Technical information Installation instructions

Transcription

1 Technical information Installation instructions UltraGas (15-50) Condensing gas heating boilers for natural gas and liquid gas for modulating operation These instructions apply to the following types: Rated output levels at 40/30ºC and for natural gas 41-UltraGas (15) 3,1-15,5 kw 41-UltraGas (20) 4,0-20,2 kw 41-UltraGas (27) 5,0-27,2 kw 41-UltraGas (35) 5,8-35,7 kw 41-UltraGas (50) 8,3-50,1 kw Hoval products must be installed and commissioned only by appropriately qualified experts. These instructions are intended exclusively for the specialist. Electrical installations may only be carried out by a qualified electrician. The floor standing gas condensing boiler UltraGas are designed and approved for use as heat generators for hot water heating systems with a permissible flow temperature of up to 85ºC1), in accordance with EN 483 and EN 677. They are designed for continuously adjustable reduced output operation in heating systems. 1) See technical data Subject to modifi cations / 00-07/15 EN

2 TABLE OF CONTENTS 1. Important notes 1.1 Safety instructions Key to symbols used Warnings Symbols Acceptance of delivery Scope of guarantee Instruction manuals Regulations, official permits Germany Austria Switzerland Assembly 2.1 Set-up, levelling Technical data 3.1 Description of the boiler Technical data Dimensions Space requirements Boiler-Flow resistance Brief description of the automatic firing device Installation 4.1 Safety information Boiler room requirements Room air dependent installation Room sealed installation Flue gas connection and flue Condensate drainage Design variants Fitting the condensate drain (standard design with siphon) Fitting the neutralisation box Fitting the condensate delivery pump Fitting the neutralisation box and the condensate delivery pump Hydraulic connection Customer-side requirements Hydraulic interconnection Electrical connection Commissioning 5.1 Safety information Filling with water Water quality Bleeding the air from the gas line Switching on the system Gas inlet pressure Setting the gas flow rate CO 2 (O 2 ) and measurement of NOx/CO content in the flue gas (flue gas measurement) Changing over to a different gas type Handover to the user Record - Activation of screed function / 00

3 TABLE OF CONTENTS 6. Maintenance 6.1 Safety information Bleeding Water refilling Renewing fuse Information for combustion controller/chimney sweep regarding emission monitor key Cleaning Cleaning the burner cylinder Cleaning the exterior of the combustion chamber and burner cylinder Leakage testing Cleaning/adjusting the ignition and ionisation device Setting the gas flow rate CO 2 (O 2 ) and measurement of NOx/CO content in the flue gas Clean siphon or neutralisation box Procedure for servicing the neutralisation installation Maintenance of the Neutralisation equipment (if available) / 00 3

4 IMPORTANT INFORMATION 1. Important notes 1.1 Safety instructions The system shall not be put into operation until all relevant standards and safety regulations are met. For a test run, the following minimum conditions must be satisfied: Safety valve installed (closed system) Controls operative (connected to power supply) Sensor for safety temperature limiter is connected (= boiler temperature sensor) System filled with water Siphon filled with water Expansion tank connected Flue gas adapter pipe with flue gas pipe connected to flue. Burner is preset (see point 6.7). WARNING The heat generator can only be de-energised by disconnection from the mains (e.g. all-pole switch). WARNING All electric power supply circuits must be switched off before accessing the terminals. 1.2 Key to symbols used Warnings!!! 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 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. Warning of cutting injuries: Avoid cutting injuries. Clearly indicate the danger of cutting on sharp-edged parts to avoid serious and costly injuries. «Warning of hot surface» sign for indicating safety. Indicates dangers of injury and burns on hot surfaces / 00

5 IMPORTANT INFORMATION Information: Provides important information. Follow the instructions for use. Requirements to comply with the instructions. 1.3 Acceptance of delivery A visual control of the heating boiler should be conducted upon delivery. In the event of damage, the necessary steps should be followed as specified in the delivery contract. The costs for correcting the damage shall be taken over by the individual risk bearer. Tool: Which tools and other equipment are required. Provides important information. Refers to standards and directives. 1.4 Scope of guarantee The guarantee does not cover defects caused by: non-observance of these instructions non-observance of the operating instructions incorrect Installation unauthorised alterations improper use contaminated operating media (gas, water, combustion air) unsuitable chemical additives to the heating water damage due to the exercise of force corrosion through halogen compounds corrosion through nonconforming water quality 1.5 Instruction manuals A summary of all the instruction manuals relevant to this system can be found in the Hoval System User Guide! In exceptional cases the instructions are kept with the respective components! Additional sources of information: Hoval catalogue Standards and regulations / 00 5

6 IMPORTANT INFORMATION 1.6 Regulations, official permits When installing and operating the system, the standards and regulations spec i fied in point to must be complied with at all times Germany DIN EN Heating systems in buildings - Methods for calculating the design heat load DIN EN Flue gas systems - Heat and flow calculation methods DIN EN Heating systems in buildings - Planning of hot water heating systems. DIN 4755 Oil fired combustion systems. Construction, design, safety requirements. DIN 4756 Gas fired combustion systems. Construction, design, safety requirements, design and execution (for gas burner operation). DIN Domestic chimneys, requirements, design and construction. TRD 702 Steam boilers with group II hot water generators. TRD 721 Safety equipment against excessive pressure / safety valves for group II steam boilers. VDI 2035 Prevention of damage through corrosion and scale formation in hot water heating systems. DIN / VDI 0116 Electrical equipment in combustion systems (VDE regulation). See enclosure N for further standards applicable in Germany Switzerland SN EN Heating systems in buildings - Methods for calculating the design heat load SN EN Flue gas systems - Heat and flow calculation methods SN EN Heating systems in buildings - Planning of hot water heating systems. VKF - Association of Cantonal Fire Insurances. Fire service regulations. SVGW Switzerland. Association of the gas and water trade. SNV Ventilation requirements for the boiler Installation room. SWKI BT Quality of water in installations of building technology. Technical tank regulations TTV and further standards and regulations issued by CEN, CEN ELEC, DIN, VDE, DVGW, TRD and by the legislator. Regulations from the local building authority, insurance companies and chimney sweeps must also be complied with. When using gas as fuel, the regulations of the responsible gas board must also be observed. An official permit may be required Austria OENORM Heating systems in buildings - Methods for calculating the design heat load OENORM Flue gas systems - Heat and flow calculation methods OENORM Heating systems in buildings - Planning of hot water heating systems. ÖNorm B 8130 Open water heating systems; safety equipment. ÖNorm B 8131 Closed water heating systems; requirements to safety, construction and testing. ÖNorm B 8133 Hot water supply systems; safety requirements. ÖNorm B 8136 Heating systems, space and other building requirements. ÖNorm M 7515 Dimensioning of chimneys; definitions and calculation procedure. ÖNorm H 5171 Heating systems - construction requirements for buildings. ÖVGW TR-Gas / 00

7 ASSEMBLY 2. Assembly 2.1 Set-up, levelling The boiler is fixed to wooden transport chocks. For transport up and down stairs, it is wise to leave these timbers in place under the boiler. A special foundation plate for the boiler is not an essential, but it is recommended. Space requirement For further information on space requirements, see chapter 3.4. The cleaning apertures must be easily accessible. Installing and levelling the boiler Remove transport chocks. Store nuts and washers. Lift the boiler on one side and put grub screws of boiler base from the bottom through the slot of the boiler sockets. Fix boiler feet using hexagonal nuts (Fig. 01). Using a spirit level, set the boiler in longitudinal and transverse direction and position it with a slight forward tilt. This is done by adjusting the nuts on the boiler feet. After this adjustment, the upper (locking) nuts on the boiler feet must be tightened. Fig / 00 7

8 TECHNICAL INFORMATION 3. Technical data 3.1 Description of the boiler The Hoval UltraGas is a low emission, energy-saving condensing gas boiler comprising the Ultraclean burner system, a gas fired premix burner with combustion air fan. The Hoval UltraGas has a vertically disposed combustion chamber of stainless steel as a primary heating surface and a secondary heating surface of a corrosion resistant aluminium alloy. The secondary heating surface is designed so that part of the water vapour contained in the flue gas is condensed and the vaporisation heat it contains is utilised for the heating circuit. The gas burner is in the form of a break draught burner, which can easily be swung up for maintenance purposes. The UltraGas is designed to operate with natural and liquid gas. The figure below shows the design principle. Gas safety and control devices Combustion air fan Feed tube on left and/or right side Electrode for ignition and flame monitoring TopTronic E controller High temperature return on left and/or right side Flue gas connection Low temperature return on left and/or right side alufer heat exchanger Condensate collection tray Fig / 00

9 TECHNICAL INFORMATION 3.2 Technical data UltraGas (15-50) Type (15) (20) (27) (35) (50) Nominal output 80/60 C with natural gas 1 kw 3,0-14,3 3,8-18,7 4,5-25,0 5,2-32,8 7,5-46,1 Nominal output 40/30 C with natural gas 1 kw 3,3-15,5 4,3-20,3 5,0-27,2 5,8-35,7 8,3-49,9 Nominal output 80/60 C with liquid gas 2 kw 4,5-13,8 4,9-18,6 6,6-24,3 6,9-32,2 9,9-45,5 Nominal output 40/30 C with liquid gas 2 kw 5,0-15,3 5,5-20,7 7,3-27,0 7,7-35,7 10,9-49,9 Nominal load with natural gas 1 kw 3,1-14,5 4,0-19,0 4,7-25,4 5,4-33,3 7,7-46,9 Nominal load with liquid gas 2 kw 4,7-14,3 5,1-19,3 6,8-25,2 7,2-33,4 10,2-47,2 Working pressure heating max./min. bar 3,0/1,0 3,0/1,0 3,0/1,0 3,0/1,0 3,0/1,0 Working temperature max. C Boiler water capacity l Flow resistance boiler 3 z-value 3,5 3,5 3,5 1,1 1,1 Min. water circulation l/h Boiler Weight (without water content, incl. casing) kg Boiler efficiency at full load at 80/60 C % (related to net/gross calorific value) 97,5/87,8 97/88,1 97,9/88,2 97,9/88,2 98,0/88,3 Boiler efficiency at partial load 30% (according to EN 303) % (related to net / gross calorific value) 107,9/97,2 108,0/97,3 108,0/97,3 108,1/97,4 108,1/97,4 Standard efficiency 40/30 C % 109,5/98,6 109,5/98,6 109,5/98,6 109,5/98,6 109,5/98,6 (net calorific value / gross calorific value) 75/60 C % 107/96,4 107/96,4 107/96,4 107,0/96,4 107,0/96,4 Heat loss rate at 70 C Watt Standard emission rate NOx. mg/kwh CO. mg/kwh Content of CO 2 in the exhaust gas max./min. power % 9,0/8,8 9,0/8,8 9,0/8,8 9,0/8,8 9,0/8,8 Dimensions See table of dimensions Connections Flow /ReturnInches R 1 R 1 R 1 R 1¼ R 1¼ Gas Inches Rp ¾ Rp ¾ Rp ¾ Rp ¾ Rp ¾ Flue gas Ø mm E80 E80 E80 E80 E80 Gas flow pressure min./ max. Natural gas E/LL mbar Liquid gas mbar Gas connection value at 0 C / 1013 mbar: Natural gas E - (Wo = 15,0 kwh/m 3 ) Hu = 9,97 kwh/m 3 m 3 /h 1,5 1,9 2,6 3,3 4,7 Natural gas LL- (Wo = 12,4 kwh/m 3 ) Hu = 8,57 kwh/m 3 m 3 /h 1,7 2,2 3,0 3,9 5,5 Propane gas (Hu = 25,9 kwh/m 3 ) m 3 /h 0,6 0,8 1,0 1,3 1,8 Operation voltage V/Hz 230/50 230/50 230/50 230/50 230/50 Control voltage V/Hz 24/50 24/50 24/50 24/50 24/50 Min./Max. electrical power consumption Watt 22/44 22/62 22/56 26/95 28/119 Standby Watt IP rating (integral protection) IP Acoustic capacity - Heating noise (EN part 1) (room air-dependent) db(a) Exhaust noise is radiated from the mouth db(a) (DIN part 47) (room air-dependent/room air-independent) Acoustic pressure level (depending on installation) 4 db(a) Condensate quantity (Natural gas ) at 40/30 C l/h 1,3 1,8 2,4 3,1 4,4 ph value of the condensate ph ca. 4,2 ca. 4,2 ca. 4,2 ca. 4,2 ca. 4,2 Value for flue calculation Temperature class T120 T120 T120 T120 T120 Flue gas mass flow kg/h ,0 78,0 Flue gas temperature at nominal output and operation 80/60 C C Flue gas temperature at nominal output and operation 40/30 C C Mass flow combustion air Nm 3 /h Feed pressure for combustion air/ flue gas system Pa Maximal Draft / negative pressure flue gas outlet Pa Data related to H u. The boiler series is tested for EE/H-settings. With a factory setting of the Wobbe coefficient of 15,0 kwh/m 3 operation at a Wobbe coefficient of 12,0 up to 15,7 kwh/m 3 is possible (a readjustment may be necessary). 2 Data related to H u. 3 Flow resistance boiler in mbar = volume flow (m 3 /h) 2 x z 4 See also notes at Engineering. Boiler flow resistence see diagram / 00 9

10 TECHNICAL INFORMATION 3.3 Dimensions (Dimensions in mm) Type UltraGas (15-27) (35,50) Fig. 03 Type A B C D E F G H UltraGas (15-27) UltraGas (35,50) Heating flow / safety flow R 1" R 1¼" 2 Low temperature-return R 1" R 1¼" 2a High temperature-return R 1" R 1¼" 3 Gas connection Rp ¾" Rp ¾" 4 Flue gas outlet DN80 DN80 5 Boiler control 6 Condensate drain (left or right) incl. siphon DN25 and 2 m PVC continuousflow tube inner Ø 19 x 4 mm 7 Draining 8 Electric cable entry point 9 Sound absorber hood 10 Heating armature group or loading group (Option) / 00

11 TECHNICAL INFORMATION 3.4 Space requirements (Dimensions in mm) Fig. 04 Boiler door incl. burner swings upward and to the left or outward. A = minimum 150 mm * Burner service position front - boiler cleaning from the right A = optimum 300 mm * - Burner service position left - boiler cleaning from the front - Boiler can be placed with the right side directly against the wall - however, a minimum gap of 160 mm is required. * without armature group, 500 mm with armature group The cleaning aperture must be easily accessible. Ensure access to the area beh / 00 11

12 TECHNICAL INFORMATION 3.5 Boiler-Flow resistance UltraGas (15-27) [mbar] UltraGas (35,50) [mbar] [m3/h] 0 0 0,5 1 1,5 2 2,5 3 3,5 4 4,5 5 m 3 /h = Volume flow mbar = Flow resistance [m 3 /h] 3.6 Brief description of the automatic firing device The automatic firing device BIC960 of the UltraGas only operates in conjunction with the heating controller TopTronic E/UG. For this reason, the automatic firing device only needs to take care of the last remaining functions to ensure the correct operation of a modulating gas boiler. The automatic firing device comprises the following functions: PWM fan control (230V AC) Modulating operation Common electrode for ignition and flame monitoring (ionisation) LPG valve and boiler room fan controllable Inputs for flow sensor 1 flow sensor 2 flue gas sensor water pressure sensor safety temperature limiter (not used) air pressure switch (not used) gas pressure switch Status outputs fault and flame signal Allows connection of additional (external) ignition device RS 485 connection to TopTronic E/UG RS 232 connection to PC Start attempts: maximum 4 Safety period: 5 sec Pre-ignition period: 5 sec Pre-purging period: 50 sec Follow-on time pump (230V AC): 5 min after heat demand Sicherungen: The BIC 960 is fitted with 3 fuses: 2AT Mains 4AT Pump 4AT Burner fan Blowing of one of the two 4AT fuses securing the pump or the burner fan, respectively, will prevent the affected device from starting. A failure of the mains fuse of the automatic firing device is displayed on the TopTronic E/UG by the failure message B:30 Bus interruption to automatic device. The failure appears when there is no communication between automatic firing device and TopTronic E/UG / 00

13 INSTALLATION 4. Installation 4.1 Safety information CAUTION Sharp edges pose a cutting hazard. Handle the cladding parts with care and avoid contact with sharp edges. 4.2 Boiler room requirements The boiler room must satisfy the applicable local building regulations. The boiler room ventilation must satisfy the applicable local regulations in this regard. Boilers may not be installed in rooms containing halogen compounds which can be carried into the combustion air (e.g. wash rooms, drying rooms, DIY rooms, hair dresser rooms). Halogen compounds can originate, for example, from cleaning and degreasing agents, solvents, glue, and bleaching lyes. Ensure that the required combustion air can flow unhindered at all times. This is important for the correct operation of all the boilers installed therein and to protect the users from an oxygen depleted atmosphere. An adequate fresh air supply meeting the local regulations must be provided Room sealed installation Configuration based on a concentric flue system: The suction air is supplied through a double-wall flue system. Ensure the boiler room is sufficiently ventilated. Configuration using a separating piece (optional): The following must be observed when laying out the intake pipe: If the intake opening is installed on the house facade near to a noise-sensitive area (e.g. bedroom windows, garden seating area, etc.) we recommend installing a noise damper in the direct fresh air suction line. The intake opening must be easily accessible. No chemicals or poisonous substances may be stored close to the intake opening The intake opening may not be installed beside fume extraction outlets or other venting outlets. Ensure that the intake aperture is free from any obstructions at all times (leaves, snow,...) A safety grid must be installed on the suction opening on the outside wall Room air dependent installation The applicable regulations do not normally provide any specific data on the size of air intakes. They only require the pressure in the boiler room not to be below 3 N/ m 2. This means that for a rated thermal output of up to 50 kw an air intake with a cross section of at least 300 cm 2 must be available. For rectangular apertures the aspect ratio should not exceed 1.5:1. If a grid is fitted on the air intake, a suitable allowance must be made to obtain an air intake cross section of 300 cm / 00 13

14 INSTALLATION 4.3 Flue gas connection and flue Due to the low flue gas temperatures, condensate forms within the flue. For this reason, Hoval gas heating boilers can not be connected to conventional house chimneys. The flue gas extraction system must comply with the following directives: DVGW (TRGI) ÖVGW SVGW/VKF Pursuant to the abovementioned regulations, a flue gas temperature limiter must be installed in the boiler. The flue gas system must meet the following requirements: Gastight Watertight Acid-proof Approved for flue gas temperatures of up to 120ºC (T 120) Approved for overpressure Unhindered back flow of condensate into the boiler can only be ensured if: The gradient of the horizontal connection elements is at least 50 mm/m. Only one heat generator may be connected to the same chimney. If two heat generators are to be connected to the same chimney, the relevant regulations must be complied with. Cross sections and maximum lengths are calculated on the basis of graphs or tables. The tables can be obtained from the chimney or flue system manufacturer. The calculation values can be obtained from the table under point 3.2. The flue gas conduit cross sections and lengths are calculated following the technical data for the boiler. The concentric supply air/exhaust system of the boiler can also be conducted horizontally backwards. The Hoval remodelling set allows a remodelling on site / 00

15 INSTALLATION 4.4 Condensate drainage The condensate drainage pipes on the boiler must be made of corrosion resistant material. The following materials are suitable for condensate drainage: Possibility 3 - see chapter 4.8 Siphon and condensate delivery pump Without neutralisation, condensate discharge into higher drain line. PVC, PE, PP, ABS The local regulations regarding condensate drainage must be observed. 4.5 Design variants Possibility 1 - see chapter 4.6 Execution with siphon Condensate discharge into lower drain line. Fig. 07 Possibility 4 - see chapter 4.9 Neutralisation box and condensate delivery pump With condensate neutralisation - condensate discharge into higher drain line. Fig. 05 Possibility 2 - see chapter 4.7 Execution with neutralisation box For condensate discharge in lower drain line, incl.condensate neutralisation. Fig. 08 Fig / 00 15

16 INSTALLATION 4.6 Fitting the condensate drain (standard design with siphon) 1. Remove front cover (1a, Fig. 09). Release lateral locking bolt (1, Fig. 09) (approx. ¼ turn to the left). Lift the front cover straight upwards and remove towards the front. 2. Remove base plate (2, Fig. 09). Lift base plate straight upwards and remove. 3. Screw siphon (3, Fig. 09) on the condensate tray (4, Fig. 09) and tighten securely (connection must be sealed)! 4. NOTICE Slide the siphon support (3a) under the siphon. 6. Fit drain (5, Fig. 09) on siphon (3, Fig. 09) and lead it outwards (optionally left or right side) through the aperture (5a, Fig. 09). 7. Fit connecting line (5, Fig. 09) to the drain line (2m hose enclosed with the boiler). 8. Reattach front cover (1a, Fig. 09) and base plate (2, Fig. 09).! CAUTION Before commissioning, the siphon must be filled with water in order to prevent flue gas leakage. If a neutralisation box is to be fitted, you will find the further installation steps on the next page. NOTICE The condensate drain must be made of corrosion-resistant material. 1 1a a 3a 5 Fig / 00

17 INSTALLATION 4.7 Fitting the neutralisation box (if fitted) 1. Remove the neutralisation box from its packaging. Remove the front and rear cover of the neutralisation box. 2. Empty the neutralisation granulate (Neutroxid) into the neutralisation box and distribute evenly. 5. Fit rear cover (9, Fig. 12) of the neutralisation box. 6. Fit jubilee clip (10, Fig. 12) approx. 20mm from the upper end of the hose and tighten slightly. The hose (10a, Fig. 12) of the connection eccentric (10b, Fig. 12) must be aligned towards the left a front Neutralisation granulate (Neutroxide) Fig Remove front cover (1a, Fig. 11). Release lateral locking bolt (1, Fig. 11) (approx. ¼ turn to the left). Lift the front cover straight upwards and remove it towards the front. 4. Remove base plate (2, Fig. 11). Lift the base plate straight upwards and remove it. 10b Fig Slide the neutralisation box (11, Fig. 13) into the boiler until the hose of the siphon (6, Fig. 10) is directly beneath the drain connection. 1 1a 11 Fig Fig / 00 17

18 INSTALLATION 8. The hose of the siphon (11, Fig. 14) can be easily pushed onto the drain connection of the condensate drip tray by lifting the neutralisation box (10a, Fig. 12). 4.8 Fitting the condensate delivery pump 13. Install the condensate delivery pump (14, Fig. 17) as shown in the drawing. Fig Slightly loosen the jubilee clip (10, Fig. 15) and push it upwards. Firmly tighten the jubilee clip (connection must be sealed) Fig. 15 Fig Fill the neutralisation box with water. 11. Fit the front cover (13, Fig. 16) of the neutralisation box. 12. Fit base plate (2, Fig. 16) and front cover (1a, Fig. 11) Fig. 16! CAUTION Before commissioning the neutralisation box must be filled with water in order to prevent flue gas leakage. The condensate drain must be made of corrosion-resistant material / 00

19 INSTALLATION 4.9 Fitting the neutralisation box and the condensate delivery pump 1. Fit condensate delivery pump. (14, Fig. 18). 4. Remove front cover (1a, Fig. 20). Release lateral locking bolt (1, Fig. 20) (approx. ¼ turn to the left). Lift the front cover straight upwards and remove towards the front. 5. Remove base plate (2, Fig. 20). Lift base plate straight upwards and remove a 2 Fig. 20 Fig Fit rear cover (9, Fig. 21) of the neutralisation box. 7. Fit jubilee clip (10, Fig. 21) approx. 20mm from the upper end of the hose and tighten slightly. The hose (10a, Fig. 21) of the connection eccentric (10b, Fig. 21) must be aligned towards the left. 2. Remove the neutralisation box from its packaging. Vorderen und hinteren Remove the front and rear cover of the neutralisation box. 3. Empty the neutralisation granulate (Neutroxide) into the neutralisation box and distribute evenly a Fig. 19 front Neutralisation granules (Neutroxide) 10b Fig / 00 19

20 INSTALLATION 8. Slide the neutralisation box (11, Fig. 22) into the boiler until the hose of the siphon (10a, Fig. 21) is directly beneath the drain connection. 11. Fill the neutralisation box with water. 12. Fit the front cover (13, Fig. 25) of the neutralisation. 13. Fit base plate (2, Fig. 25) and front cover (1a, Fig. 20). Fig The hose of the siphon (10a, Fig. 21) can be easily pushed onto the drain connection of the condensate drip tray by lifting the neutralisation box (11, Fig. 23).! 2 13 Fig. 25 CAUTION Before commissioning the neutralisation box must be filled with water in order to prevent flue gas leakage. The condensate drain must be made of corrosion-resistant material. Fig Slightly loosen the jubilee clip (10, Fig. 24) and push it upwards. Firmly tighten the jubilee clip (connection must be sealed). Fig / 00

21 INSTALLATION 4.10 Hydraulic connection The boiler comprises the following safety equipment, in accordance with EN 12828: Minimum pressure limiter DBmin Safety maximum pressure limiter DBmax Hydraulic pressure monitor DBmax + 50% Thermostat Temperature monitor TBmax + 20% Safety temperature limiter Example: UltraGas (15-50) with calorifier and direct heating circuit Hydraulic schematic BDEE005 To achieve an optimal efficiency, ensure that the return pipe is properly connected. 1 2 Fig. 27 Fig High temperature return (e.g. venting group or calorifier) 2. Low temperature return (e.g. underfloor heating) Customer-side requirements A pressure expansion tank adapted to the heating system, water volume and static height. TTE-WEZ B1 AF DKP Optional RBM TTE-GW NOTICE Make sure to close off unused connectors tightly. TopTronic E basic module heat generator (installed) Flow temperature monitor (optional) Outside sensor Pump for heating circuit without mixer TopTronic E room control module TopTronic Gateway Hydraulic interconnection When combining a calorifier with floor heating, a mixer needs to be installed. A minimum amount of circulating water is not required. Regarding suitable hydraulic connections, please observe the notes in the planning documentation of the relevant Hoval sales company! / 00 21

22 INSTALLATION 4.11 Electrical connection The electrical connection must be carried out by an approved electrician. The connection diagram is located within the boiler control box. The electrical circuit diagram is supplied separately. Refer to this for the conductor cross section required for the mains supply. The following applies to Austria and Germany: A connection diagram is provided with the boiler control unit. The power supply must be fitted with an omnipolar isolation switch with a contact gap of at least 3 mm. The following applies to Switzerland: The electrical connections must comply with the systemspecific electrical circuit diagram! Safety measures for EMC installation Bei Regelgeräten mit eigenem Netzanschluss, Netz- Fühler- bzw. Busleitungen getrennt verlegen. CAUTION Do not reach into the marked area (Fig. 28) when folding out the terminal box. Danger of cuts and pinching in the area of the trim strip (7). Wear gloves. Grip the terminal box by the left and right sides, not by the underside! Cable trunking with dividing partitions should be used. The electrical connection must be connected in accordance with the applicable standards of nationally or internationally recognised professional associations. Procedure to remove the front covering panel 1. Remove front cover (1, Fig. 28), after first releasing the lateral locking bolt (1a, Fig. 28) (turn approx. ¼ turn to the left and pull out as far as the stop). Lift the front cover (1) straight upwards and remove towards the front. 2. Remove lower front cover (2, Fig. 28), after first releasing the lateral locking bolt (2a) (turn approx. ¼ turn to the left and pull out as far as the stop). Slightly raise the lower front cover (2 and 4, Fig. 28) and remove towards the front. 3. Remove the locking screw (3a, Fig. 28) on the right. 4. Lift the switch control box (3, Fig. 28) and fold it out. 5. Cable entry refer to the Technical Datasheet (6, Fig. 28). The electrical connection is to be made in accordance with the diagram supplied. 1 1a 3a The mains connection for the heating system (boiler-control panel-control unit) must be configured in form of an independent electric circuit. No other electrical loads (light, power outlets,...) may be connected to that electric circuit. The external sensor may not be installed close to transmitters or receivers (garage door openers, amateur radio aerials, radio alarm systems,...). Recommended conductor cross sections: Conductor type Cross section Length Power supply of the heat generator (230 V) Cables carrying mains supply voltages from actuators Extra-low voltage cables (sensors) Data bus cables (screened) min 1.5 mm 2 with 13 A fuse min 1.0 mm 2 min 0.5 mm 2 2x2x0.6 mm 2 unlimited m unlimited m max. 50m max. 100m Fig / 00

23 COMMISSIONING 5. Commissioning After filling the system with water, bleed any air and check for water leaks. Before putting the boiler into operation, the siphon and neutralisation tank needs to be filled with water. When starting up the system for the first time, the correct operation of all the safety and control devices must be verified. The operation and maintenance of the system must be explained to the user in detail. he combustion air needs to be filtered in very dusty environments. The gas flow pressure must be checked and the CO 2 value set correctly. 5.1 Safety information! CAUTION Sharp edges pose a cutting hazard. Handle the cladding parts with care and avoid contact with sharp edges! Danger of injury for unqualified personnel. Maintenance and cleaning work may only be performed by trained personnel or by the Hoval Customer Service. NOTICE Danger of damaging the system by filling it with incorrect liquids. Water filled into the system must have drinking quality. 5.2 Filling with water Filling of the heating system may only be carried out by qualified personnel. Die ÖNORM H5195, The European Standard EN and the Directive VDI 2035 must be observed (see point 5.3). 1. Open the isolating valves in the flow and return lines. 2. Connect the water hose to the filling tap. 3. Fill the heating system slowly. Monitor the water level on the manometer. Use only chemical additives with suppliers confirmation of their safe usage. Anti-freeze additive may be filled up to a maximum of 40% and to a minimum according to the manufacturer s information. The anti-freeze or anti-corrosion agent concentration must be checked at least once per year. The identical product must be used when replenishing the anti-freeze or anti-corrosion agents. When transferring to operation without antifreeze or anti-corrosion agents, the system is to be thoroughly flushed through several times before refilling with water / 00 23

24 COMMISSIONING 5.3 Water quality Heating Water The European Standard EN and the directive VDI 2035 must be observed. In particular, attention must be paid to the following stipulations: Hoval boilers and calorifi ers are designed for heating plants without signifi cant oxygen intake (plant type I according to EN 14868). Plants with - continuous oxygen intake (e.g. underfloor heating systems without diffusion proof plastic piping) or - intermittent oxygen intake (e.g. where frequent refilling is necessary) must be equipped with separate circuits. Treated fi lling and replacement water must be tested at least 1x yearly. According to the inhibitor manufacturer s instructions, more frequent testing may be necessary. A refi lling is not necessary if the quality of the heating water in existing installations (e.g. exchange of boiler) conforms to VDI The Directive VDI 2035 applies equally to the replacement water. New and if applicable existing installations need to be adequately cleaned and fl ushed befor being fi lled. The boiler may only be fi lled after the heating system has been fl ushed! Parts of the boiler / calorifi er which have contact with water are made of ferrous materials and stainless steel. On account of the danger of stress cracking corrosion in the stainless steel section of the boiler the chloride, nitrate and sulphate content of the heating water must not exceed 50 mg/l. The ph value of the heating water should lie between 8.3 and 9.5 after 6-12 weeks of heating operation. Filling and replacement water For a plant using Hoval boilers untreated drinking water is generally best suited as heating medium, i.e. as fi lling and replacement water. However, as not all drinking water is suitable for use as as fi lling and replacement water the water quality must fulfi l the standard set in VDI Should the mains water available not be suited for use then it must be desalinated and/ or be treated with inhibitors. The stipulations of EN must be observed. In order to maintain a high level of boiler effi ciency and to avoid overheating of the heating surfaces the values given in the table should not be exceeded (dependent on boiler performance ratings - for multi-boiler plants rating of smallest boiler applies - and on the water content of the plant). The total amount of fi lling and replacement water which is used throughout the total service life of the boiler must not exceed three times the water capacity of the plant. Maximum filling capacity based on VDI 2035 Total hardness of the filling water up to... [mol/m 3 ] 1 <0,1 0,5 1 1,5 2 2,5 3 >3,0 f H < >30 d H <0,56 2,8 5,6 8,4 11,2 14,0 16,8 >16,8 e H <0,71 3,6 7,1 10,7 14,2 17,8 21,3 >21,3 ~mg/l <10 50,0 100,0 150,0 200,0 250,0 300,0 >300 Conductance 2 <20 100,0 200,0 300,0 400,0 500,0 600,0 >600 Boiler size of the individual boiler maximum filling quantity without desalination to 50 kw NO REQUIREMENT 20 l/kw 1 Sum of alkaline earths 2 If the conductance in µs/cm exceeds the tabular value an analysis of the water is necessary / 00

25 COMMISSIONING 5.4 Bleeding the air from the gas line Observe the relevant regulations when bleeding the gas line Open the gas shut-off valve. Bleed the air up to the gas armature. 5.5 Switching on the system Switch on blocking switch to release the burner. WARNING The heat generator is live when it has been connected to the mains. 5.6 Gas inlet pressure The gas flow may only be adjusted and the heating system therefore started up, if the minimum flow pressure values are achieved (see point 5.7 Adjusting the gas flow). The minimum flow pressure in the connector pipe must reach the following values: Natural Gas 18 to 50 mbar Liquid gas 37 to 50 mbar / 00 25

26 COMMISSIONING 5.7 Setting the gas flow rate CO 2 (O 2 ) and measurement of NOx/CO content in the flue gas (flue gas measurement) Torx T40, screwdriver, size 5 and/or allen key 4 mm The Honeywell multiple actuator allows measuring the inlet pressure on meas uring nipple A. A B C D Measuring nipple gas inlet pressure Measuring nipple gas outlet pressure Gas choke Offset screw D 1. Press the emission monitoring key. After 20 min. the controller switches over to normal operation automatically. 2. Position the emission monitor in the flue gas duct. 3. Set the boiler to maximum output (100%). 4. Set the CO 2 (O 2 ) value by turning the chokescrew C. The content in the flue gas must be between CO 2 = (O 2 = 5,9-5,5) vol% (dry). 5. Set the boiler to minimum output (1%) 6. Set the CO 2 (O 2 ) value by turning the choke screw D. The content in the flue gas must be between CO 2 = (O 2 = 5,9-5,5) vol% (dry). 7. Measurement of NOx and CO content. The measured values must meet the limiting values prescribed by the regulations. Values exceeding these reference values are an indication of faulty burner setting, gas burner or heat exchanger contamination or gas burner defect. NOTICE If the limiting values prescribed by the regulations are exceeded, the boiler must be put out of operation and the corresponding measures for repair work must be initiated. 8. Press the emission monitoring key. Fig. 29 C B A Flow setting operation: To set the flow on the venturi, both flue gas values need to be controlled. e.g.: Set upper value - control lower value - value incorrect - set lower value - control upper value / 00

27 COMMISSIONING 5.8 Changing over to a different gas type This changeover may only be carried out by an authorised specialist or by the Hoval Customer Service. 5. Set the CO 2 (O 2 ) content to CO 2 = (O 2 = 5,9-5,5) vol% (dry). (flow setting operation as described in section 6.7) 6. Install the boiler hood Changeover from natural gas H to natural gas L An emission check is required when changing to a natural gas of lower calorific value; a correction of the CO 2 (O 2 ) value may be necessary (see point 6.7 Setting the gas flow rate). Changeover from natural gas to liquid gas The applicable local provisions for operating a boiler with liquid gas are to be complied with. VKF, DVGW, ÖVGW Changeover only possible by means of a conversion kit. NOTICE Ensure that the fuel type in the measuring device has been set correctly. 5.9 Handover to the user The manufacturer of the unit is responsible for providing operating instructions for the complete system. The following must be carried out during handover to the user: Provide instructions in the operation and maintenance of the system Handover of all the instruction manuals and documents Explain to the user that these instructions must be kept with the system at all times Written confirmation of receipt of instruction The handover report is on the last page of the document. The conversion kit contains: gas pressure switch yellow sticker Removing the gas pressure switch: 1. Close the gas shut-off valve. 2. Set the blocking switch to «0» and disconnect the heat generator from the mains (main switch, fuse). 3. Take off the boiler hood 4. Remove the gas pressure switch Install the liquid gas pressure switch: NOTICE Ensure that the liquid gas line is free of any air. Any air in the liquid gas line can have a negative influence on the flue gas values. 1. Install the liquid gas pressure switch Set the AMP flat pin to position 1 and 3 2. Affix the yellow sticker on the boiler name plate 3. Open the gas valve 4. Set the main system switch to 1 NOTICE Adjust fan speed of rotation according to the list of parameters Liquid gas adaptations / 00 27

28 COMMISSIONING 5.10 Record - Activation of screed function Description of function The control module of the TopTronic E contains a functional sequence used for drying out screed fl oors. To start the screed drying, it is necessary for the individual functions to be set accordingly. Flow temperature Heating-up phase ( ) Inertia phase (04-064) Cool down phase ( ) 40 C 35 C Stabilisation temperature (04-063) 30 C 5 K -5 K 25 C Current heat generator temperature = start temperature 1 d 1 d 20 C 0 Start End Days Function Parameters Value Description Heating-up phase K/d Kelvin per day (rising) Stabilisation temperature C Set maximum temperature Inertia phase Number of days in stabilisation temperature Cooling off phase K/d Kelvin per day (falling) Activate screed function (ON) Start and stop screed drying NOTICE The graphic/table shows the factory settings. The time profi le and the maximum fl ow temperature must be discussed with the screed layer, otherwise there could be damage to the screen and in particular, cracks. REACTION screed function Start/stop: Switch parameter ON (1) or OFF (0) Power failure in heating-up phase: program restart Failure in the steady-state phase: Retain maximum temperature and add the failure time to the steady-state phase Power failure in the cooling off phase: Measurement of actual fl ow value and continue cooling until start value reached Program end: Previous basic program active again Settings in the TopTronic E control module Can only be set in the corresponding user level. Settings under Start screen > Main menu > Service > H-GEN > Heating circuit > Heating circuit 1, 2, 3* > Screen > to * If there are several heating circuits, a separate screed function must be assigned to each heating circuit / 00

29 COMMISSIONING Function display 1 2 No. Icon Function 1 Screed drying active Various settings can be made as well. Prioritisation of the screed function means the settings are only active at the end of the function. 2 Information remaining run time Request of the active function phase, the ACT temperature as well as the remaining run time. Logging Please cut out the log and attach it to the controller during active screed function. NOTICE The time profi le and the maximum fl ow temperature must be discussed with the screed layer, otherwise there could be damage to the screen and in particular, cracks. Screed function activated by: Profile and flow temperature discussed with: Screed function activated on: Screed function ends on:... Date and signature / 00 29

30 MAINTENANCE 6. Maintenance NOTICE Missing or faulty cleaning and maintenance may cause damage to the installation. The heating installation must be surveyed and cleaned once a year. If required, installation maintenance must be carried out. Defects must be remedied immediately in order to prevent damages to the installation! 6.1 Safety information CAUTION Sharp edges pose a cutting hazard. Handle the cladding parts with care and avoid contact with sharp edges. 6.3 Water refilling The European Standard EN and the Directive VDI 2035 must be observed (see point 5.3). The systems warns when the water pressure falls below 1 bar and the boiler output is reduced to 50%. If the water pressure falls below 0.5 bar, the boiler is set automatically to a fault state. The system must be refilled with water when the pressure falls below the minimum system pressure: 5. Connect the filling hose to the water supply 6. Remove the air from the filling hose 7. Connect the filling hose to the filling and draining cock 8. Top up with water (see point 5.2).! CAUTION Danger of injury for unqualified personnel. Maintenance and cleaning work may only be performed by trained personnel or by the Hoval Customer Service. NOTICE After repair work respectively exchanging boiler parts, a flue gas measurement according to point 6.7 must be carried out imperatively. WARNING The heat generator must be de-energised for maintenance. Set the blocking switch to «0» and disconnect the heat generator from the mains (main switch, fuse). 6.4 Renewing fuse WARNING Electrical installations may only be carried out by a qualified electrician. 1. Set the blocking switch to «0» and disconnect the heat generator from the mains (main switch, fuse). 2. Remove the front casing according to the procedure in chapter Remove the cover from TopTronic E - WEZ (press to the side and remove). 4. Renew fuse (T 10A 250V). WARNING All electric power supply circuits must be switched off before accessing the terminals. Perform reset. See operating manual. 6.2 Bleeding 1. Open all radiator valves. 2. Heat up the system for at least half a day with a high flow temperature. 3. Turn off the boiler and wait 5 minutes. 4. Bleed all the air form the system. 5. Mount protecting cover, close casing. 6. Restore the electrical power supply. Fig / 00

31 MAINTENANCE 6.5 Information for combustion controller/chimney sweep regarding emission monitor key This chapter is exclusively intended to describe the function of emissions and manual operation settings for the fi ring monitoring technician / chimney sweep. All operating elements are described in the operating instructions.! CAUTION Danger of scalding with hot water, since the hot water temperature can exceed the target setpoint temperature. NOTICE In order to protect underfl oor heating systems against impermissible superheating during emissions measurement / manual operation, it is necessary to implement appropriate safety measures (e.g. pump switch-off with maximum thermostat). The output and duration of the emission measurement can be set in the "Emission" main menu, and reactivated if required. Emission metering Setting at: Home screen > Main menu (page 1) > Emission. For detailed information see operating instructions, "Emission" chapter. Power limitation with 2-stage burner: 0 to 50% = 1st stage 51 to 100% = 2nd stage REACTION to emission metering Go back after expiry of the time unit/time specifi cation of return to the main menu Setpoint temperature = Maximum temperature limit Forced energy is used in an attempt to keep the corresponding heat generator temperature to 60 C Regulate heating circuits and the calorifi ers to their maximum temperature (in the direct heating circuit only if the hot water basic program is set to parallel operation) Manual mode Settings under: Home screen > Main menu (page 2) > Manual operation. For detailed information see operating instructions, "Emission" chapter. REACTION for manual operation Setting the required setpoint temperature using the selected heating or hot water circuit All heating pumps ON Note the maximum permissible temperature of surface heating! / 00 31

32 MAINTENANCE 6.6 Cleaning The boiler may only be cleaned by an authorised technician or by the Hoval Customer Service. Reassembly: 1. Replace the gasket on the gas connection 2. Reassemble the burner in reverse order 3. Check for leaks 4. Carry out a flue gas measuring according to point 5.7 The Hoval gas heating boiler should be cleaned and maintained once every year. If the Hoval gas heating boiler was in operation during the building phase, it will be necessary to carry out a check for cleanliness. If the boiler is dirty, clean it Cleaning the burner cylinder The burner cylinder must be cleaned if visible contamination exists (such as deposits, e.g. builder s dust) Fig. 31 Adjustable spanner, screw driver, open end spanner SW 8, vacuum cleaner, compressed air, water. Preparation: 1. Set the blocking switch to «0» and disconnect the heat generator from the mains (main switch, fuse). 2. Close the main gas valve 3. Remove the sound insulation covers 4. Disconnect all the burner connector plugs 5. Pull the corrugated hose (1, Fig. 31) off the venturi tube on the burner (if present). 6. Disconnect the earthing cable (2, Fig. 32) from the burner cylinder 7. Disconnect the gas connection from the gas armatures. 8. Unscrew the fan with the gas mixing unit in place (3, Fig. 32) Removal and cleaning: CAUTION Danger of burns, let the boiler cool down or wear protective clothing Fig. 32 Fig Safety gloves must be worn when removing the burner cylinder 2. Lift the burner cylinder out (4, Fig. 33). 3. Clean the premix burner with compressed air inside and out, or rinse thoroughly with water 4. Remove dust and dirt particles with a vacuum cleaner (Fig. 34). Fig / 00

33 MAINTENANCE Cleaning the exterior of the combustion chamber and burner cylinder! WARNING Chemical burn hazard through cleaning agents. Safety gloves and eye protection must be worn when using cleaning agents. Observe the information on the original packaging. NOTICE The system can be damaged when using incorrect cleaning agents. Use only cleaning agents approved for gas boilers with aluminium components. Spray on the cleaning agent undiluted Open end spanner SW 17, adjustable spanner, screw driver, spray gun Preparation: 1. Set the main switch on the boiler control unit to 0. vom Netz trennen (Hauptschalter, Sicherung). 2. Close the main gas valve 3. Remove the sound insulation cover 4. Disconnect all the burner connector plugs 5. Pull the corrugated hose off the venturi tube on the burner (if present) Reinigen: 1. Spray the combustion chamber and alufer tubes (10, Fig. 36). The best results are obtained with a spray gun with a suitable wide jet nozzle (fan or conical jet). We recommend, e.g.: Desoxin 2. Leave the applied cleaning agent to react as instructed by the manufacturer 3. Then remove the contamination on the combustion chamber and alufer tubes by spraying them with clean water Use a powerful jet 4. Repeat the procedure in case of stubborn dirt 5. Flush clean the bottom tube plate Use an angled spray lance 6. Clean and dry the boiler tray 7. Clean the siphon see point 6.8: screw it off clean it screw it back on fill it with water 8. Clean the fabric material in the burner cylinder with compressed air 9. Reconnect the gas and electrical connections 10. Place the boiler into operation 11. Carry out a flue gas measuring according to point 5.7. Correct the settings, if necessary. Complete a measurement record. 10 Opening the combustion chamber: 1. Loosen the cap nut SW17 2. Lift and turn the burner with the boiler door sideways (8, Fig. 35) 3. Remove the neutralisation box and siphon or maintenance of the neutralisation unit see point 6.9) Fig Fig / 00 33

34 MAINTENANCE Leakage testing After cleaning or at least every five years, the seal between the combustion chamber and the condensate drip tray must be checked for leakage. This can be done by filling the boiler with water. Ignition electrode Ignition/ionisation electrode 80 1 Fig Water fill level Fig mm 5 mm Cleaning/adjusting the ignition and ionisation device The distance between the ignition electrode and the burner cylinder must be approx. 4 mm. Fine sanding paper, long-nosed pliers, blowtorch, compressed air. Fig. 39 Preparation: 1. Set the blocking switch to «0» and disconnect the heat generator from the mains (main switch, fuse). 2. Open the combustion chamber as described under point mm Cleaning: 1. Sand the ignition and ionisation device with fine sanding paper. 2. Clear the sanding dust. Adjustment: 1. Heat the ignition electrode at the kink with the blowtorch until it glows red (Fig. 38). 2. Bend the ignition electrode with the long-nosed pliers (Fig. 39). Distance to the burner cylinder 10 mm. Assembly: 1. Renew seal on gas connection. 2. Assemble burner in the reverse order. 3. Check for gas leaks. Fig Setting the gas flow rate CO 2 (O 2 ) and measurement of NOx/CO content in the flue gas (according to point 5.7.) Maintenance should be carried out at least every second year or after consumption of the neutralisation granulate (check ph value with litmus paper, if necessary) / 00