Table of Contents
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EN
Technical information
Installation instructions
Gas condensing boiler
TopGas
(30,35,45,50,60)
®
for natural and liquid gas
Hoval products must be installed and commis-
sioned only by appropriately qualifi ed experts.
These instructions are intended exclusively for
the specialist. Electrical installations may only
be carried out by a qualifi ed electrician.
Rated output levels at 40/30°C and
natural gas
5/6-TopGas
(30)
®
5/6-TopGas
(35)
®
5/6-TopGas
(45)
®
5/6-TopGas
(50)
®
5/6-TopGas
(60)
®
Wall-mounted gas boilers TopGas
50,60) according to DIN 4702, DIN EN 483 and
DIN EN 677 are suitable and approved as heat
producers for hot water heating systems with
a permissible flow temperature of up to 85°C).
They are designed for a flexibly reduced opera-
tion in heating systems according.
4 205 254 / 03 - 05/10
6,8 - 30,1 kW
6,8 - 35,0 kW
11,1 - 45,0 kW
12,8 - 52,9 kW
12,8 - 60,7 kW
(30,35,45,
®
Subject to modifi cations
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Summary of Contents for Hoval TopGas 30
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Page 1: Technical Information
TopGas (30,35,45,50,60) ® for natural and liquid gas Hoval products must be installed and commis- sioned only by appropriately qualifi ed experts. These instructions are intended exclusively for the specialist. Electrical installations may only be carried out by a qualifi ed electrician. -
Page 2: Table Of Contents
Boiler flow resistance ..........................8 Short description of the automatic firing unit BIC 335 ................ 8 Control of the boiler ..........................9 Adjustable parameters ......................... 11 Installation .......................... 13 Description of the Hoval TopGas ....................... 13 ® 3.1.1 Diaphragm expansion tank........................13 3.1.2... - Page 3 Table of contents 4 205 254 / 03 Commissioning ........................21 Setting the control ..........................21 Water quality ............................21 4.2.1 Heating water ............................21 Filling and replacement water ......................22 4.3.1 Filling up the system ..........................23 4.3.2 Gas adjustment ............................23 4.3.3 Bleeding the gas pipeline ........................
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Page 4: Important Information
Hoval gas boilers are only to be installed by ap- - Replace all removed covers and cladding on proved specialists. No modifications are to be completion of the repair / maintenance work. -
Page 5: Regulations, Official Approvals
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... -
Page 6: Technical Details
Technical details 4 205 254 / 03 Technical details Technical Data (30) (35) (45) (50) (60) • Rated heating capacity 80/60°C with natural ga 6,0-27,4 6,0-31,8 10,0-41,0 11,7-48,3 11,7-55,3 • Rated heating capacity 40/30°C with natural gas 6,8-30,1 6,8-35,0 11,1-45,0 12,8-52,9 12,8-60,7 •... -
Page 7: Dimensions
Technical details 4 205 254 / 03 Dimensions • Distance from the side 50 mm • Distance from the ceiling dependent on the utilised flue gas pipeline system • In the front 500 mm View from below Top View Borehole drawing 1 Gas connection R ¾"... -
Page 8: Boiler Flow Resistance
Technical details 4 205 254 / 03 Boiler flow resistance Boiler incl. connection kit Boiler only Flow rate [m Short description of the automatic fir- ing unit BIC 335 The automatic firing unit operates both without con- Interface to display troller (TTT/N) and also without room station (RS- OpenTherm- interface (RS-OT, TTT/N) OT). -
Page 9: Control Of The Boiler
Technical details 4 205 254 / 03 Control of the boiler Control elements on the boiler control panel / Basic control N4.1 Usually, no settings of the basic control have to be made by the user. All settings have been made by the installer or by the manufacturer. - Page 10 Technical details 4 205 254 / 03 Function Meaning, Description Current flow temperature (Heating water temperature) e.g. 45° Current return temperature e.g. 40° Current temperature in water heater e.g. 60° Current outdoor temperature e.g. 3° It is possible to read monetary Current flue gas temperature e.g.
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Page 11: Adjustable Parameters
Technical details 4 205 254 / 03 Adjustable parameters Parameter 7 (2AH) – Set point DHW charging temperature – Using this parameter the reference value for the DHW temperature can be set where there is no room con- trol unit or other regulatory device installed. If a reference value is transmitted via an OT bus, the latter (value via OT) will always override this parameter. - Page 12 Technical details 4 205 254 / 03 Parameter 24 (2BN) – Pump after-run time (heating operation – During the time which can be set using this parameter the pump continues to run after a phase of heating demand. Parameter 25 (2BO) – Maximum fan speed in heating operation mode – This parameter is used to set the maximum permitted fan speed in % in heating operation mode.
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Page 13: Installation
(30,35,45,50,60) can be combined ® 45,50,60) operates with very high efficiency. with a service water heater (e.g. Hoval CombiVal). On leaving the heat exchanger the cooled flue gas is The electrical connections for connecting the storage transferred to the flue gas pipeline system... -
Page 14: Topgas ® Component Designation
Installation 4 205 254 / 03 3.1.8 TopGas component designation ® Picture 3.1.8-1 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... -
Page 15: Boiler Installation Room
During the burner operation a circulation pump must For suitable hydraulic connections, please note the always be in operation too. The minimum flow rate instructions in the Hoval project planning documen- indicated in the technical data must always be pro- tation. -
Page 16: To Be Provided By Customer
Installation 4 205 254 / 03 3.4.5 To be provided by customer A pressure expansion tank adapted to heating system, water volume and static height. 3.4.6 Hydraulic interconnection Examples TopGas (30,35,45,50,60) with water heater ® and direct heating circuit TopTronic T RS-T Dies ist ein unerlaubter Weg! -
Page 17: Flue Gas Connection, Chimney And Condensate Pipeline
Your Hoval agent can supply a suitable and approved flue gas system for your TopGas ® In both cases the cross sections and maximum lengths... -
Page 18: Installation Examples For Room-Air-Dependent Operation
Installation 4 205 254 / 03 • Single flue gas pipes can be shortened to the 3.5.3 Installation examples necessary length but must however be cleanly de- for room-air-dependent operation burred before the assembly, to prevent damage to the seal in the counter-piece. •... -
Page 19: Exhaust Gas System For Room-Air-Independent Operation
Installation 4 205 254 / 03 3.5.4 Exhaust gas system for 3.5.5 Attic heating center room-air-independent operation (vertical exhaust gas conduit installation) Verbrennungsluft Combustion air Combustion air Verbrennungsluft Falls erforderlich ist ein Inspektions-T- If necessary, an inspection Stück einzusetzen T-piece has to be inserted Falls erforderlich ist ein Inspektions-T- If necessary, an inspection... -
Page 20: Connection Of Pipelines
Installation 4 205 254 / 03 3.5.7 Connection of pipelines 3.5.9 Gas connection On of the boiler installation the pipelines are connected The installation of the gas pipeline and first directly to the feed and the return connectors. Please placing in operation must be carried out by a note the designations for the pipeline connectors in recognised expert. -
Page 21: Electrical Connection (Grid) 230 V, 50 Hz
10 cm. Where low voltage and power current cables have to be installed in cable ducts, these are to be kept apart by a separator. Your Hoval agent will provide you with a detailed 3.6.2 Electrical connection (grid) 230 V, 50 Hz description of the power outputs of this type of con- The boiler is wired ready for connection. -
Page 22: Filling And Replacement Water
Filling and replacement water • Plants with • For a plant using Hoval boilers untreated drinking - continuous oxygen intake (e.g. underfloor heat- water is generally best suited as fil ling and replace- ing systems without diffusion proof plastic piping ment water. -
Page 23: Filling Up The System
4.3.6 Gas fitting ple of the maximum fill-up quantity. The Hoval TopGas is equipped with a Honeywell ® pneumatic modulating multiple setting device. scope Example: maximum fill-up quantity (as in table 1, of supply includes two solenoid valves (B+B), a screen chapter 4.3) 1200 l, maximum fill-up and top-off wa-... -
Page 24: Changing To A Different Kind Of Gas
Commissioning 4 205 254 / 03 If the connection pressure of natural gas is c) Press the „-“ key to set the boiler to 0%. below 15 or above 25 mbar, no setting and no Check the CO )-content of the flue gas. It must commissioning can take place. -
Page 25: Handing Over To The User
Commissioning / Decommissioning 4 205 254 / 03 Changeover from natural gas H to natural gas L The changeover to a low calorie natural gas is simple. Also available on request for flow with the boiler are copies of the official description for submission to the Only a check or correction of the CO ) value at max. -
Page 26: Maintenance
Maintenance 4 205 254 / 03 Maintenance Caution! Wet clean the heat exchanger (do not use steel Missing or faulty cleaning and main- wire brushes) (picture 6.4.3, see next page) tenance may cause damage to the in- Clean siphon (picture 6.4.4 and 6.4.5, below) stallation. - Page 27 Maintenance 4 205 254 / 03 Bolting Burner plate Gas screw connection Picture 6.4.1 Picture 6.4.2 Picture 6.4.3...
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Page 28: Troubleshooting
Troubleshooting 4 205 254 / 03 Troubleshooting If a fault occurs the boiler will be shut down immediately. There is a differentiation between blocking and locking. Blocking means that the boiler can restart itself when there is no more failure. After repairing locking fault it is necessary to press the Reset-key to confirm, so the boiler can start again. - Page 29 Troubleshooting 4 205 254 / 03 Locking: E 01 Flow sensor short-circuit If the temperature is higher than 125°C the connected flow sensor seems as short-circuit and responds with a locking. Temperature jumps, which are higher than 50°C/sec, it also occurs locking. E 02 Locking temperature flow If the temperature is higher than 100°C by the flow sensor occurs a locking.
- Page 30 Troubleshooting 4 205 254 / 03 E 12 Fan speed out of the limits If the fan actual-speed is out of a range of the fan set-speed for more than 15 seconds, a locking is occured. A maximum variation is 20 % of the set value. E 13 Parameter programming After loading of a parameter from the laptop to the automatic firing unit the boiler will be locked automatically.
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Page 31: Parameter List Automatic Burner Bic 335
Adjustment on the BIC 335 may only be executed by authorised Hoval after-sales service personnel. Factory settings Bic 335 TopGas (30,35,45,50,60) ® The following data-sheet is only for information for the Hoval after sales service personnel! Description DHW Operation P2AA flow temperature surplus (DHW) 1°C OEM... - Page 32 Parameter list automatic burner BIC 335 4 205 254 / 03 Description P2EB fan decrement value /s OEM 5(00) –1 P2EC maximum fan speed 60(00) 49(00) 58(00) 59(00) 49(00) 58(00) –1 P2ED fan speed – second phase of pre-ventilation 30(00) 25(00) 29(00) 29(00) 29(00) 29(00) –1 P2EE...
- Page 33 4 205 254 / 03...
- Page 34 Copy for plant user C O N F I R M A T I O N 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 concerning the heat generator and any further components.
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