher than the value of the parameter 59 plus There is a differentiation between blocking and locking.
  • Page 33 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.

  • Page 34: Automatic Firing Unit Bic 335-Parameter List

    Automatic firing unit BIC 335-Parameter list Adjustment on the BIC 335 may only be executed by autho- rised Hoval after-sales service personnel. The following data- sheet is only for information for the Hoval after sales service personnel! Description DHW Operation...
  • Page 35 AUTOMATIC FIRING UNIT BIC 335-PARAMETER LIST Description P2EB fan decrement value 5(00) –1 P2EC maximum fan speed 60(00) 64(00) –1 P2ED fan speed – second phase of pre-ventilation 30(00) 32(00) –1 P2EE fan speed following false start 60(00) 64(00) –1 P2EF fan speed following normal shutdown or blocking condition 14(00)
  • Page 36 4 213 894 / 01...
  • Page 37 4 213 894 / 01...
  • Page 38 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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