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Technical information
Installation instructions
TopGas
classic (35,45,50,60,80,100,120)
®
Wall-mounted gas condensing boilers
for natural gas and liquid gas
Hoval products may only be installed and commissi-
oned by appropriately qualified experts. These ins-
tructions are intended exclusively for the specialist.
Electrical installation must be performed by a licensed
electrical company.
Subject to modifi cations
|
4 219 316 / 00 - 03/20
Nominal output ranges at 50/30 °C
and natural gas
47-TopGas
®
47-TopGas
®
47-TopGas
®
47-TopGas
®
47-TopGas
®
47-TopGas
®
47-TopGas
®
TopGas
classic (35,45,50,60,80,100,120) wall-mount-
®
ed gas condensing boilers in accordance with
EN 15502-1/ 15502-2-1 are designed and approved for
use as heat generators for hot water heating systems
with per mis si ble flow temperatures of up to 85 °C. They
are de sig ned for continuously controlled reduced oper-
ation in heating systems.
classic (35)
7.4 - 34.9 kW
classic (45)
9.1 - 44.3 kW
classic (50) 16.0 - 52.0 kW
classic (60) 12.8 - 60.3 kW
classic (80) 14.8 - 79.1 kW
classic (100) 20.7 - 100.0 kW
classic (120) 22.9 - 120.5 kW
EN
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Summary of Contents for Hoval TopGas classic 35
- Page 1 (100) 20.7 - 100.0 kW ® 47-TopGas classic (120) 22.9 - 120.5 kW ® Hoval products may only be installed and commissi- TopGas classic (35,45,50,60,80,100,120) wall-mount- ® oned by appropriately qualified experts. These ins- ed gas condensing boilers in accordance with tructions are intended exclusively for the specialist.
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Page 2: Table Of Contents
On delivery ...................................5 Guarantee ....................................5 Instructions ..................................5 Transport and storage .................................5 Regulations, standards, ordinances to be complied with for proper use......................6 Technical information ..........................7 Description of the Hoval TopGas classic ..........................7 ® 2.1.1 Diaphragm expansion tank ..............................7 2.1.2 Boiler casing ..................................7 2.1.3... - Page 3 TABLE OF CONTENT Commissioning ............................. 32 Setting the controller.................................32 Water quality ..................................32 4.2.1 Heating water..................................32 4.2.2 Filling and replacement water ............................32 4.2.3 Filling the system ................................33 Venting the gas pipe ................................33 Switching on ..................................33 Gas inlet pressure ................................33 Gas adjustment ..................................34 4.6.1 Gas valve..................................34 4.6.2...
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Page 4: Important Notes
IMPORTanT nOTES Important notes Explanation of the symbols 1.2.1 Warnings General safety instructions The following points must be observed when performing DANGER work on the TopGas classic: ® ... indicates a situation of immediate danger which will lead to serious or fatal injuries if CAUTION not avoided. -
Page 5: Information
Tool: All instructions relevant to your system can be found in Which tools and other equipment are required. the Hoval system manual! In exceptional cases, the in- structions can be found with the components! Further sources of information: Provides important information. Refers to •... -
Page 6: Regulations, Standards, Ordinances To Be Complied With For Proper Use
IMPORTanT nOTES Regulations, standards, ordinances to be Austria § • ÖNORM EN 12828 Heating systems in buildings - De- complied with for proper use sign of hot water heating systems The locally applicable heating system regulations must • ÖNORM EN 12831 Energy efficiency of buildings - be followed when planning, installing and operating the Method for calculation of the design heat load gas heat generator:... -
Page 7: Technical Information
® The calorifier sensors and the loading pump must be prises a corrosion-resistant aluminum casting, through connec ted at the corresponding terminals of the Hoval which the heating water flows in series-parallel fashion TopGas classic controller (see electrical connection dia- ®... -
Page 8: Topgas ® Classic Component Designation
TECHnICaL InFORMaTIOn 2.1.8 TopGas classic component designation ® Fig. 01 1. Sound absorber 2. Fan 3. Flue gas supply air connection 4. Water pressure switch 5. Flue gas temperature sensor 6. Flow temperature sensor 7. Return temperature sensor 8. Ignition/ionisation electrode 9. -
Page 9: Meaning Of The Data On The Data Plate
TECHnICaL InFORMaTIOn Meaning of the data on the data plate Manufacturer Gas supply pressure depending on the gas device category and the country of destination Subsidiaries • Column 1: Country of destination Boiler type (left) and production date (right) • Column 2: Gas device category Boiler type (left) and serial No. -
Page 10: Technical Data For Topgas ® Classic (35-120)
TECHnICaL InFORMaTIOn Technical data for TopGas classic (35-120) ® Type (35) (45) (50) (60) • Nominal heat output at 80/60 °C, natural gas 6.9-31.7 8.3-39.8 14.6-48.3 11.9-54.1 • Nominal heat output at 50/30 °C, natural gas 7.4-34.9 9.1-44.3 16.0-52.0 12.8-60.3 •... - Page 11 TECHnICaL InFORMaTIOn Type (80) (100) (120) • Nominal heat output at 80/60 °C, natural gas 13.4-71.8 18.6-91.2 20.7-109.7 • Nominal heat output at 50/30 °C, natural gas 14.8-79.1 20.7-100.0 22.9-120.5 • Nominal heat output at 80/60 °C, propane 18.4-73.7 22.9-90.4 23.7-107.6 •...
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Page 12: Dimensions Topgas Classic (35-80)
TECHnICaL InFORMaTIOn Dimensions TopGas classic (35-80) ® Measurements (mm) • Lateral clearance 50 mm • Distance from ceiling depending on exhaust flue system used • Front 500 mm View from bottom Gas connection R ¾″ Flow R 1¼″ Return R 1¼″ Condensate drain DN 40 LAS flue gas/combustion air connection... -
Page 13: Dimensions Topgas Classic (100,120)
TECHnICaL InFORMaTIOn Dimensions TopGas classic (100,120) ® Measurements (mm) • Lateral clearance 50 mm • Distance from ceiling depending on exhaust flue system used • Front 500 mm View from bottom Gas connection R ¾″ Flow R 1½″ Return R 1½″ Condensate drain DN 40 LAS flue gas/combustion air connection... -
Page 14: Flow Resistance On The Heating Water Side
TECHnICaL InFORMaTIOn Flow resistance on the heating water side TopGas classic (35,45) TopGas classic (50,60,80) ® ® Volume flow rate (m Volume flow rate (m TopGas classic (100,120) ® 10.0 Volume flow rate (m Brief description of the functions - Interface to display - OpenTherm interface (RS-OT, TTE) of automatic function device BIC 335 - RS 232 interface to PC... -
Page 15: Heating System Control
TECHnICaL InFORMaTIOn Heating system control Operating elements on the boiler control panel / basic controller 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 16 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 the calorifier e.g. 3° Current outside temperature It is possible to read current values e.g. 55° Current flue gas temperature from here e.g.
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Page 17: Parameters To Be Set
TECHnICaL InFORMaTIOn Parameters to be set Parameter 21 (2BK) – maximum outside temperature – Parameter 7 (2AH) – set value, DHW charging – If the maximum outside temperature defined here is ex- • Operation without controller: cee ded, heat demand is no longer applied. As soon as Set value is used as DHW set value for the automatic the parameterised value is reached, the minimum heating function device. - Page 18 TECHnICaL InFORMaTIOn Parameter 62 (2GG) – DHW charging (switch / pump) – This parameter defines whether a pump is present for DHW charging or whether only a switch is in use in addi- tion to the main pump. The setting "0" means a KKP (pump output) and additio- nally a switch (switch output) is used.
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Page 19: Installation
(room tem pe rature control/weath- er-controlled boiler and heating cir cuit con trol) without lower temperature limit. Please observe the notes in the configuration documents of the responsible Hoval companies with respect to the ap propriate hydraulic switching. 4 219 316 / 00... -
Page 20: Gravity Brake
InSTaLLaTIOn 3.2.3 Gravity brake 3.2.4 Minimum water circulation volume It is recommended to install a gravity brake, to avoid heat During the burner operation a circulation pump must al ways losses due to gravity circulation (particularly important be in operation. The minimum water circulation vo lu me in- when changing existing, open installations). - Page 21 InSTaLLaTIOn TopGas classic (100,120) ® Gas boiler with - free-standing calorifier - 1 direct circuit - 1 direct circuit + 1-... mixer circuit(s) Hydraulic schematic BDDE030 TTE-GW TTE-WEZ B1.1 TopGas classic ³ 35 Option / Opzione TTE-WEZ TopTronic E basic module heat generator ®...
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Page 22: Connection Of The Pipes
In Switzerland, the VKF guidelines (edition 1993, clause 3.4.8) specify that a flue gas temperature limiter as defi- Your Hoval dealer can supply an approved flue gas sys- ned in these guidelines must be installed on the unit out- tem suitable for your Hoval TopGas classic. -
Page 23: Air/Flue Gas Pipe
InSTaLLaTIOn 3.3.2 air/Flue gas pipe Design variants Combustion air taken from the surrounding environment, ᴓ80 PPS Flue gas outlet into the chimney, suction of air from the surrounding environment. End piece of the flue gas outlet above the roof. Combustion air taken from the surrounding environment, ᴓ80/125 PPS/aluminum C13/C13x Flue gas outlet and air intake through the outer wall in the same pressure range. -
Page 24: Project Planning Instructions, Flue Gas Systems
The following only applies to countries in which wall ducts Flue gas temperature are allowed: The Hoval flue duct systems E80 PP, E100 PP, E80 Flex For C53 construction boilers, the air intake opening for PP, E100 Flex PP, C80/125 PP, C100/150 PP and E130 the combustion air must not be on the opposing wall of PP are long-term temperature resistant to 120°C. -
Page 25: Design Examples For Room Air Dependent Operation
The following diagrams were computed assuming a geo- room air dependent operation graphic altitude of 1000 m above sea level. Use the suitable flue gas system from Hoval or a flue gas system certified in accordance with DIN EN 14471. Stain- Assembly kit... -
Page 26: Design Examples For Room Air Independent Operation
InSTaLLaTIOn 3.3.6 Design examples for TopGas classic (35,45) ® Assembly kit room air independent operation TG K1 C80/125 PP TG K1 C80/125 Flex PP Verbrennungs- luft Combustion air TopGas classic (35) ® Falls erforderlich ist TopGas classic (45) ® ein Inspektions-T- If necessary, insert an Stück einzusetzen inspection T-piece... - Page 27 InSTaLLaTIOn TopGas classic (35) ® Assembly kit TG K-LAS C80/125 PP TG KD-LAS C80/125 PP Combustion air Verbrennungs- luft Falls erforderlich ist If necessary, insert an ein Inspektions- inspection T-piece Stück einzusetzen TopGas ® (35) Maximum horizontal length connecting pipe (m) ®...
- Page 28 InSTaLLaTIOn Assembly kit TG AW C80/125 PP Combustion Verbrennungs- luft TopGas classic (35) ® Falls erforderlich ist ein Inspektions-T- If necessary, insert an Stück einzusetzen inspection T-piece Maximum horizontal length connecting pipe (m) Anbindeleitung [m] Assembly kit TG AW2 C100/150 PP ®...
- Page 29 InSTaLLaTIOn Maximum exhaust duct lengths TG DHZ1 C80/125PP TopGas classic (35): ® TopGas classic (45): ® Combustion air TG DHZ2 C100/150PP Verbrennungs- luft TopGas classic (35): 16 m ® TopGas classic (45): 19 m ® TopGas classic (60): 11 m ®...
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Page 30: Condensate Discharge And Neutralisation
InSTaLLaTIOn Condensate discharge and neutralisation Gas connection Condensate from gas condensing boilers must be fed in- to the public sewer system or separate waste water treat- WARNING ment plant in accordance with the relevant regulations The installation of the gas pipeline and first and - where prescribed - must first be neutralised. -
Page 31: Regulations For Electrical Connections
During assembly of the system, the requirements of VDE 3.6.4.1 TopTronic RS-OT ® 0100 and the regulations imposed by the responsible en- There is the option of operating the Hoval TopGas classic ® ergy company must be complied with. with a TopTronic RS-OT controller to be mounted exter- ®... -
Page 32: Commissioning
As a rule, untreated mains water is best suited as filling and replacement water for a system with Hoval boilers. Hoval boilers and calorifiers are suitable for heating sys- How ever, the quality of the untreated mains water must... -
Page 33: Filling The System
COMMISSIOnInG If a reduction in water hardness is necessary we recom- NOTICE mend a complete desalination (no softening) with bypass, so that the sum of the alkaline-earths in the filling water Corrosion damage to the system and venting re mains of approx. 0,5 mol/m . -
Page 34: Gas Adjustment
If the minimum connection pressure (chapter 4.5) is too ed by Hoval or by Hoval customer service. low (e.g. because of clogged gas filter, under-dimensio- ned gas supply), the boiler will not achieve the rated out- Compliance with the maximum permissible li mit put indicated by the manufacturer. -
Page 35: 4.6.2.2 Changing To A Different Type Of Gas
COMMISSIOnInG 4.6.2.2 Changing to a different type of gas The adjustment value is calculated as follows: Heat load NB (kW) WARNING Setting value E = Operation calorific value H (kW/m Changes are only to be carried out by a rec- ognised specialist! 1000 After changing to a different type of gas, the... -
Page 36: Topgas ® Classic (100,120)
COMMISSIOnInG Please comply with the following points when exchang- ing or readjusting the valve VR 4615V: For a boiler which is already connected: - Open the gas cock The valve supplied as a spare part is open and must be - Energise the heat generator (e.g. -
Page 37: 4.6.3.2 Changing To A Different Type Of Gas
COMMISSIOnInG Setting is performed as follows: ) setting Check the setting of the minimum and maximum speed of rotation at the automatic function device in ac cor dan ce with the parameter list. Establish the gas and electrical connections for the boil er. Press the "MODE"... -
Page 38: Handover To The Operator
COMMISSIOnInG Changing from natural gas H to liquid gas propane Set CO ) content according to chapter 4.6.3.1 at nom- Compliance with the special local provisions inal output and minimum output to CO = 9,9 - 10,2 (O (VKF/DVGW/ÖVGW) for operating a boiler on 5,9 - 5,5) vol.-% (dry). -
Page 39: Decommissioning
DECOMMISSIOnInG Decommissioning The following measures must be taken if the boiler is to be taken out of operation for several weeks: Where there is a frost hazard, have the system drained as prescribed by the heating installer or add frost protec tion agent in accordance with the heating installer’s instruc tions. -
Page 40: Maintenance
MaInTEnanCE Maintenance Maintenance comprises - Cleaning the flue gas heat exchanger and condensate Checking the water connections for collector leakage - Dismantle siphon and clean and rinse condensate Tighten screw connections on the water side while the drainage boil er is still at operating temperature. - Clean burner and check for damage - Checking the ignition electrode, distance from burner ap prox. -
Page 41: Function Check
MaInTEnanCE Function check 9. Remove the surface burner - Set gas condensing boiler as described in chapter 4.6 - Check the connections of the gas condensing boiler for leaks - Check the system pressure, top up if necessary (at least 1,5 bar) - Vent the gas condensing boiler - Create inspection record Emission measurement... -
Page 42: Faults
FauLTS Faults P 27 Water pressure too low If a fault occurs the boiler will be shut down immediately. There is a differentiation between blocking and locking. If the water pressure drops too sharply, the water pressu- Blocking means that the boiler can restart itself when re switch signals this. - Page 43 FauLTS E 04 Return sensor short circuit E 14 Fault while loading parameters If a temperature threshold of 125 °C is exceeded, the A communication fault during loading of the parameters con nec ted return sensor is considered to be short-circuit- with SITBIC335Iab has occurred.
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Page 44: Parameter List For Bic 335 Automatic Function Device
Parameter list for BIC 335 automatic function device WARNING Changes to the BIC may only be made by authorised Hoval customer service technicians. The following table is intended solely to provide information for the Hoval customer service technician! TopGas classic (35,45,50,60,80,100,120) automatic function device ®... - Page 45 PaRaMETER LIST FOR BIC 335 auTOMaTIC FunCTIOn DEVICE Description 33 P2EA Rising ramp of fan /s OEM 10(00) 10(00) 10(00) 10(00) 10(00) 10(00) 10(00) –1 34 P2EB Downward ramp of fan /s OEM 5(00) 5(00) 5(00) 5(00) 5(00) 5(00) 5(00) –1 35 P2EC Maximum fan speed 58(00) 58(00) 53(00) 55(00) 64(00) 65(00) 73(00)
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- Page 47 4 219 316 / 00...
- Page 48 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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