ENERGY TOP Condensing boiler solutions 1
ENERGY TOP > ENERGY TOP RANGE A wide array of flexible solutions both for centralised residential application and big commercial plants The increasing need for families to be able to manage their central heating system freely and independently led to the expansion of independent systems, gaining ground over the traditional centralised approach to heating. Independent systems have been and continue to be preferred by users, mainly due to: - independent management - costs exactly corresponding to own consumption; - less possibility of controversies between residents. Nonetheless, centralised systems, albeit less appreciated by users, have been recently reappraised thanks to some undeniable qualities : less overall capacity installed; less environmental impact due to the use of just one flue or stack, and separate installation of the generator in a boiler room. The development of centralised systems with independent billing, using so-called submeter, combine all the advantages of independent and centralised systems mentioned above. For this reason, the new series of ENERGY TOP modular heat generators together with submeter DADO (not described in this catalogue) represent a modern and complete solution to the latest needs, which require a balance between centralised production of heat and independent and individual management of consumption. Both in the residential and the commercial field, wide output modulation range of Energy Top, additionally enhanced in modular installation, together with its low hydraulic pressure drop, allows design and carrying out of flexible systems with extremely compact dimensions, fully in line with the latest heating technology design criteria. PRODUCT IN BRIEF Possible outdoor installation in a partially sheltered site (EN297 pr A6) with minimum temperature -5 C (ENERGY TOP W) Possible outdoor installation with minimum temperature -10 C (ENERGY TOP B/BK) Remote monitoring of boiler functions through Opentherm remote control (ROMEO) Electronics features built-in master-slave cascade operation, without additional controllers Possible connection to an optional outdoor probe, thus enabling system flow temperature compensation Class 5 emissions, i.e. the most severe and ecological class according to European directives (EN 297 and 483) AISI 316 stainless steel casing, highly resistant to atmospheric agents (ENERGY TOP BI/BKI) > DADO (metering cassettes for centralized heating and domestic hot water production) > ENERGY TOP W (side-by-side) > ENERGY TOP B (side-by-side) > ENERGY TOP B (back-to-back) > ENERGY TOP B 160 > ENERGY TOP B 250 > ENERGY TOP B 80 > ENERGY TOP B 125 > ENERGY TOP BK 80 > ENERGY TOP BK 125 > ENERGY TOP W 80 > ENERGY TOP W 125 2
ENERGY TOP > THE HEART HEATING UNIT The HEART of ENERGY TOP is an innovative heating unit that ensures the product excellent characteristics in terms of efficiency and flexible modulation. The new total premixed air-gas combustion unit with variable speed fan, pneumatic gas valve and cylindrical metal fibre burner allows a range of modulation that, depending on the model, can extend from 11 to 100% of rated output, with efficiency exceeding 107%. Heat exchange takes place in the spiral corrugated pipe exchanger, which features low pressure drop. Despite the high heat exchange surface, it is particularly sturdy and compact. The quality of the materials used ensures the exchanger a high level of resistance to corrosion and thermal dilations, supporting a max T of 40 C. The very low polluting emissions - NOx and CO - as well as minimising the environmental impact of these heat generators (class 5 according to EN 297/A5), also let the heat exchanger remaining clean over time, reducing to the minimum maintenance intervention. Ignition is electronic, with flame control by ionisation. The heating units have been designed with two different heat input ratings: 75 and 116 kw, and based on the total output, the various models of ENERGY TOP can house one or two units of 75 or 116 kw each, always inside a unique cabinet structure. The models with two heating units are also managed by the same electronic controller. 100% 50% 30% 22% 11% ENERGY TOP 80 > MODULATION RANGE ENERGY TOP 125 ENERGY TOP 160 ENERGY TOP 250 PREMIX BURNER Premixed air-gas, metal fibre burner, with variable speed fan. EXCHANGER Consisting in a spiral corrugated pipe ENERGY TOP B with two heating units 3
ENERGY TOP > THE MIND CONTROL UNIT 2 3 2 3 1 6 4 7 KEY 1 Display 2 Central heating temperature setting 3 Domestic hot water temperature setting (with optional storage cylinder) 4 Summer/Winter mode 5 On/Off 6 Reset parameters 7 Economy/Comfort mode 5 Remote timer control connected Information Reset generator Fault Generator off Temperature compensation mode Central heating mode Pump ON Burner ON Economy mode Domestic hot water operation Read parameters Domestic hot water mode The evolved electronics on ENERGY TOP can perfectly manage applications where multiple heat generators are used in cascading, minimising the configuration and commissioning operations. The MASTER/SLAVE function allows operation of a series of cascaded boilers, without requiring an additional control unit. With just a simple connection (two wires) between the control boards of the boilers in the cascade, the entire system acts as a single virtual boiler. The safety circuit reduces boiler lockout and system shutdown, automatically attempting to ignite the module three times in the event of temporary shutdown (natural gas versions). If the shutdown occurs repeatedly, the system goes into permanent lockout mode, for safety reasons. Control board features a series of input and output signals, both analogue and digital (on/off), in order to control or adjust the operation of the single boiler or the entire cascade system also via a remote connection. Below are some examples: FAULT SIGNAL Active in case of boiler s fault message BURNER ON SIGNAL Active when at least one heating unit is on RESET SIGNAL Used to reset temporary faults Combined management of the signals allows the operating status of the heat generator to be checked and set via a remote connection C/%P 10 Volt 0-10 VOLT INPUT SIGNAL Allows the boiler (or cascade of boilers) to be controlled via a remote connection, in system outlet temperature or output percentage mode. ELECTRONIC INSTALLATION SUPERVISOR 4
ENERGY TOP > THE MIND CONTROL UNIT 0-10 Volt input signal, available on the electronics, enables the boilers to be interfaced to any generic external control unit featuring a 0-10 Volt output. In this way, the ENERGY TOP series generators can be very easily installed in existing systems with electronic supervisor. Below some examples using the 0-10 Volt signal are shown. > 0-10 V CONTROL: ON MASTER MODULE 0-10 Volt signal Installation SUPERVISOR ZONE 1 ZONE 2 ZONE 3 Control based on the central heating flow temperature or percentage of equivalent generator output, using a unique 0-10 Volt signal connected to the MASTER generator. Information received by the MASTER generator will be used to control the SLAVE ones. > 0-10 V CONTROL: INDIVIDUALLY ON SLAVE MODULES Installation SUPERVISOR 0-10 Volt signal ZONE 1 ZONE 2 ZONE 3 Control based on the system outlet temperature or percentage of equivalent generator output using individual 0-10 Volt signals. 5
RANGE TECHNICAL DRAWINGS The ENERGY TOP W series boilers are wall-hung heat generators for inside or outside installation, central heating only, featuring a premix burner, condensing operation with very high efficiency and very low polluting emissions. They consequently ensure high energy savings and are environmentally-friendly (4 star energy rating according to Directive 92/42 EEC, Class 5 emissions according to EN 297/A5). Wall-hung structure with removable jacket split in 3 sections, for easy access to the inner components. Possible installation as standard outdoor in partially protected places, with temperatures untill to -5 C, without using the additional frost protection kit. The cascaded connection of multiple generators can be carried out using dedicated cascade flues and hydraulic collective manifold. The appliances are factory configured for operation on natural gas and can be converted to LPG using the appropriate conversion kit available upon demand. > THE RANGE ENERGY TOP W 80 Wall hung model with single heating unit and thermal input from 17 to 75 kw ENERGY TOP W 125 Wall hung model with double heating unit and total thermal input from 25 to 116 kw KEY 1 CH flow 1 1/2 F 3 Gas inlet1 M 5 Ch return 1 1/2 F ENERGY TOP W A mm 80 65 125 63 6
TECHNICAL DATA ENERGY TOP W 80 W 125 Performances Heating thermal input max kw 75 116 Heating thermal input min kw 17 25 Thermal output max (80-60 C) kw 73,5 113,7 Thermal output min (80-60 C) kw 16,7 24,6 Thermal output max (50-30 C) kw 79,5 123 Thermal output min (50-30 C) kw 18,3 26,9 Efficiency Pmax (80-60 C) % 98 98 Efficiency Pmin (80-60 C) % 98,5 98,5 Efficiency Pmax (50-30 C) % 106 106 Efficiency Pmin (50-30 C) % 107,5 107,5 Efficiency 30% (30 C) % 109 109 Energy marking (92/42 ECC) Nox emission class (EN 297/A5 Directive) 5 5 Gas flow (G 20) max m 3 /h 79,4 12,38 Gas flow (G 20) min m 3 /h 1,8 2,65 Operating gas pressure (G20) mbar 20 20 G31 gas delivery max kg/h 5,87 9,08 G31 gas delivery min kg/h 1,33 1,96 G31 pressure at burner mbar 37 37 Max operating temperature C 95 95 Operating pressure max bar 6 6 Operating pressure min bar 0,8 0,8 Max exchanger T C 40 40 Water content litres 5 7 Electric characteristics IP protection rating IP X5D X5D Power supply voltage V/Hz 230/50 230/50 Electrical absorption (pump excluded) W 95 200 Dimensional characteristics Empty weight kg 46 51 Height mm 900 900 Width mm 445 445 Depht mm 430 430 Hydraulic Circuit flow/return connections inches 1 1/2 1 1/2 Gas connection inches 3/4 1 Combustion data Chimney loss (with burner on) Pmax-Pmin % 2,2-1,3 1,8-1,3 Jacket loss (with burner on) Pmax-Pmin % 0,2-0,2 0,2-0,2 Loss at chimney with burner OFF % 0,03 0,02 Loss at jacket with burner OFF % 0,4 0,4 Flues temperature Pmax-Pmin (80-60 C) C 65-60 67-60 Flues temperature Pmax-Pmin (50-30 C) C 43-33 45-34 Flues flow Pmax-Pmin kg/h 126,2-30,1 195,2-44,3 Condensate production Pmax-Pmin kg/h 8,7-2 13,5-3,2 CO2 Pmax-Pmin (G20) % 9-8,5 9-8,5 CO2 Pmax-Pmin (G31) % 10-9,2 10-9,2 CO average mg/kwh 35 35 NOx average mg/kwh 29 29 Max head at stack pascal 250 350 7
WATER CIRCUIT 29 16 The water circuit is simple, rational and allows easy access to the inner components. 36 44 345 81 278 82 KEY - 7 Gas inlet 10 Central heating flow outlet 11 Central heating return inlet 16 Fan 22 Main burner 29 Flue gas outlet manifold 36 Automatic air vent 38 Flow-switch 44 Gas valve 81 Ignition electrode 82 Detection electrode 114 Water pressure switch 154 Condensate drain connection 186 Return sensor 188 Ignition electrode 193 Drain trap 196 Condensate basin 278 Double sensor (heating + safety) 345 Exchanger safety thermostat 22 196 The central heating pump is available as a dedicated optional kit complete with on-off valves, non-return valves and safety valve. The low water pressure drop in the exchanger coil and the use of a central heating pump with 8 m head ensure high net head in the system. 154 193 114 10 11 7 38 186 HYDRAULIC KIT FOR SINGLE BOILER, SPEED PUMP code 042021X0 HYDRAULIC KIT FOR SINGLE BOILER, MODULATING PUMP code 042043X0 Hydraulic kit complete with central heating pump, central heating flow and return on-off valves, non-return valve, 6 bar safety valve. > BOILER PRESSURE DROP DIAGRAMS ENERGY TOP W 80 ENERGY TOP W 125 > PUMP KIT FLOW-RATE / HEAD DIAGRAM code 042021X0 / WITH 3 SPEED PUMP code 042043X0 / WITH MODULATING PUMP 8
CASCADE A series of water circuit accessories and self-supporting frames is available for the ENERGY TOP W boilers, used to create different cascading layouts. As structure is self-supporting, it does not need to be anchored to the walls, so installation can eventually be made also in the middle of the boiler room. 3A code. 042021X0 Hydraulic kit for modular installation, complete with on-off valves and 3 speed pump 1 code 042031X0 Basic kit self-supporting frame for first boiler of the cascade, complete with support brackets 2 code 042032X0 Self-supporting frame extension kit for individual boiler (after the first one in the cascade), complete with support brackets 1 1 2 2 2 3B code 042043X0 Hydraulic kit for modular installation, complete with on-off valves and modulating pump 3A/B 3A/B 3A/B 3A/B 4 code 042030X0 Hydraulic separator 7 4 5 6 6 6 7 5 code 042028X0 Basic water manifold for first boiler in the cascade, DN65 (2 1/2) with safety devices (excluding safety valve) and gas manifold, DN40 (1 1/2) 6 7 code 042029X0 code 042033X0 Water manifold extension kit for individual boiler (after the first Flange kit, containing: 3 blind one in the cascade), DN65 (2 1/2) and gas manifold, DN40 flanges, 3 drilled flanges, gaskets (1 1/2) 9
FLUE GAS EVACUATION Various solutions are available for the air intake and flue gas evacuation on the ENERGY TOP W wall-hung boilers, for either individual and modular installation. The low flue gas temperature implies special polypropylene accessories can be used. As regards individual discharge system, both 80 mm separate and 80/125 mm coaxial flue gas outlet configurations are available, with comburent air intake either from the room or the outside. All basic accessories close to boiler s stack are fitted with test fittings for combustion analysis. > INDIVIDUAL EVACUATION SYSTEM > TECHNICAL DATA code 041000X0 90 PPs bend, Ø 80 mm, with flue test point code 1KWMA70W PPs vertical connection, Ø 80 mm, with flue test point code 041007X0 80/125 coaxial adapter, with flue test point ENERGY TOP W 80 W 125 Stack Maximum stack pressure head at Pmax pascal 200 250 Maximum length 80/125 m 4 2 Maximum separate length meq 20 10 As regards the modular installations, flue gas manifolds are available for total output of around 500 kw. If these ducts are used, combustion air intake occurs directly from the boiler room, through the air intake grills included in the kit. 8 9 9 9 9 10 11 8 code 041026X0 Condensate drain trap complete with fastening brackets 10 code 041019X0 1 mt PPs extension, ø 200 mm MF > POSSIBLE MODULAR CONFIGURATIONS INPUT kw TOT. OUTPUT (kw) MODULES QTY TOP W DIMENSIONS W x D x H 80/60 C 50/30 C 1 2 3 4 mm FLUES MANIFOLD DIAMETER 75 73,5 79,5 80 - - - 820x450x2240-116 113,7 123,0 125 - - - 820x450x2240-150 147,0 159,0 80 80 - - 1325x450x2240 191 187,2 202,5 125 80 - - 1325x450x2240 225 220,5 238,5 80 80 80-1830x450x2240 200 mm 232 227,4 246,0 125 125 - - 1325x450x2240 266 260,7 282,0 125 80 80-1830x450x2240 9 code 041028X0 Grey PPs flue gas manifold kit (L=600mm - ø 200 mm) for side-by-side modular installation, complete with clapet valves, vertical connections, gaskets and brackets INPUT kw 11 code 041016X0 90 PPs bend, ø 200 mm MF TOT. OUTPUT (kw) MODULES QTY TOP W DIMENSIONS W x D x H 80/60 C 50/30 C 1 2 3 4 mm 300 294,0 318,0 80 80 80 80 2335x450x2240 307 300,9 325,5 125 125 80-1830x450x2240 341 334,2 361,5 125 80 80 80 2335x450x2240 348 341,1 369,0 125 125 125-1830x450x2240 382 374,4 405,0 125 125 80 80 2335x450x2240 423 414,6 448,5 125 125 125 80 2335x450x2240 464 454,8 492,0 125 125 125 125 2335x450x2240 FLUES MANIFOLD DIAMETER 200 mm 10
SETTING AND CONTROL The ENERGY TOP W series boilers boast an evolved electronics that can manage as standard up to two direct heating zones or an eventual storage cylinder with one direct zone, without requiring additional electronic controllers. PS: Diagrams are for mere example only and need to be verified according to the specific installation. > MIXED CIRCUIT WITH PRIORITY TO THE STORAGE TANK Legionella disinfection signal Recirculation timer Each boiler or cascade of boilers can be connected to an outdoor temperature probe for flow temperature compensation operation. MASTER-SLAVE interconnection between the boilers permits multiple cascade configurations without requiring additional control boards. > MIXED CIRCUIT WITH PRIORITY OR SIMULTANEOUS OPERATION OF THE STORAGE TANK Legionella disinfection signal Recirculation timer The Legionella protection function, after a programmable time interval, ensures the temperature inside the storage cylinder remains at 65 C for 15 minutes. When Legionella protection is active, the boiler s electronics sends an output signal (voltage-free contact) that can be used to control a recirculating pump. This ensures the entire water content in the circuit is protected. In the case of combined systems (without diverting valve) domestic hot water storage cylinder can be heated simultaneously with the central heating or as a priority function depending on the characteristics of the system. 11
SETTING AND CONTROL > CENTRAL HEATING ONLY DIAGRAM WITH DIRECT OUTLET ZONE 1 ZONE 2 It is possible to manage two direct zones, without adding additional controllers. > MIXED CIRCUIT WITH STORAGE TANK AND DIRECT OR MIXED HEATING ZONES ZONE 1 ZONE 2 ZONE 3 Legionella disinfection signal Recirculation timer More complex system diagrams, on the other hand, can be managed by using zone controllers that can interface directly with the boiler s electronics, thus achieving maximum efficiency by adapting the operation of the boilers according to actual system load requirements. In this case too, the operation of the domestic hot water circuit can be managed with priority or together with the central heating circuits. 12
ACCESSORIES LIST FOR MODULAR SYSTEMS The table herebelow lists the components that can be used to create cascading configurations. They are sub-divided into basic accessories - required to create the basic structure for water circuit and flue gas evacuation - and additional accessories that may be used to configure and complete the system depending on the type of installation carried out (e.g.: hydraulic separator, zoning controller, flues extensions etc.). > CONFIGURATION SAMPLES PS: TO BE CONSIDERED MERELY AS AN EXAMPLE AND TO BE VERIFIED ACCORDING TO THE SPECIFIC PLANT HEAT INPUT kw HEAT OUTPUT 80/60 C kw MODULES ENERGY TOP W condensate drain trap for ø 200 mm flue gas manifold ø 200 mm flue gas manifold Hydraulic kit complete with on/off or modulating pump * Water manifold kit for first boiler in the cascade. Includes safety devices (excluded safety valve) Self-supporting frame for first boiler in the cascade Water manifold extension kit for each additional boiler in the cascade Frame extension kit for each additional boiler in the cascade Flange kit Water circuit separator Additional system flow probe Zoning controller (max 2 mixed and a direct one) Outdoor probe Additional probe for handling an eventual DHW tank (5 mts) 041026X0 041028X0 042021X0 042028X0 042031X0 042029X0 042032X0 042033X0 042030X0 043005X0 013013X0 013018X0 043005X0 041019X0 041016X0 042043X0 75 75 80 - - - - - 1 1 1 - - 1 1 1 1 1 1 - - 116 116 125 - - - - - 1 1 1 - - 1 1 1 1 1 1 - - 150 147 80 80 - - 1 2 2 1 1 1 1 1 1 1 1 1 1 x x 191 187,2 125 80 - - 1 2 2 1 1 1 1 1 1 1 1 1 1 x x 225 220,5 80 80 80-1 3 3 1 1 2 2 1 1 1 1 1 1 x x 232 227,4 125 125 - - 1 2 2 1 1 1 1 1 1 1 1 1 1 x x 266 260,7 125 80 80-1 3 3 1 1 2 2 1 1 1 1 1 1 x x 300 294 80 80 80 80 1 4 4 1 1 3 3 1 1 1 1 1 1 x x 307 300,9 125 125 80-1 3 3 1 1 2 2 1 1 1 1 1 1 x x 341 334,2 125 80 80 80 1 4 4 1 1 3 3 1 1 1 1 1 1 x x 348 341,1 125 125 125-1 3 3 1 1 2 2 1 1 1 1 1 1 x x 382 374,4 125 125 80 80 1 4 4 1 1 3 3 1 1 1 1 1 1 x x 423 414,6 125 125 125 80 1 4 4 1 1 3 3 1 1 1 1 1 1 x x 464 454,8 125 125 125 125 1 4 4 1 1 3 3 1 1 1 1 1 1 x x MODULES BASIC ACCESSORIES EVENTUAL ADDITIONAL ACCESSORIES 1 mt MF flue gas manifold extension, ø 200 mm 90 MF bend, ø 200 mm PS: - not possible; x qty according to the flues required installation PS2: * use the same kit type on alla modules: only on-off pump (042021X0) or only modulating one (042043X0) 13
ENERGY TOP B/BK RANGE TECHNICAL DRAWINGS ENERGY TOP B/BK vertical modules are floor-standing heat generators for indoor or outdoor installation, central heating only, featuring a premix burner, condensing operation with very high efficiency and very low polluting emissions. They consequently ensure high energy savings and are environmentally friendly (4 star energy rating according to Directive 92/42 EEC, emission Class 5 as per EN 297/A5). The insulated painted steel cabinet, with reversible door (left-right), can be installed as standard outdoor in completely open places with minumum temperature -10 C, without using additional frost protection kits. Each module is complete with insulated central heating flow and return manifolds - DN 100 - and gas manifold - DN 65. The cascaded connection of more generators can be performed using dedicated flue gas and hydraulic accessories. The appliances are factory configured for operation on natural gas and can be converted to LPG using an appropriate conversion kit. The range features four sizes, two with single heating unit and two with double heating unit. only mod. BK REVERSIBLE CONNECTION RIGHT/LEFT FOR FREE-STANDING WATER TANK MOD. B: HEATING ONLY MOD. BK: HEATING OPERATION WITH CONNECTION TO FREE-STANDING WATER TANKS. > THE RANGE ENERGY TOP B/BK 80 Vertical module, single furnace with heat input from 17 to 75 kw ENERGY TOP B/BK 125 Vertical module, single furnace with heat input from 25 to 116 kw ENERGY TOP B 160 Vertical module, double furnace with heat input from 17 to 150 kw ENERGY TOP B 250 Vertical module, double furnace with heat input from 25 to 232 kw KEY a1 Central heating flow (DN 100) a2 Central heating return (DN 100) a3 Condensate drain ø 40 mm a5 Gas inlet (DN 65) (only for mod. BK) a6 Flow to tank s coil 1 1/2 a7 Return from tank s coil 1 1/2 ENERGY TOP B mod. 160-250 ENERGY TOP B/BK mod. 80-125 ENERGY TOP BK ENERGY TOP B 14