Technical information Installation instructions

Transcription

1 Technical information Installation instructions TopGas classic (35,45,60,80,100,120) Wall-mounted gas condensing boilers for natural gas and liquid gas Nominal output ranges at 40/30 C and natural gas 42-TopGas classic (35) 7,4-35,4 kw 42-TopGas classic (45) 8,5-45,2 kw 42-TopGas classic (60) 12,2-62,0 kw 42-TopGas classic (80) 14,7-81,0 kw 42-TopGas classic (100) 21,3-100,0 kw 42-TopGas classic (120) 22,7-120,0 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. TopGas classic (35,45,60,80,100,120) wall-mounted gas condensing boilers in accordance 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. They are designed for continuously controlled reduced operation in heating systems. Subject to modifi cations / 01-01/16 EN

2 TABLE OF CONTENTS 1. Important notes On delivery Guarantee Instructions Regulations, official approvals Transport and storage Safety instructions Warning levels Warning symbols Informationen Technical information Technical data TopGas classic (35,45,60,80) Technical data TopGas classic (100,120) Dimensions TopGas classic (35-80) Dimensions TopGas classic (100,120) Boiler flow resistance Brief description of the functions of automatic firing device BIC Heating system control Parameters to be set Installation Description of the Hoval TopGas classic Diaphragm expansion tank Boiler casing Gas valve Control unit for gas burner and heating regulator Heating circulation pump Hot water supply Scope of delivery TopGas classic component designation Boiler installation room Installing the boiler Hydraulic switching Engineering guidelines for the hydraulic switching Water pressure guard for water shortage protection Gravity brake Minimum water circulation volume To be provided on site Hydraulic integration Connection of the pipes Flue gas connection, chimney and condensate discharge Flue gas conduits approved under building law Air/Flue gas pipe Project planning instructions, flue gas systems Design examples for room air dependent operation Design examples for room air independent operation Condensate discharge and neutralisation Gas connection Electrical connection Regulations for electrical connections Electrical connection (mains) 230 V, 50 Hz Boiler controller/electrical connection diagram Connecting the heating regulator TopTronic RS-OT TopTronic E / 01

3 TABLE OF CONTENTS 5. Commissioning Setting the controller Water quality Heating water Filling and replacement water Filling the system Gas adjustment Venting the gas pipe Commissioning Gas inlet pressure Gas valve TopGas classic (35-80) Setting the gas flow rate CO 2 (O 2 ) and measure ment of NOx/CO content in the flue gas (flue gas measurement) Changing to a different type of gas TopGas classic (100,120) Setting the amount of gas Changing to a different type of gas Handover to the operator Instructions for the operator Checking the water level Maintenance Decommissioning Maintenance Checking the water connections for leakage Refilling Maintenance comprises: Cleaning the heat exchanger Function check Emission measurement Faults Parameter list - automatic firing device BIC / 01 3

4 IMPORTANT NOTES 1. Important notes The following points must be observed when performing work on the TopGas classic:! CAUTION If you smell flue gas or gas avoid naked flames and the occurrence of sparks, do not smoke, take the system out of operation, close the gas shut-off valve, Open windows and doors The system may only be placed in operation if all the relevant standards and safety regulations have been complied with. However, for trial operation, the following are the minimum conditions requiring fulfilment: Safety valve installed (closed system) Control in operation (connected to the mains current supply system) System filled with water Expansion tank connected Boiler connected to a flue gas conduit installed in com pliance with the relevant regulations. Burner preset. When performing maintenance and repairs Allow the gas condensing boiler to cool down. Switch off the gas condensing boiler and disconnect it from the power supply. Close the gas shut-off valve. Close all cut-off valves on the unit (cold water, heating flow and return). If work on the components of the gas condensing boiler which carry water is not performed correctly, the heating medium may escape and lead to scalding. After performing repair and maintenance work, reattach all cover plates which were removed. Do not exceed the maximum operating pressure and operating temperature (see type label) for the gas condensing boiler. Open all cut-off valves on the unit (cold water, heating flow and return). Open gas shut-off valve. 1.1 On delivery Carry out a visual inspection immediately on receiving the boiler. If any damage is found, take the necessary steps as defined in the delivery contract. The respective risk carrier bears the cost of repairs. 1.2 Guarantee The warranty does not cover defects attributable to: Failure to comply with these instructions Failure to comply with the operating instructions Incorrect installation Impermissible modifications Incorrect handling Contaminated operating materials (gas, water, combustion air) Unsuitable chemical additives to the heating water Damage caused by the application of force Corrosion by halogen compounds (e.g. paints, adhesives, solvents) Corrosion caused by not observing the required water quality 1.3 Instructions All instructions relevant to your system can be found in the Hoval system manual! In exceptional cases, the instructions can be found with the components! Further sources of information: Hoval catalogue Standards, regulations WARNING The heat generator can only be de-energised by disconnection from the mains (e.g. allpole switch). WARNING All electric power supply circuits must be switched off before accessing the terminals / 01

5 IMPORTANT NOTES 1.4 Regulations, official approvals For installation and operation of the system, the following regulations and the generally accepted engineering principles must be observed: Germany DIN EN Heating systems in buildings - Method for calculation of the design heat load DIN EN Flue gas systems - Calculation methods in heat and flow engineering DIN EN Heating systems in buildings - Design of hot water systems. VDI 2035 Prevention of damage by corrosion and the formation of scale in hot water heating systems. Firing ordinance of the federal states DVGW-TRGI Technical specifications of the gas supply companies VDE 0100 for electrical installation and the TAB (technical connection requirements of the relevant energy supply company) ATV technical bulletin M251 Accident prevention regulations VBG 1 General regulations VBG 4 Electrical installations and equipment Regulations governing the discharge and treatment of condensate are subject to the specifications of the local water authorities and may deviate from waste water guideline ATVM251. Please contact your water authority for details of the applicable local regulations. 1.5 Transport and storage On receipt of the unit, please remove the packaging and check that the delivery is complete, consistent with your order and has not been damaged in transit. The unit should always be transported and stored in the original packaging. Interim storage of Hoval condensing boilers may only take place in the original packaging and in locations protected against the elements. The ambient conditions during storage must comply with the following limit values: Air temperature: -10 C C Air humidity: % relative humidity condensation-free Austria OENORM Heating systems in buildings Procedure for calculation of the standard heating load OENORM Waste gas systems Procedures for heat and flow calculations OENORM Heating systems in buildings Design of hot water systems OENORM H5152 Condensing appliances economisers for furnace installations OENORM H Prevention of damage by corrosion M 7443, (Part 2,3,7) Gas appliances with atmospheric burners M 7446, Condensing appliances for gaseous fuels M 7457, Gas appliances with mechanically assisted pre- mix surface burners M 7444, Special gas-fired boilers with atmospheric burners M 7459, Gas appliances with combined control or governing of gas and air ÖVGW TR-Gas (Austrian Gas and Water Confederation - Technical Guidelines) Technical specifications of the gas supply companies and further standards and regulations issued by CEN, CEN ELEC, DIN, VDE, DVGW, TRD and by the legislator. Also to be complied with are the regulations of the local building authorities, insurance companies and chimney sweeping operations. When using gas as a fuel, the regulations of the responsible gas supply company are also to be complied with and any necessary official approval obtained / 01 5

6 SAFETY 2. Safety instructions 2.1 Warning levels!!! 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. 2.2 Warning symbols! General warning of a danger zone Warning of dangerous electrical voltage 2.3 Informationen Information: Provides important information / 01

7 TECHNICAL INFORMATION 3. Technical information 3.1 Technical data TopGas classic (35,45,60,80) Type (35) (45) (60) (80) Nominal output 80/60 C with natural gas 1 kw 6,7-32,5 7,66-41,5 11,06-56,6 13,3-73,7 Nominal output 40/30 C with natural gas 1 kw 7,42-35,47 8,5-45,25 12,25-62,0 14,7-81,0 Nominal output 80/60 C with propane 3 kw 9,5-32,5 10,4-41,5 14,06-56,6 18,4-73,7 Nominal output 40/30 C with propane 3 kw 10,5-36,3 11,45-45,8 15,5-61,1 20,3-79,9 Nominal load with natural gas 1 kw 6,9-33,0 7,9-42,1 11,4-57,7 13,7-75,4 Nominal load with propane 3 kw 9,8-33,0 10,7-42,1 14,5-57,7 19,0-74,4 Working pressure heating maximum/minimum bar 4 / 1 4 / 1 4 / 1 4 / 1 Working temperature maximum C Boiler water content l 4,0 4,0 5,4 5,4 Minimum water flow l/h Boiler weight (without water content, incl. casing) kg Boiler efficiency at full load at 80/60 C (related to net H i /gross calorific value H s ) Boiler efficiency at partial load 30 % (according to EN 303) (related to net H i /gross calorific value H s ) % 99,8 / 89,9 99,0 / 89,2 99,4 / 89,6 98,8 / 89,0 % 110,5 / 99,6 110,5 / 99,6 110,4 / 99,5 110,8 / 99,9 Standard efficiency (according to DIN 4702 part 8) 40/30 C % 109,1 / 98,3 109,0 / 98,2 109,1 / 98,3 109,0 / 98,2 (related to net H i /gross calorific value H s ) 75/60 C % 106,1 / 95,6 106,0 / 95,5 106,1 / 95,6 106,0 / 95,5 Stand-by loss at 70 C Watt Standard emission rate Nitrogen oxides NOx mg/kwh Content of CO 2 in the exhaust gas maximum/minimum output % 8,8 / 8,8 8,8 / 8,8 8,8 / 8,8 8,8 / 8,8 Dimensions See table of dimensions Connections Flow/return Inches Rp 1 ¼ Rp 1 ¼ Rp 1 ¼ Rp 1¼ Gas Inches R ¾ R ¾ R ¾ R ¾ Flue gas/combustion air Ø mm C100 / 150 C100 / 150 C100 / 150 C100 / 150 Gas flow pressure minimum/maximum Natural gas E/LL mbar 17, , , ,4-50 Propane mbar Gas connection value at 0 C/1013 mbar: Natural gas E (Wo = 15,0 kwh/m 3 ) H i = 9,97 kwh/m 3 m 3 /h 0,69-3,3 0,79-4,2 1,14-5,8 1,37-7,5 Natural gas LL (Wo = 12,4 kwh/m 3 ) H i = 8,57 kwh/m 3 m 3 /h 0,80-3,35 0,92-4,91 1,33-6,73 1,60-8,80 Propane 3 (H i = 25,9 kwh/m 3 ) m 3 /h 0,38-1,31 0,41-1,65 0,56-2,20 0,73-2,88 Operation voltage V/Hz 230 / / / / 50 Control voltage V/Hz 24 / / / / 50 Minimum/maximum electrical power consumption Watt 24 / / / / 138 Stand-by Watt Protection rating IP Sound power level Heating noise (EN part 1) (room air dependent) db(a) Sound pressure level (depending on installation conditions) 2 db(a) Condensate quantity (natural gas) at 40/30 C l/h 3,1 4,0 5,4 7,1 ph value of the condensate Flue gas system: requirements, values, temperature class T120 T120 T120 T 120 Type of connection B23, C13(x), C33(x), C53(x), C63(x) Flue gas mass flow kg/h 54,8 70,6 95,1 124,5 Flue gas temperature at nominal output and operation 80/60 C C 61,5 65,3 65,6 74,4 Flue gas temperature at nominal output and operation 40/30 C C 40,3 45,5 44,8 52 Volume flow rate combustion air Nm 3 /h 41,3 53,1 71,6 92,8 Feed pressure total at the combustion air/flue gas pipe Pa Maximum draught/depression at flue gas outlet Pa Data related to H i. 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 without new settings. 2 See also notes at Engineering. 3 Data related to H i. TopGas classic can also be operated with propane / 01 7

8 TECHNICAL INFORMATION 3.2 Technical data TopGas classic (100,120) Type (100) (120) Nominal output 80/60 C with natural gas 1 kw 19,1-90,4 20,4-107,6 Nominal output 40/30 C with natural gas 1 kw 21,3-100,0 22,7-120 Nominal output 80/60 C with propane 3 kw 22,9-90,4 23,7-107,6 Nominal output 40/30 C with propane 3 kw 25,3-100,0 26,1-120 Nominal load with natural gas 1 kw 19, ,1-111,5 Nominal load with propane 3 kw 23, ,6-111,5 Working pressure heating maximum/minimum bar 4 / 1 4 / 1 Working temperature maximum C Boiler water content l 7,0 7,0 Minimum water flow l/h Boiler weight (without water content, incl. casing) kg Boiler efficiency at full load at 80/60 C (related to net H i / gross calorific value H s ) Boiler efficiency at partial load 30 % (according to EN 303) (related to net H i / gross calorific value H s ) % 98,3 / 88,6 97,7 / 88,0 % 110,9 / 99,9 109,0 / 98,2 Standard efficiency (according to DIN 4702 part 8) 40/30 C % 109,4 / 98,6 109,4 / 98,6 (related to net H i / gross calorific value H s ) 75/60 C % 106,1 / 95,6 106,1 / 95,6 Stand-by loss at 70 C Watt Standard emission rate Nitrogen oxides NOx mg/kwh Content of CO 2 in the exhaust gas maximum/minimum output % 8,8 / 8,8 9,2 / 8,8 Dimensions See table of dimensions Connections Flow/return Inches Rp 1½ Rp 1½ Gas Inches R ¾ R ¾ Flue gas/combustion air Ø mm C100 / 150 C100 / 150 Gas flow pressure minimum/maximum Natural gas E/LL mbar 17, ,4-50 Propane mbar Gas connection value at 0 C/1013 mbar: Natural gas E (Wo = 15,0 kwh/m 3 ) H i = 9,97 kwh/m 3 m 3 /h 1,98-9,32 2,04-10,7 Natural gas LL (Wo = 12,4 kwh/m 3 ) H i = 8,57 kwh/m 3 m 3 /h 2,31-10,85 2,47-13,02 Propane 3 (H i = 25,9 kwh/m 3 ) m 3 /h 0,91-3,59 0,95-4,17 Operation voltage V/Hz 230 / / 50 Control voltage V/Hz 24 / / 50 Minimum/maximum electrical power consumption Watt 26 / / 202 Stand-by Watt 7 7 Protection rating IP Sound power level Heating noise (EN part 1) (room air dependent) db(a) Sound pressure level (depending on installation conditions) 2 db(a) Condensate quantity (natural gas) at 40/30 C l/h 8,9 10,3 ph value of the condensate Flue gas system: requirements, values, temperature class T120 T 120 Type of connection Flue gas mass flow kg/h Flue gas temperature at nominal output and operation 80/60 C C 69 74,9 Flue gas temperature at nominal output and operation 40/30 C C 48 52,7 Volume flow rate combustion air Nm 3 /h 115,2 132,3 Feed pressure total at the combustion air/flue gas pipe Pa Maximum draught/depression at flue gas outlet Pa Data related to H i. 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 without new settings. 2 See also notes at Engineering. 3 Data related to H i. TopGas classic can also be operated with propane / 01

9 TECHNICAL INFORMATION 3.3 Dimensions TopGas classic (35-80) Measurements (mm) Lateral clearance 50 mm Distance from ceiling depending on exhaust flue system used Front 500 mm 1 Gas connection R ¾ 2 Flow R 1¼ 3 Return R 1¼ 4 Condensate drain DN 40 5 LAS flue gas/combustion air connection C100/150 6 Cover control panel 7 Safety valve 8 Ball valve / 01 9

10 TECHNICAL INFORMATION 3.4 Dimensions TopGas classic (100,120) Measurements (mm) Lateral clearance 50 mm Distance from ceiling depending on exhaust flue system used Front 500 mm 1 Gas connection R ¾ 2 Flow R 1½ 3 Return R 1½ 4 Condensate drain DN 40 5 LAS flue gas/combustion air connection C100/150 6 Cover control panel / 01

11 TECHNICAL INFORMATION 3.5 Boiler flow resistance Alternating resistance [mbar] TopGas classic (35,45) Flow rate [m 3 /h] Alternating resistance [mbar] TopGas classic (60,80) Flow rate [m 3 /h] Alternating resistance [mbar] TopGas classic (100,120) Flow rate [m 3 /h] 3.6 Brief description of the functions of automatic firing device BIC 335 The automatic firing device can be operated without controller (TTE) and without room station (RS-OT) and therefore comprises the following functions: PWM fan (230V~) Modulating operation Inputs for Flow sensor Return sensor Flue gas sensor Gas pressure switch Air pressure switch: (not used) Water pressure switch Safety limit thermostat: (external flue gas thermostat) DHW tank sensor Outdoor sensor Inhibiting input: (burner blocking) Status output Fault (can be inverted via parameter setting) Three-way valve control for heating/dhw or charging pump control (230V~outputs); output for three-way valve / DHW charging pump can be inverted via a parameter. Common electrode for ignition and flame monitoring (ionisation) Allows control of main gas valve (possibly LPG valve)/ boiler room fan Interface to display OpenTherm interface (RS-OT, TTE) RS 232 interface to PC Start attempts: 4 Safety period: 5 sec Ignition period: 5 sec Pre-ventilation period: 20 sec Main/heating pump follow-on time (230V ~): 10 min Three-way valve/dhw charging pump follow-on time: 2 min Restart interlock after heat demand: 2 min Restart interlock after temperature blocking: 2 min Fuses The automatic firing device is equipped with a mains fuse. If this fuse (2AT) blows, the display will remain dark although the main switch is turned on. Ionisation current The ionisation current value is displayed in the information level on sub-level 8. Access to the information level is explained in Chapter / 01 11

12 TECHNICAL INFORMATION 3.7 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. Display: mode Display: temperature RESET Fault clearance (display is blinking, if there is a failure) Changing of the values Saving of the settings Function selection (step by step selection on the display) Selection of the setting (parameter) to be changed (e.g. calorifier temperature) ON/OFF Manometer Function Mode indication Parameter indication Value indication Meaning, description Standby mode Normal position, Start position current flow temperature no indication 0 = = Standby, no heat demand, waiting period, main gas valve 1 = = Rinsing 2 = = Ignition 3 = = Burner on in heating operation 4 = = Burner on in hot water operation 5 = = Air pressure switch defective (no air pressure switch in use) 6 = = Burner off in heating operation (flow temp. > flow temp. ref. + blocking offset heating operation) 7 = = Pump follow-on time in heating operation 8 = = Pump follow-on time in DHW operation 9 = = Burner off in DHW operation (flow temp. > flow temp. ref. + par. 1 (2AB)) Fr = = Frost protection is active Su = = Short summer operation is active / 01

13 TECHNICAL INFORMATION Function Mode indication Parameter indication Value indication Meaning, description Information Mode It is possible to read current values from here Settings can be changed in this mode. Point is blinking 0 e.g. 45 Current flow temperature (heating water temperature) 1 e.g. 40 Current return temperature 2 e.g. 60 Current temperature in the calorifier 3 e.g. 3 Current outside temperature 4 e.g. 55 Current flue gas temperature 5 e.g. 50 Set flow value in heating operation 6 e.g. 70 Set flow value in DHW operation 7 e.g.23 RPM Fan speed in hundred rpm 8 e.g. 4 µ A Ionisation current P = DHW reference value if there is no TopTronic attached Procedure: P = Max. flow temperat. during heating operation Parameter Mode 1. Select parameter mode (press mode key twice) The parameter (P.7) and the setting value are displayed alternately. 2. Select the parameter to be changed (step key) 3. Change setting using + - keys 4. Save (press store key once) Point appears Flow temperature Par. 18 Outside temperature Further parameters only with service code Return to standby mode automatically after 20 minutes or by pressing mode key. Setting the service code To set the code, the Mode and Step keys must be pressed at the same time. The digit which flashes can be changed using the + and - keys. The Step key is used to switch between the digits. The complete code is confirmed and saved with the Store key. The screen switches to display level after 20 minutes. Parameter level (constant dot) Parameter level is indicated by a constant dot after the second character. If neither the + or the - key is pressed, P + parameter number and then the corresponding parameter value are displayed alternately. The corresponding parameter value can be changed by pressing the + or - key. Changes made are saved by pressing Store and are confirmed by the display flashing twice - (wait for this flashing signal before pressing another key!). If the Store key is not pressed, the setting is not applied / 01 13

14 TECHNICAL INFORMATION 3.8 Parameters to be set Parameter 7 (2AH) set value, DHW charging This parameter is used to define the set value for the DHW temperature if no room station or no TopTronic E controller (H-Gen) is connected. If a set value is transferred via the OT bus, it will be applied. Parameter 8 (2AI) pump follow-on time for DHW Here, you can define the follow-on time for the pump after the end of DHW demand. The follow-on time is effective before switchover to heating operation and before switching to Standby mode (switching to Standby on the RS-OT or controller) or switching the automatic firing device to OFF. It is of course also effective when the desired DHW temperature has been reached and there is no demand for heating operation. Parameter 9 (2AJ) anti-legionella period Periodic heating to the temperature set under Parameter 2AF takes place to realise anti-legionella protection. The interval at which this takes place must be set here. At a setting of 0, the anti-legionella function is deactivated. Parameter 10 (2AK) Maximum fan speed in DHW mode This parameter defines the maximum speed of the fan in DHW operation. Parameter 18 (2BH) Maximum heating temperature (at minimum outside temperature) The value set here defines the flow temperature applied when the outside temperature falls below the minimum outside temperature specified in Parameter 19 (2BI) or if no outside sensor is connected. If the OT bus transmits a set value to the automatic firing device, this value is limited by the value defined here. Parameter 19 (2BI) minimum outside temperature This parameter defines the minimum outside temperature, i.e. if the outside temperature falls below this value, the flow temperature should equal the temperature defined under parameter 18 (2BH). Parameter 20 (2BJ) minimum heating temperature (at maximum outside temperature) If the outside sensor measures the value set under parameter 21 (2BK), the parameterised minimum heating temperature is applied. If the temperature measured by the outside sensor is above the parameterised value, the heat demand is reset. Parameter 21 (2BK) maximum outside temperature If the maximum outside temperature defined here is exceeded, heat demand is no longer applied. As soon as the parameterised value is reached, the minimum heating temperature defined under parameter 20 (2BJ) is applied. Parameter 22 (2BL) switching delay after temperature block during heating operation After shutdown of the boiler as a result of a temperature elevation, i.e. after a set value plus the set offset is exceeded, start-up of the boiler in response to a future heat demand is delayed for a time defined with this parameter, independent of whether the value is within the hysteresis. Parameter 23 (2BM) switching delay after heat demand in heating operation Directly following a heat demand, renewed start-up of the boiler is delayed. This means that if the set value to the automatic firing device is reset via the OT bus and the boiler switched off as a result, the downtime of the boiler when a new set value is applied is at least equal to the time set here. Parameter 24 (2BN) pump follow-on time heating operation The time set here defines the pump follow-on time after the end of heating operation. Parameter 25 (2BO) maximum fan speed in heating operation This parameter defines the maximum fan speed which can be applied in heating operation in %. Parameter 60 (2GE) waiting period after opening of the main gas valve/activation of the boiler room fan If a burner request is pending, boiler start-up is delayed by the time set here. During this waiting period, which is required for opening the main gas valve or for pre-ventilation via the boiler room fan, the display reads 0. Parameter 61 (2GF) - external main gas valve (possibly LPG valve)/ boiler room fan present This parameter defines whether an external main gas valve or a boiler room fan is connected / 01

15 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 addition to the main pump. The setting 0 means a KKP (pump output) and additionally a switch (switch output) is used. The setting 1 means, that the pump at the pump output (X8-5/6) is only working in heating mode and the DHW pump at the output X8-7/8 is getting active in the DHW mode. Parameter 63 (2GH) pump minimum PWM value This parameter specifies the minimum permissible output of the PWM pump in %. The minimum PWM value is applied in the case of minimum boiler output. Parameter 64 (2GI) pump - maximum PWM value This parameter specifies the maximum permissible output of the PWM pump in %. The maximum PWM value is applied in the case of maximum boiler output. The pump speed increases in linear manner between minimum and maximum boiler output. Parameter 65 (2GJ) three-way valve inverted The output for controlling the three-way valve can be inverted via this parameter / 01 15

16 INSTALLATION 4. Installation 4.1 Description of the Hoval TopGas classic The heat exchanger of the Hoval TopGas classic (35,45, 60,80,100,120) comprises a corrosion-resistant aluminum casting, through which the heating water flows in series-parallel fashion from bottom to top. A fan draws in combustion air through openings in the top casing cover from the installation room or via an air-flue gas system (for room air independent operation). A predefined quantity of fuel gas is mixed with the combustion air in front of the fan via a combined gas and air control. The homogeneous fuel gas/air mixture is then fed to the pre-mix surface burner via a distributor for low-emission combustion. The pre-mix surface burner is made from high-temperature stainless steel mesh which is optimally protected against damage through overheating. The design of the heat exchanger is such that the flue gas is cooled to below the flue gas dew point at correspondingly low system temperatures. As a result of additional exploitation of the latent flue gas heat (calorific value utilisation), the Hoval TopGas classic (35,45, 60,80,100,120) operates with very high levels of efficiency. After leaving the heat exchanger, the cooled flue gas is fed to the flue gas system Hot water supply The Hoval TopGas classic (35,45,60,80,100,120) can be combined with a DHW calorifier (e.g. Hoval CombiVal). The calorifier sensors and the loading pump must be connected at the corresponding terminals of the TopGas classic controller (see electrical connection diagram in the boiler) Scope of delivery Pressure gauge Autom. air vent in the boiler flow Plastic siphon in condensate drain Water pressure switch as protection against water shortage Flue gas temperature sensor Gas connection R ¾ Electrical connecting cable, length approx. 1.5 m, with plug Gas pressure monitor Diaphragm expansion tank Depending on hydraulic conditions, a sufficiently dimensioned diaphragm expansion tank with a pre-pressure at least 0,3 bar higher than the hydrostatic pressure on-site must be installed Boiler casing In sheet steel, white powder-coated, front sections easily removable Gas valve Gas controlled system Honeywell VK4125V + VK4615 for automatic regulation of the gas/combustion air ratio, see chapter Control unit for gas burner and heating regulator Automatic firing device BIC 335 (for brief description, see chapter 3.6) Heating circulation pump The TopGas classic (35,45,60,80,100,120) is delivered without an installed heating circulation pump. A sufficiently dimensioned heating circulation pump must be installed on site / 01

17 INSTALLATION TopGas classic component designation Fig 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 Heat exchanger 10 Gas valve 11 Gas pressure monitor 12 ON/OFF switch 13 Control panel automatic firing device 14 Control module TTE (optional) 15 Pressure gauge Fig / 01 17

18 INSTALLATION 4.2 Boiler installation room Hoval condensing boilers in the series TopGas classic (35,45,60,80,100,120) can be combined with flue gas conduits which a) draw in combustion air from the installation room (room-air dependent gas firing system) b) draw in combustion air from outside via a closed system (room-air-independent gas firing system) The boiler installation rooms must comply with the relevant local regulations (firing ordinance, regulations of the fire prevention authority). In particular, the stipulations of: DVGW - TRGI must be observed and complied with. In the case of room air dependent operation, it must be ensured that the combustion air is free of contamination (dust, building materials,...) and aggressive substances (halogens such as chloride, fluoride etc.). Gas boilers should not be connected to the mains gas supply or put into operation until all construction work in the installation room is completed Installing the boiler The Hoval TopGas classic (35,45,60,80,100,120) is delivered as follows. Box: Boiler; casing parts; installation and operating instructions. NOTE The boiler must not be placed on its connector elements. NOTE When modernising an old heating system with an open expansion tank, this is to be converted to a closed heating system with a diaphragm expansion tank and safety valve Engineering guidelines for the hydraulic switching Installation of a sludge collector in the boiler return is recommended (observe the correct dimensioning). An adequately dimensioned expansion tank must be provided. The minimum pre-pressure in the expansion tank must be 1,2 bar and the working pressure in the boiler must be 1,5 bar. The pump is to be connected in the boiler return and the expansion tank in the suction side of the pump. If the system pressure cannot to be reached (e.g. roof central heating plants), the expansion tank must be installed in the boiler flow. (Note: starting from 70 C an additional in-line vessel is necessary). Plants with continuous oxygen intake (e.g. underfloor heating systems without diffusion-proof plastic piping) or intermittent oxygen intake (e.g. requiring frequent topping-up) must be equipped with separate circuits. We also recommend the conclusion of a maintenance contract! The boiler is mounted in the desired position on the wall. Side clearance: at least 5 cm; distance from the ceiling: the required clearance for the type and dimensions of the lines for combustion air and flue gas must be observed. Please note dimensions and instructions in the drawings in the chapters 3.3 and Hydraulic switching The Hoval TopGas classic (35,45,60,80,100,120) is designed for continuously controlled operation (room temperature control/weather-controlled boiler and heating circuit control) without lower temperature limit. Please observe the notes in the configuration documents of the responsible Hoval companies with respect to the appropriate hydraulic switching Water pressure guard for water shortage protection To protect the boiler against excessively low water pressure/water level, a water pressure switch is mounted on the return distributor as standard (AMP connectors at positions 1 and 3). The boiler is switched off if the water pressure falls below 1 bar ( P27 is shown on the display). Please check the system pressure and top up with water if necessary / 01

19 INSTALLATION Gravity brake It is recommended to install a gravity brake, to avoid heat losses due to gravity circulation (particularly important when changing existing, open installations). The gravity brake is necessary for summer operation with indirectly heated storage tank calorifier Minimum water circulation volume During the burner operation a circulation pump must always be in operation. The minimum water circulation volume indicated in the technical data must always be provided To be provided on site A pressure expansion tank appropriate for the heating system, water volume and hydrostatic pressure Hydraulic integration Examples TopGas classic (100,120) Gas boiler with free-standing calorifier 1 direct circuit Hydraulic schematic BDDE020 RS-OT B1 BA BW Y7 SLP M5 Room station (OpenTherm) Flow temperature guard (if required) Outdoor sensor Calorifier sensor Switching valve Solar circuit pump Boiler circuit pump / 01 19

20 INSTALLATION TopGas classic (100,120) Gas boiler with free-standing calorifier 1 direct circuit 1 direct circuit mixer circuit(s) Hydraulic schematic BDDE030 AF RBM TTE-GW TTE-WEZ TTE- HK/WW WG VF1 B1.1 VF2 B1.2 T T T T T T TopGas >35 DKP MK1 MK2 T YK1 YK2 P SF M 5 SLP T T P Option / Opzione TTE-WEZ TopTronic E basic module heat generator (installed) VF1 Flow temperature sensor 1 B1.1 Flow temperature guard (if required) MK1 Pump mixer circuit 1 YK1 Actuator mixer 1 AF Outdoor sensor SF Calorifier sensor DKP Pump for heating circuit without mixer SLP Calorifier charging pump M5 Boiler circuit pump Option RBM TTE-GW WG TopTronic E room control module TopTronic E Gateway Wall casing TTE-FE HK TopTronic E module expansion heating circuit VF2 Flow temperature sensor 2 B1.2 Flow temperature guard (if required) MK2 Pump mixer circuit 2 YK2 Actuator mixer / 01

21 INSTALLATION Connection of the pipes The pipes are connected directly to the flow/return connections after completing installation of the boiler. Please observe the designations of the pipe connections given in the chapters 3.3 and Flue gas connection, chimney and condensate discharge Condensate from the flue gas conduit may always be discharged via the boiler. Due to the water vapour content in the flue gases at low temperatures and the resulting further condensation inside the flue gas system, gas condensing boilers cannot be connected to conventional domestic chimneys. Flue gas evacuation must comply with the applicable regulations and the specific requirements of the DVGW (TRGI) and ÖVGW guidelines. In Switzerland, the VKF guidelines (edition 1993, clause 3.4.8) specify that a flue gas temperature limiter as defined in these guidelines must be installed on the unit outlet or in the flue gas conduit. There are two possible ways to evacuate flue gas from gas condensing boilers: a) use of special flue gas conduits approved by the building authorities, b) use of moisture-resistant flue gas systems which are approved for flue gas temperatures of over 40 C, connected to the gas condensing boiler in the boiler installation room by means of approved flue gas conduits Flue gas conduits approved under building law Flue gases from the gas condensing boiler Hoval TopGas classic (35,45,60,80,100,120) can be extracted via a gastight, temperature- and corrosion-resistant flue gas conduit. Only flue gas systems approved and tested by the respective country or state (in Austria, the approval requirements of the respective provinces must be observed) may be connected to the Hoval TopGas classic (35,45,60,80,100,120). The manufacturers of the flue gas conduits supply suitable boiler connection fittings for the transition from the boiler flue gas outlet to the flue gas conduit. The flue gas outlet on the Hoval TopGas classic (35,45,60,80,100,120) has a concentric flue gas connection, ø 100/150 mm. We recommend installation of the connector piece (boiler flue gas connector vertical flue gas pipeline) in the same diameter as the flue gas connector on the TopGas classic (35,45,60,80,100,120). When designing and installing flue gas conduits, manufacturer s instructions for design and routing and the requirements of building law must be observed. We recommend that you consult the regional chimney inspector in good time. Your Hoval dealer can supply an approved flue gas system suitable for your TopGas classic (35,45,60,80,100,120). Please observe the technical information supplied with your flue gas conduit. In both cases, the cross-sections and maximum lengths must be calculated on the basis of the flue gas mass flow, flue gas temperature and available maximum delivery pressure at the flue gas outlet (DIN 4705). See chapters 3.1 and 3.2. As a rule, calculation is effected on the basis of diagrams or tables provided by the manufacturer of the moisture-resistant flue gas system or approved flue gas conduit. In some cases, the manufacturer can perform the calculation using a special calculation program for the specific product. We recommend that you consult the regional chimney inspector before designing and installing a flue gas evacuation system for a gas condensing boiler / 01 21

22 INSTALLATION Air/Flue gas pipe Design variants Combustion air taken from the surrounding environment, ᴓ80 PPS B23 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. C33/C33x The flue gas outlet and air intake through the chimney must be in the same pressure range. Vertical end piece of the flue gas outlet. C53/C53x Air intake and flue gas outlet outside in areas with different pressure. Vertical end piece of the flue gas outlet. C63/C63x Device developed specially for the connection to separately approved air/flue gas systems. C83/C83x Air intake outside the building, flue gas outlet into the chimney / 01

23 INSTALLATION Project planning instructions, flue gas systems All applicable regional and country-specific regulations and laws pertaining to the routing of flue gas must be observed and complied with. Measure opening Each supply and exhaust pipe must be equipped with a testing vent (already included in the construction sets). These should be placed in such a way that they can conveniently be reached to perform a measurement. Length adjustment The concentric length elements should not be shortened. Insert the length compensators or reducing lengths to adjust to the required lengths. The basic flue pipes can be reduced in length to fit. However, the cut ends must be carefully smoothed to avoid damage to the gasket of the connecting piece. Distance holder When installing the pipes in a shaft a spacer must be used at least every 2 metres. To provide support for the chimney stack the lowest element must be fixed (bearing rail or pipe clip). Flue gas temperature The Hoval flue duct systems E80 PP, E100 PP, E80 Flex PP, E100 Flex PP, C80/125 PP, C100/150 PP and E130 PP are long-term temperature resistant to 120 C. Connecting pipes Horizontal connection lines must be routed with a downward slope of at least 5 cm per running metre of their length in the direction of the boiler to ensure that condensate can flow back to the boiler unhindered. The whole exhaust system must be installed so that condensate can never collect at any point.! WARNING The flue gas lines must be secured against unwanted loosening of the plug connections. Condensate drain Condensation water accumulating in the flue gas pipe can be drained via the boiler / 01 23

24 INSTALLATION Design examples for room air dependent operation Use the suitable flue gas system from Hoval or a flue gas system certified in accordance with DIN EN Stainless steel flue gas systems in accordance with EN 483 can also be used. Sizing basis The following diagrams were computed assuming a geographic altitude of 1000 m above sea level. Assembly kit TG K1 E80 PP / TG K1 E80 Flex PP Falls erforderlich ist If necessary, ein Inspektions- insert an inspection T-Stück einzusetzen T-piece Maximum effective height flue gas pipe (m) Höhe [m] TopGas classic (35) TopGas classic (45) Maximum horizontal length connecting pipe (m) Combustion air Gitter Grid zur to Schachthinterlüftung shaft back ventilation Verbrennungsluft TopGas Example TG K1 C80/125 PP 1 Reducer E100 PP -> E80 PP 2 Inspection T-piece with measure opening E80-90 PP 3 Duct E80, wall plate 220 x 220 mm with seal ring and casing tube Ø 150 mm, L = 300 mm 4 Length element E80 L = 450 mm PP 5 Bearing rail E flue gas pipe support in shaft 6 Support arch E80-90 PP 7 Distance holder E80 set (2 pieces) of polypropylene for centring tube in shaft; 3 sets 8 End tube E80 L = 500 mm to top part E80, stainless steel 9 Top part E80 for chimney end for back ventilation with shaft cover 400 x 400 mm, clamp tape and seal ring To determine the total length of flue gas pipe and combustion air duct, the total lengths can be obtained from the diagrams and calculated for the simple chimney installation. For the remaining formpieces which have to be installed, the lengths to be removed must be read off from the table. TopGas (35,45) Assembly kit TG K2 E100 PP-A Assembly kit TG K2 E100 Flex PP-A Maximum effective height flue gas pipe (m) Maximum horizontal length connecting pipe (m) TopGas (60) Assembly kit TG K2 E100 PP-A Assembly kit TG K2 E100 Flex PP-A Maximum effective height flue gas pipe (m) ,5 1 1,5 2 2,5 3 3,5 4 4,5 Maximum horizontal length connecting pipe (m) / 01

25 INSTALLATION Design examples for room air independent operation TopGas (35,45) Assembly kit TG K1 C80/125 PP TG K1 C80/125 Flex PP Combustion Verbrennungsluft air Falls erforderlich ist If necessary, ein Inspektions- insert an inspection Stück einzusetzen T-piece Maximum effective height flue gas pipe (m) TopGas classic (35) 10 TopGas classic (45) Anbindeleitung [m] Maximum horizontal length connecting pipe (m) TopGas (35,45) Assembly kit TG K2 C100/150 PP-A Assembly kit TG K2 C100/150 Flex PP-A TopGas Gitter Grid zur to Schachthinterlüftung shaft back ventilation Maximum effective height flue gas pipe (m) Maximum horizontal length connecting pipe (m) Example TG K1 C80/125 PP 1 Concentric reducer C100/150 -> C80/125 PP white coated 2 Inspection T-piece with measure opening C80/125 PP 3 Length adjustment piece C80/125 L = mm 4 Wall plate to wall duct C80/125, 220 x 220 mm 5 Wall socket to wall duct D = 150 mm, L = 300 mm 6 Bearing rail E flue gas pipe support in shaft 7 Support arch C80/ PP 8 Distance holder E130 set (2 pieces) of spring steel; a distance holder must be used at least every 2 meters 9 Top part E130 for chimney end for back ventilation with shaft cover 10 Rain keep-off rail D = LAS mouthpiece C80/125 PP flue gas pipe of stainless steel, white coated TopGas (60) Assembly kit TG K2 C100/150 PP-A Assembly kit TG K2 C100/150 Flex PP-A Maximum effective height flue gas pipe (m) Anbindeleitung [m] Maximum horizontal length connecting pipe (m) / 01 25

26 INSTALLATION Combustion air Verbrennungsluft 11 TopGas (35) Assembly kit TG K-LAS C80/125 PP TG KD-LAS C80/125 PP Falls erforderlich ist If necessary, ein Inspektions- insert an inspection Stück einzusetzen T-piece Maximum effective height flue gas pipe (m) TopGas (35) Maximum horizontal length connecting pipe (m) TopGas 2 1 Gitter Grid zur to Schachthinterlüftung shaft back ventilation Example TG K-LAS1 C80/125 PP 1 Concentric reducer C100/150 -> C80/125 PP white coated 2 Inspection T-piece with measure opening C80/125 PP 3 Length adjustment piece C80/125 L = mm 4 Wall plate to wall duct C80/125, 220 x 220 mm 5 Wall socket to wall duct D = 150 mm, L = 300 mm 6 Bearing rail E flue gas pipe support in shaft 7 Support arch C80/ PP 8 Distance holder E130 set (2 pieces) of spring steel; a distance holder must be used at least every 2 meters 9 Top part E130 for chimney end for back ventilation with shaft cover 10 Rain keep-off rail D = LAS mouthpiece C80/125 PP flue gas pipe of stainless steel, white coated / 01

27 INSTALLATION Min. 1m Combustion Verbrennungsluft air Falls erforderlich ist If necessary, ein Inspektions-T- insert an inspection Stück einzusetzen T-piece Assembly kit TG AW C80/125 PP Maximum effective height flue gas pipe (m) TopGas classic (35) Maximum horizontal length connecting pipe (m) Assembly kit TG AW2 C100/150 PP TopGas Example TG AW2 C100/150 PP 1 Inspection T-piece with measure opening C100/150 PP 2 Length adjustment piece C100/150 L = mm 3 Concentric wall duct with wall plate 220 x 220 mm C100/150 white coated (RAL9016) 4 Outside wall support Ø 150 mm incl. mounting material, stainless steel 5 Elbow T-piece C100/150 6 Outside wall-distance holder Ø 150 mm stainless steel 7 Lead pan with bowl C100/150 for roof execution (gradient adjustable), ground plate 500 x 500 mm 8 Rain keep-off rail 9 LAS-mouthpiece C100/150 PP flue gas pipe of stainless steel, white coated Maximum effective height flue gas pipe (m) Anbindeleitung [m] Maximum horizontal length connecting pipe (m) TopGas classic (45) TopGas classic (35) TopGas classic (60) / 01 27

28 INSTALLATION Maximum exhaust duct lengths TG DHZ1 C80/125PP TopGas classic (35): 9 m TopGas classic (45): 6 m Combustion Verbrennungsluft air 4 TG DHZ2 C100/150PP TopGas classic (35): TopGas classic (45): 16 m 19 m TopGas classic (60): 11 m Falls erforderlich ist If necessary, ein Inspektions-T- insert an inspection Stück einzusetzen T-piece TopGas Example TG DHZ2 C100/150 PP 1 Length adjustment piece C100/150 with measure opening for flue gas and supply air; PP 2 Length adjustment piece C100/150 L = mm 3 Lead pan with bowl C100/150 for roof execution (gradient adjustable), ground plate 500 x 500 mm, brick-red coated 4 Intake air/flue gas roof bushing C100/150 including pipe clip, brick-red coated / 01

29 INSTALLATION Condensate discharge and neutralisation Condensate from gas condensing boilers must be fed into the public sewer system or separate waste water treatment plant in accordance with the relevant regulations and - where prescribed - must first be neutralised. Please comply with the instructions of the responsible local waste water authorities. In Austria: Please observe the planning guidelines for condensing appliances economisers for furnace installations in Ö-NORM H 5152 and especially those of the ÖVGW (G 41). It is important to contact the relevant authority before planning and installing the boiler system, to ensure that the condensate drain is planned and installed in accordance with the regulations. The siphon drain pipe must be directed into a funnel Gas connection! WARNING The installation of the gas pipeline and first placing in operation must be carried out by a recognised expert. The regulations applicable in the respective countries (ÖVGW guidelines, DVGW- TRGI 86-96, DIN 4750) and the requirements imposed by the relevant local gas company must be complied with. A manual shut-off device (gas shut-off valve) in accordance with local requirements must be installed directly upstream of the boiler. Please ask your local gas company whether it is mandatory to fit an approved gas filter between the manual shut-off device and the boiler to avoid malfunctions as a result of dirt particles in the gas. In Germany, some local building regulations require the installation of a thermally triggered shut-off valve directly in front of the boiler. Please contact your local building authority for details of the applicable regulations.! WARNING It is imperative to check all gas-carrying pipelines for leaks before initially placing the boiler in operation. 4.5 Electrical connection WARNING The heat generator can only be de-energised by disconnection from the mains (e.g. allpole switch). WARNING All electric power supply circuits must be switched off before accessing the terminals. CAUTION The electrical connection (sensors, pumps and all other devices and components to be connected) must be connected in accordance with the applicable standards of nationally or internationally recognised professional associations / 01 29

30 INSTALLATION Regulations for electrical connections All electrical installation work, in particular implementation of protective measures, must be performed in accordance with the pertinent laws and any specific regulations imposed by the local energy company; local requirements must be observed in particular. During assembly of the system, the requirements of VDE 0100 and the regulations imposed by the responsible energy company must be complied with. Accident prevention regulations General regulations (VBG1) Electrical installations and equipment (VBG4) Electrical connections must be established in accordance with the electrical connection diagram in the boiler. The electrical connection diagram does not include protective measures. The appropriate protective measures must be implemented during installation of the system and when connecting the unit in accordance with VDE 0100 and the regulations of the local energy company Boiler controller/electrical connection diagram Electrical connection must be performed in accordance with the electrical connection diagram in the boiler Connecting the heating regulator TopTronic RS-OT There is the option of operating the TopGas classic (35, 45,60,80,100,120) with a TopTronic RS-OT controller to be mounted externally. Please ask your Hoval representative to describe in detail the output range of this regulator TopTronic E Optionally, the TopGas classic (35,45,60,80,100,120) can be equipped with an integrated TopTronic E control ler. The boilers may only be installed in rooms which meet the requirements of the unit s protection class (IP20). To avoid induction voltages, low voltage and high voltage (230 V~) lines must be routed separately with a spacing of at least 10 cm. If the lines are laid in cable ducts, low voltage and high voltage lines must be separated using separator strips Electrical connection (mains) 230 V, 50 Hz The boiler is delivered pre-wired and ready for connection. It has an electrical connection cable with a length of approx. 1,5 m, with a mains plug. A socket must be installed in the direct vicinity of the boiler (not more than 1m from the edge of the boiler casing). The backup fuse selected must ensure that the limit values specified in the Technical Data are never exceeded. Failure to comply with this instruction may lead to a short-circuit with serious consequences for the control unit or the system. Please ask your Hoval representative to describe the power outputs of these regulators in detail. Installation of the TopTronic E - ZE1 kit is described in separate assembly instructions. TopTronic E In principle, the TopTronic E controller (H-Gen) allows weather-driven, fully continuous control of a mixer circuit, a direct circuit and water heating with an indirectly heated calorifier (e.g. Hoval CombiVal). A possible hydraulic system configuration is listed under chapter The gas condensing boiler must always be disconnected from the power supply before performing work on it! During electrical installation and commissioning of the system, the accident prevention regulations and the generally accepted engineering principles must be observed. WARNING Automatic firing units are safety devices and are not to be opened / 01

31 COMMISSIONING 5. Commissioning 5.1 Setting the controller Please refer to the operating instructions for the heating regulator to set the heating curve etc. 5.2 Water quality Detailed planning is increasingly important to maintain the increased profitability and reduced pollution of modern boiler systems over many years. o assist you in this work we should like to inform you of the engineering guidelines of this boiler. The condensing boiler TopGas classic (35, 45,60,80,100,120) is only suited for closed hydraulic systems Heating water The requirements of European Standard EN and VDI 2035 must be met. In particular, the following specifications must be complied with: Hoval boilers and calorifiers are suitable for heating systems without significant oxygen intake (system type I in accordance with EN 14868). Plants with continuous oxygen intake (e.g. underfloor heating systems without diffusion-proof plastic piping or open expansion tank) or intermittent oxygen intake (e.g. requiring frequent topping-up) frost protection in heating water must be equipped with separate circuits. Treated heating water must be tested at least 1x per year, or more frequently if specified by the manufacturer of the inhibitor. On existing systems (for example if the boiler is replaced), where the quality of the existing heating water meets the requirements of VDI 2035, re-filling of the system is not recommended. The requirements of VDI 2035 also apply to replacement water. Before filling new systems and, where necessary, existing systems, the heating system must be professionally cleaned and flushed! The boiler must not be filled until the heating system has been flushed. All parts of the boiler which come into contact with water are made of aluminium. Due to the danger of pitting, the sum of the chloride, nitrate and sulphate contents in the heating water must not exceed 200 mg/l. The ph value of the heating water should be between 8.0 and 8,5 after 6-12 weeks of heating operation Filling and replacement water As a rule, untreated mains water is best suited as filling and replacement water for a system with Hoval boilers. However, the quality of the untreated mains water must still meet the requirements of VDI 2035 or be demineralised and/or treated with inhibitors. The requirements of EN must be met in this context. To maintain high boiler efficiency and prevent overheating of the heating surfaces, the values in Table 1 should not be exceeded, taking into consideration the boiler output (smallest individual boiler in multi-boiler plants) and the water content. The total quantity of filling and replacement water added to the boiler over its service life must not be higher than three times the system water content. Filling is only allowed to be performed by a specialist company when aluminium inhibitors are involved. Table 1: Maximum filling capacity based on VDI 2035 Valid for boilers with < 0,3 l/kw water capacity 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 up to 28 kw NO DEMAND 50 l/kw 20 l/kw 30 to 50 kw 50 l/kw 50 l/kw 20 l/kw 20 l/kw 20 l/kw 50 to 200 kw 50 l/kw 20 l/kw 20 l/kw always desalinate 1 total of alkaline earths 2 If the conductance in µs/cm exceeds the tabular value an analysis of the water is necessary / 01 31

32 COMMISSIONING If a reduction in water hardness is necessary we recommend a complete desalination (no softening) with bypass, so that the sum of the alkaline-earths in the filling water remains of approx. 0,5 mol/m 3. During the filling procedure the conductance of the filling water should be monitored. This should be to approx. 100 µs/cm. After filling, the conductance of the system water should be between 50 and 200 µs/cm. The ph value will thus start at 6,5-7,5 and settle at 8,0-8,5 after a few weeks. If this is not the case, call in a specialist company to treat the water. Once the correct ph value has been set by inhibitors that are suitable for aluminium materials, this should also involve regular checks of the inhibitor concentration and the ph value. NOTICE Corrosion damage to the system and venting problems are frequently caused during refilling and topping up of the system. The odour trap on the condensate drain must be filled with water. 5.3 Gas adjustment Compliance with the maximum permissible limit values for CO and NOx must be verified through measurement at the installation location Filling the system Both old and new systems must be professionally cleaned and flushed before filling. Filling for the first time or refilling the system: The requirements for the filling and replacement water according to must be met. The maximum quantity of water (sum of filling and replacement water) added to the heat generating system over its service life must not be higher than three times the specified filling quantity. Example: maximum filling quantity (as in table 1) 1600 l, maximum filling and replacement water quantity over service life 4800 l.! WARNING Before commissioning, the siphon must be filled with water to prevent flue gas leakage. Installation of a strainer in the boiler return is recommended. Minimum system pressure at the boiler: Type Min. system pressure at the boiler TopGas classic (35,45,60, 80,100, 120) 1,5 bar The system must be filled slowly via the filling and drain cock on the boiler and with the radiators open. Do not close the air-bleeding valves until only water emerges Venting the gas pipe Open the gas shut-off valve and vent the gas pipe up to the gas valve, observing the pertinent regulations Commissioning Put the boiler into operation as prescribed in the detailed operating instructions provided Gas inlet pressure The gas flow pressure in the unit connection line must reach the following values: Natural gas = min. 17,4 mbar max. 50 mbar Propane gas = min. 37 mbar max. 55 mbar If the gas flow pressure for natural gas is below 18 or over 50 mbar, no settings may be made and the boiler must not be put into operation Gas valve The Hoval TopGas classic (35,45,60,80,100,120) is equipped with pneumatically modulating multifunctional valves manufactured by Honeywell. The equipment comprises two solenoid valves (B+B), a strainer and an integrated balanced pressure (1:1) - gas/air - servo controller. The fan, which is controlled by the boiler s electrical system, generates a speed-dependent air stream. This causes the air pressure to drop in a Venturi nozzle. The air pressure is fed to the servo controller of the multifunctional valve where it changes the gas volume flow in proportion to the air pressure. The gas stream follows the air stream in the preset ratio (constant air coefficient in the modulation range) / 01

33 COMMISSIONING 5.4 TopGas classic (35-80) Measuring and setting points of the Honeywell multiple setting device VR 4615V Fig. 03 C D B A A Measuring nipple, inlet pressure B Measuring nipple, outlet pressure C Throttle screw max. output (Allen 4 mm) D Offset screw min. output (Torx T40) Setting the gas flow rate CO 2 (O 2 ) and measure ment of NOx/CO content in the flue gas (flue gas measurement) Important basic information: If the minimum connection pressure (chapter is too low (e.g. because of clogged gas filter, under-dimensioned gas supply), the boiler will not achieve the rated output indicated by the manufacturer. In this case, please contact the gas supply company. NOTICE If the connection pressure of natural gas is below 15 or above 50 mbar, no setting and no commissioning can take place. b) Establish the gas and electrical connections for the boiler. Press the MODE and + keys to switch to Service mode! Display on the screen in Service mode: the current level alternates with SEr on the display! after accessing this operating mode, an output of 50 % is applied. The output can then be set to between 0 % and 100 % using the + and - keys. Exit this operating mode: by pressing the Reset key or automatically after 20 minutes. Use the + key to set the boiler to 100 %. Check the CO 2 (O 2 ) content of the flue gas. It has to be between CO 2 = 8,5-8,8 (O 2 = 5,9-5,5) vol.-% (dry). Correct the CO 2 (O 2 ) value if necessary by turning the throttle screw C of the Venturi (chapter ). Then check the gas flow rate at the gas meter (volumetric method). To calculate the gas flow rate which should be set, you require the net heating value H ub, which you can obtain from your gas company. The adjustment value is calculated as follows: Setting value E = = Heat load NB (kw) Operation calorific value H ub (kw/m 3 ) NB 1000 l x H ub 60 min The gas flow rate is corrected by changing the fan speed: Increase in the max. fan speed at the automatic firing device: -> gas flow rate increases (at constant CO 2 (O 2 ) value) Decrease in the max. fan speed at the automatic firing device: -> gas flow rate decreases (at constant CO 2 (O 2 ) value) c) Use the - key to set the boiler to 0 %. Check the CO 2 (O 2 ) content of the flue gas. It must be between CO 2 = 8,5-8,8 (O 2 = 5,9-5,5) vol.-% (dry). Correct the CO 2 (O 2 ) value if necessary by turning the offset screw D (remove the protective cap first). The Honeywell multifunctional valve (chapter 5.4 has two measuring nipples for measuring the gas inlet pressure A and gas outlet pressure B. The gas/air mixture is prepared by a state-of-the-art, complete unit consisting of mixing device (Venturi), multifunctional valve and fan. Setting is performed as follows: a) Check the setting of the minimum and maximum speed of rotation at the automatic firing device in accordance with the parameter list. Fig / 01 33

34 COMMISSIONING d) 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.! WARNING If the limiting values prescribed by the regulations are exceeded, the boiler must be put out of operation and the corresponding meas ures for repair work must be initiated. After a correction, the upper/lower limit should be approached again for testing/correction purposes. The boiler is now correctly set. To return to normal operation, press RESET. B) Remove the boiler cover. C) Dismantle natural gas gas pressure monitor and fit new gas pressure monitor for liquid gas. Wire gas pres sure monitor (AMP connector at positions 1 and 3). D) Attach the yellow sticker Change of set gas type: liquid gas to boiler rating plate. E) For a boiler which is already connected: Open the gas cock Set system switch on control panel to I F) Set CO 2 (O 2 ) content according to at nominal output and minimum output to CO 2 = 9,9-10,2 (O 2 = 5,9-5,5) vol.-% (dry). 5.5 TopGas classic (100,120) Measuring and setting points of the Honeywell multiple setting device VR 4615V B C D A Changing to a different type of gas! WARNING Changes are only to be carried out by a recognised specialist! The boilers are preset at the factory to natural gas H (Wobbe value 15.0 kwh/m 3 ). Changing from natural gas H to natural gas L Changeover to low-calorie natural gas can be performed easily. All you need to do is check/correct the CO 2 (O 2 ) value at at maximum and minimum output (see chapter 5.3.4). Changing from natural gas H to liquid gas propane Compliance with the special local provisions (VKF/DVGW/ÖVGW) for operating a boiler on liquid gas is imperative in each case. Ensure that the fuel type in the measuring device has been set correctly! The conversion kit for liquid gas propane consists of: 1 yellow sticker Change of set gas type: liquid gas for the boiler rating plate 1 liquid gas gas pressure monitor A) For a boiler which is already connected: Close the gas cock Set the system switch on the control panel to 0 Fig. 05 A Measuring nipple, inlet pressure B Measuring nipple, outlet pressure C Throttle screw max. output (slot - red) D Offset screw min. output (Torx T40 for cover and offset screw) Please comply with the following points when exchanging or readjusting the valve VR 4615V: The valve supplied as a spare part is open and must be set in advance. To do this, turn the screw marked in red one turn (360 ) to the right. In this way, you are near the correct CO 2 /O 2 value. Now install the valve correctly and make the fine setting of the gas quantity according to The preset information relates to natural gas / 01

35 COMMISSIONING New valve: fully open Preset: approx. 8,8 % CO 2 screw marked in red one turn (360 ) to the right Screw marked in red (throttle screw) to the right = less gas Setting the amount of gas Important basic note: If the minimum gas flow pressure falls below the minimum limit (chapter 5.3.3) (e.g. as a result of clogged gas filters, under-dimen sioning of the gas supply line), the boiler will not reach the nominal output defined by the manufacturer. If this happens, please inform your gas company. NOTICE If the gas flow pressure of natural gas is below 18 or above 50 mbar, no setting and no commissioning can take place. The Honeywell multifunctional valve (Fig. 05, chapter 5.5) has two measuring nipples for measuring the gas inlet pressure A and gas outlet pressure B. Exit this operating mode: by pressing the Reset key or automatically after 20 minutes. Use the + key to set the boiler to 100 %. Check the CO 2 (O 2 ) content of the flue gas. It has to be between CO 2 = 8,5-8,8 (O 2 = 5,9-5,5) vol.-% (dry). Correct the CO 2 (O 2 ) value if necessary by turning the throttle screw C of the Venturi (Fig. 05). Then check the gas flow rate at the gas meter (volumetric method). To calculate the gas flow rate which should be set, you require the net heating value H ub, which you can obtain from your gas company. The adjustment value is calculated as follows: Setting value E = = Heat load NB (kw) Operation calorific value H ub (kw/m 3 ) NB 1000 l x H ub 60 min The gas flow rate is corrected by changing the fan speed: Increase in the max. fan speed at the automatic firing device: -> gas flow rate increases (at constant CO 2 (O 2 ) value) Decrease in the max. fan speed at the automatic firing device: -> gas flow rate decreases (at constant CO 2 (O 2 ) value) c) Use the - key to set the boiler to 0 %. Check the CO 2 (O 2 ) content of the flue gas. It must be between CO 2 = 8,5-8,8 (O 2 = 5,9-5,5) vol.-% (dry). Correct the CO 2 (O 2 ) value if necessary by turning the offset screw D (remove the protective cap first). CO 2 (O 2 ) setting The gas/air mixture is prepared by a state-of-the-art, complete unit consisting of mixing device (Venturi), multifunctional valve and fan. Setting is performed as follows: a) Check the setting of the minimum and maximum speed of rotation at the automatic firing device in accordance with the parameter list. b) Establish the gas and electrical connections for the boiler. Press the MODE and + keys to switch to Service mode! Display on the screen in Service mode: the current level alternates with SEr on the display! after accessing this operating mode, an output of 50 % is applied. The output can then be set to between 0 % and 100 % using the + and - keys. Fig. 06 After a correction, the upper/lower limit should be approached again for testing/correction purposes. The boiler is now correctly set. To return to normal operation, press RESET / 01 35

36 COMMISSIONING Changing to a different type of gas! WARNING Changes are only to be carried out by a recognised specialist! The boilers are preset at the factory to natural gas H (Wobbe value 15,0 kwh/m 3 ). Changing from natural gas H to natural gas L Changeover to low-calorie natural gas can be performed easily. All you need to do is check/correct the CO 2 (O 2 ) value at at maximum and minimum output (see 5.5.1). Changing from natural gas H to liquid gas propane Compliance with the special local provisions (VKF/DVGW/ÖVGW) for operating a boiler on liquid gas is imperative in each case. Ensure that the fuel type in the measuring device has been set correctly! The conversion kit for liquid gas propane consists of: 1 yellow sticker Change of set gas type: liquid gas for the boiler rating plate 1 liquid gas gas pressure monitor A) For a boiler which is already connected: Close the gas cock Set the system switch on the control panel to 0 B) Remove the boiler cover. C) Dismantle natural gas gas pressure monitor and fit new gas pressure monitor for liquid gas. Wire gas pres sure monitor (AMP connector at positions 1 and 3). D) Attach the yellow sticker Change of set gas type: liquid gas to boiler rating plate. E) For a boiler which is already connected: Open the gas cock Set system switch on control panel to I F) Adjust fan speed in accordance with parameter list Adjustments for liquid gas (parameters 35-41). G) Set CO 2 (O 2 ) content according to at nominal output and minimum output to CO 2 = 9,9-10,2 (O 2 = 5,9-5,5) vol.-% (dry). 5.6 Handover to the operator Instructions for the operator Have the operator confirm with his signature that he has been adequately instructed on how to operate and service the system, he has received and noted the content of the operating and maintenance instructions and where applicable other documentation on the burner, heating regulator etc., he is therefore sufficiently familiar with the system. A preprinted form (in duplicate) for this confirmation can be found on the last page of these installation instructions. In addition, on request, official preprinted forms for submission to the trade supervisory board or for the approval procedure can be prepared via the responsible local technical inspection agency and supplied with the boiler. The operating instructions and technical information are always to be kept in the boiler installation room Checking the water level The customer must be informed of the two values between which the movable pointer on the pressure gauge may move. The customer should be shown how to top up and vent the system Maintenance On handover, the customer must be notified that inspection and cleaning of the gas combustion system and heating surface and the condensate neutralisation unit which may be mandatory must be performed regularly - normally once per year - by the licensed installer or responsible customer service organisation. The conclusion of a service contract is also an important contribution towards economical operation in accordance with energy conservation laws and ensuring that the burner is always correctly adjusted so that the system passes the inspections for flue gas losses and emission of pollutants prescribed by law / 01

37 DECOMMISSIONING 6. 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 protection agent in accordance with the heating installer s instructions / 01 37

38 MAINTENANCE 7. Maintenance 7.1 Checking the water connections for leakage Tighten screw connections on the water side while the boiler is still at operating temperature. 7.2 Refilling The system must be topped up with water if the water pressure falls below the set pre-pressure. To do this, allow the heating water to cool down, vent the filling hose and then pour in water via the filling and drain cock. 7.3 Maintenance comprises: Cleaning the flue gas heat exchanger and condensate collector Checking the burner Checking the ignition electrode, distance from burner approx. 4-5 mm, if necessary, positioning the ignition electrode correctly or replacing it Taking CO 2 (O 2 ) measurement (according to chapter 5.3) 7.5 Function check Set gas condensing boiler as described in chapter 5.3 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 7.6 Emission measurement To access the service operation menu, press MODE and +. Service operation, which is carried out in heating mode, can be recognised by the fact that the current level alternates with the characters SEr in the display. When this operation mode is accessed, the burner starts up at 50 % capacity. The output can then be varied between 0 and 100 % using the + and - keys. To exit this operation mode, press the RESET key (or the mode is automatically exited after 20 minutes). If applicable, observe other instructions! 7.4 Cleaning the heat exchanger Disconnect gas condensing boiler from the power supply (pull the plug) Close the unit gas cock Remove front cover (open control damper; slide front cover upwards and pull it out) Unplug electrical connection of gas solenoid valve Disconnect connector plug on fan Release the threaded connection of the supply line to the gas solenoid valve (Fig. 07) Release burner plate screw attachments (Fig. 07) Remove the burner plate and the surface burner (Fig. 08) and (Fig. 09) Wet-clean heat exchanger (do not use a steel brush) (Fig. 10) Clean condensate drain After cleaning the heat exchanger, reassemble in reverse order. After assembly, the entire gas path/gas line must be checked for leaks (using leak detection spray) / 01

39 SYSTEM MAINTENANCE AND CLEANING Screw connection burner plate Burner plate Gas screw connection Plug connections Fig. 07 Fig. 08 Fig. 09 Fig / 01 39