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4 213 893 / 01

TABLE OF CONTENTS

1. 

Important Information ............................................................................................................................. 4

1.1 

On delivery ...........................................................................................................................................................................4

1.2 Guarantee ............................................................................................................................................................................4

1.3 Instructions 

 .........................................................................................................................................................................4

1.4 

Regulations, official approvals ...........................................................................................................................................5

1.5 

Transport and storage .........................................................................................................................................................5

2. 

Safety instructions .................................................................................................................................. 6

2.1 

Warning levels .....................................................................................................................................................................6

2.2 

Warning symbols .................................................................................................................................................................6

2.3 Information ..........................................................................................................................................................................6

3. 

Technical information ............................................................................................................................. 7

3.1 

Technical Data .....................................................................................................................................................................7

3.2 

Boiler-flow resistance .........................................................................................................................................................8

3.3 Dimensions ..........................................................................................................................................................................9

3.4 

Short description of the automatic firing unit BIC 335 ....................................................................................................10

3.5 

Heating system control .....................................................................................................................................................11

3.6 

Adjustable parameters ......................................................................................................................................................13

4. Installation ............................................................................................................................................. 15

4.1 

Description of the Hoval TopGas

®

 .....................................................................................................................................15

4.1.1 

Diaphragm expansion tank ..............................................................................................................................................15

4.1.2 

Boiler casing ...................................................................................................................................................................15

4.1.3 

Gas fittings .....................................................................................................................................................................15

4.1.4 

Automatic gas firing unit and heating controller ...............................................................................................................15

4.1.5 

Heating circulation pump .................................................................................................................................................15

4.1.6 

Hot water supply .............................................................................................................................................................15

4.1.7 

Scope of supply ..............................................................................................................................................................15

4.1.8 TopGas

®

 component designation .....................................................................................................................................16

4.2 

Boiler installation room .....................................................................................................................................................17

4.3 

Installing the boiler............................................................................................................................................................17

4.4 

Hydraulic connection ........................................................................................................................................................17

4.4.1 

Protection planning guidelines for the hy draulic connection .............................................................................................17

4.4.2 

Boil-dry safeguard ...........................................................................................................................................................17

4.4.3 

Gravity brake ..................................................................................................................................................................18

4.4.4 

Minimum flow rate ...........................................................................................................................................................18

4.4.5 

To be provided by customer ............................................................................................................................................18

4.4.6 

Examples of hydraulic interconnection ............................................................................................................................18

4.5 

Flue gas connection, chimney and condensate pipeline .................................................................................................20

4.5.1 

Waste gas pipelines in compliance with building construction law ...................................................................................20

4.5.2 

Project planning information for the TopGas

®

 ..................................................................................................................20

4.5.3 

Installation examples for room-air-dependent operation ..................................................................................................21

4.5.4 

Exhaust gas system for room-air-independent operation .................................................................................................21

4.5.5 

Roof heating centre concentric flue (vertical exhaust gas conduit installation) .................................................................22

4.5.6 

Wall penetration (permitted only in Austria) .....................................................................................................................22

4.5.7 

Connection of the pipes ..................................................................................................................................................23

4.5.8 

Condensate draining and neutralisation ..........................................................................................................................23

4.5.9 

Gas connection ...............................................................................................................................................................23

4.6 

Electrical connection .........................................................................................................................................................23

4.6.1 

Regulations for electrical connections .............................................................................................................................24

4.6.2 

Electrical connection (mains) 230 V, 50 Hz ......................................................................................................................24

4.6.3 

Boiler control / electrical connection diagram ..................................................................................................................24

4.6.4 

Connection of the heating controller ................................................................................................................................24

4.6.4.1 TopTronic

®

 RS-OT ..........................................................................................................................................................................24

4.6.4.2 TopTronic

®

 E ...................................................................................................................................................................................24

Summary of Contents for TopGas 35

Page 1: ...minal output ranges at 40 30 C and with natural gas 41 TopGas 35 6 8 35 0 kW 41 TopGas 45 11 1 45 0 kW 41 TopGas 60 12 8 60 7 kW Wall mounted condensing gas boilers TopGas 35 45 60 in accordance with DIN 4702 DIN EN 483 und 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 continuousl...

Page 2: ...ection 17 4 4 1 Protection planning guidelines for the hy draulic connection 17 4 4 2 Boil dry safeguard 17 4 4 3 Gravity brake 18 4 4 4 Minimum flow rate 18 4 4 5 To be provided by customer 18 4 4 6 Examples of hydraulic interconnection 18 4 5 Flue gas connection chimney and condensate pipeline 20 4 5 1 Waste gas pipelines in compliance with building construction law 20 4 5 2 Project planning inf...

Page 3: ...he gas flow rate CO2 O2 and measurement of NOx CO content in the flue gas flue gas measurement 27 5 5 Changing to a different kind of gas 28 5 6 Handing over to the user 28 5 6 1 Instruction the user 28 5 6 2 Checking the water level 28 5 6 3 Maintenance 28 6 Decommissioning 29 7 Maintenance 29 7 1 Checking the water connections for leakage 29 7 2 Refilling 29 7 3 Maintenance includes 29 7 4 Clean...

Page 4: ... 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 WARNING The heat generator can only be de energised by disconnection from the mains e g all pole switch WARNING All electric p...

Page 5: ... Heating systems in buildings Methods for calculating the design heat load SN EN 13384 Flue gas systems Heat and flow calculation methods SN EN 12828 Heating systems in buildings Planning of hot water heating systems Requirements of the VKF Cantonal Fire Insurance Association Fire service regulations SVGW directives gas guiding standard G1 SNV271020 Aeration and ventilation of the boiler installat...

Page 6: ...ible 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 dangerous electrical voltage as a warning for accident prevention Ensures that people do not come into contact with electrical voltage The danger sign with the black lig...

Page 7: ...5 C80 125 Gas flow pressure min max Natural gas E LL mbar 18 50 18 50 18 50 Liquid gas mbar 37 50 37 50 37 50 Gas connection value at 0 C 1013 mbar Natural gas E Wo 15 0 kWh m3 Hu 9 97 kWh m3 m3 h 3 3 4 3 5 8 Natural gas LL Wo 12 4 kWh m3 Hu 8 57 kWh m3 m3 h 3 9 5 0 6 7 Propane gas 3 Hu 25 9 kWh m3 m3 h 1 27 1 64 2 21 Operation voltage V Hz 230 50 230 50 230 50 Control voltage V Hz 24 50 24 50 24 ...

Page 8: ...400 350 300 250 200 150 100 50 0 0 0 0 5 1 0 1 5 2 0 2 5 3 0 3 5 4 0 4 5 5 0 5 5 m3 h Maximum residual overpressure TopGas 35 60 with connection set AS32 TG UPM2 32 60 Maximum residual overpressure TopGas 35 60 with connection set AS32 TG UPM GEO 32 85 TopGas 30 60 mit AS32 TG UPM GEO 32 85 0 100 200 300 400 500 600 700 800 900 0 0 1 0 2 0 3 0 4 0 5 0 mbar m3 h mbar TopGas 30 60 mit AS32 TG UPM2 3...

Page 9: ...depending on exhaust flue system used Front 500 mm Ansicht von oben Ansicht von unten View from bottom View from top Fig 01 1 Gas connection R 2 Heating flow Rp 1 3 Heating return Rp 1 4 Condensate drain Ø 32 5 LAS flue gas combustion air connection DN 80 125 6 Automatic deaeration 7 Boiler control cover 8 Safety valve 9 KFE ball valve ...

Page 10: ...it for a three way valve HW loading pump is invertible by a parameter Collective electrode for ignition and flame guide Ionisa tion Main gas valve ev LPG valve heating room ventila tion accessable Interface to display OpenTherm interface RS OT TTE RS 232 interface to PC Start attempts 4 Safety period 5 sek Ignition period 5 sek Pre ventilation period 20 sek After run time main pump heating pump 23...

Page 11: ...ode indication Parameter Indication Value indication Meaning Description Standby Mode Normal position Start position current flow temperature no indication 0 Standby no heat demand waiting time main gasvalve 1 Rinsing 2 Ignition 3 Burner on in heating operation 4 Burner on in hot water operation 5 Air pressure deflector defectiv no air pressure deflector in use 6 Burner off in heating operation fl...

Page 12: ...n Mode indication Parameter Indication Value indication Meaning Description Informations Mode It is possible to read monetary values from here 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 water heater 3 e g 3 Current outdoor temerature 4 e g 55 Current flue gas temperature 5 e g 50 Flow set value i...

Page 13: ... the value set using parameter 21 2BK then the system targets the minimum heating temperature set using this parameter If the outside temperature exceeds the parameter value the heating demand is cancelled Parameter 21 2BK Maximum outside temperature If the outside temperature exceeds the values set using this parameter the heating demand is cancelled At the point where the parameter value is reac...

Page 14: ...8 7 8 is getting active in the WW mode Parameter 63 2GH Pump minimum PWM value This parameter is used to determine the minimum permit ted capacity of the PWM pump in The minimum PWM value is effective when the boiler output is at a minimum Parameter 64 2GI Pump maximum PWM value This parameter is used to determine the maximum per mitted capacity of the PWM pump in The maximum PWM value is effectiv...

Page 15: ...tem 4 1 1 Diaphragm expansion tank Depending on the hydraulic situation of the system an ad equately dimensioned diaphragm expansion tank with an inlet pressure of at least 0 3 bar above the static pressure must be installed by the customer 4 1 2 Boiler casing This is of sheet steel with a white powder paint finish with easily removable front 4 1 3 Gas fittings Honeywell VK4125V gas controller for...

Page 16: ... air inlet 4 Water pressure deflector 5 Flue gas temperature sensor 6 Flow temperature sensor 7 Return temperature sensor 8 Ignition ionisation electrode 9 Heat exchanger 10 Gas fitting 11 Gas pressure deflector 12 ON OFF deflector 13 Automatic firing unit control panel 14 TTE control panel optional 15 Manometer 13 12 14 15 Fig 03 ...

Page 17: ... flexible op eration room temperature control or weather supported boiler and heating control temperature limiting For suitable hydraulic connections please note the in structions in the Hoval project planning documentation NOTICE 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 4 ...

Page 18: ...height 4 4 6 Examples of hydraulic interconnection Gas boiler with Free standing calorifier 1 direct circuit Hydraulic schematic BDDE020 Fig 04 RS OT Room station OpenTherm B1 Flow temperature monitor if required BA Outdoor sensor BW Calorifier sensor Y7 Switching valve SLP Solar circuit pump M5 Boiler circuit pump The example schematics merely show the basic prin ciple and do not contain all info...

Page 19: ...ion Verbindungshinweise Notice Nota Remarque 4 1 24 03 2015 30 Name WG P TopGas 35 VF1 YK1 YK2 MK1 T T DKP T T SLP T T MK2 T T B1 2 VF2 B1 1 Option Opzione P M 5 TTE WEZ SF T TTE HK WW AF RBM TTE GW Fig 05 TTE WEZ TopTronic E basic module heat generator installed VF1 Flow temperature sensor 1 B1 1 Flow temperature monitor if required MK1 Pump mixer circuit 1 YK1 Actuator mixer 1 AF Outdoor sensor ...

Page 20: ... pipeline Only flue gas systems ap proved and tested by the relevant region or province are to be connected to the Hoval TopGas 35 45 60 the ad missions of individual federal states should be complied with in Austria The suppliers of the flue gas pipelines supply suitable boiler connectors for the transition from the boiler to the flue gas pipeline The flue gas connector on the Hoval TopGas 35 45 ...

Page 21: ...k einzusetzen Verbrennungsluft TopGas If necessary an inspection T piece has to be inserted Combustion air Fig 06 4 5 4 Exhaust gas system for room air independent operation TopGas Falls erforderlich ist ein Inspektions T Stück einzusetzen Verbrennungsluft If necessary an inspection T piece has to be inserted Combustion air Fig 07 ...

Page 22: ...e vertical exhaust gas conduit installation TopGas Falls erforderlich ist ein Inspektions T Stück einzusetzen Verbrennungsluft If necessary an inspection T piece has to be inserted Combustion air Fig 08 4 5 6 Wall penetration permitted only in Austria TopGas Fig 09 ...

Page 23: ...ant national regulations SVGW directives ÖVGW directives DVGW TRGI 86 96 DIN 4750 as well as local regulations of gas supply en terprises should be observed A manually operated shut off device gas shut off cock in accordance with the local regulations is to be installed directly before the boiler Please ask your local gas supply authority whether it is necessary for an approved gas filter to be in...

Page 24: ...socket is to be installed directly adjacent to the boiler maximum 1 m from the edge of the casing The fusing is to be selected so that the limits detailed in the Technical Data are never exceeded Non compliance with this regulation can have serious consequences for the controller in the event of a short circuit When working on the gas boiler the appliance is to be dis con nected from the electrica...

Page 25: ...ter should lie between 8 0 and 8 5 after 6 12 weeks of heating operation 5 3 Filling and replacement water For a plant using Hoval boilers untreated drink ing wa ter is generally best suited as fil ling and replacement water However the qual ity of the untreated drinking water must at least fulfil the standard set in VDI 2035 or be desalinat ed and or be treat ed with inhibitors The stipulations o...

Page 26: ...imum system pressure at the boiler Type TopGas 35 45 60 Minimum system pressure at the boiler 1 5 bar The unit needs to be filled up slowly at the fill up and drain cock on the boiler while the radiators are open NOTICE System corrosion and bleeding problems are often caused by refilling or topping up Drain trap at the condensate drain must be filled with water 5 4 Gas adjustment Compliance with t...

Page 27: ...as side and electrically To get into the service mode press the MODE and keys Indication on the display during service mode The current level shows SEr on the display after entering into this mode an efficiency of 50 is achieved The efficiency can be changed between 0 and 100 with the and keys exit of this mode Press the Reset key or automatically after 20 minutes Adjust the boiler to 100 with the...

Page 28: ...uid gas Wire up the gas pressure deflector AMP connector at position 1 and 3 D Affix the yellow sticker change to the set gas type Liquid gas to the boiler rating plate E with boiler already connected open the gas valve place the system deflector to I F Set the CO2 O2 content according to chapter 5 4 5 at rat ed and minimum output to CO2 9 9 10 2 O2 5 9 5 5 Vol dry 5 6 Handing over to the user 5 6...

Page 29: ...ter to cool bleed the filling hose and refill via the filling and draining cock 7 3 Maintenance includes Cleaning the flue gas heat exchanger and condensate collector Checking the burner Checking the ignition electrode distance from burner ap prox 4 5 mm set position correctly where necessary or replace Flue gas measuring according to chapter 5 4 5 7 4 Cleaning the heat exchanger Disconnect the bo...

Page 30: ... Complete the test record sheet 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 alter nates 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 be tween 0 and 100 using the ...

Page 31: ...n 40 C so a blocking of the boiler oc curs A hysteresis of 10K needs to be extended before the blocking Flow rate control is cancelled This control is both valid for heating and hot water operation P 30 Temperature difference flow return too large As soon as the difference between flow and return tem perature is higher than the value of the parameter 59 plus 15K a blocking occurs The range between...

Page 32: ...parameters with SITlab is occured The progress needs to be repeated E 15 Internal fault in the automatic firing unit E 16 Internal fault in the automatic firing unit E 17 Flow Return 45K for 10 seconds If the difference between the flow temperature and return temperature is higher than 45K for more than 10 seconds during a heating demand a locking is occurred E 18 Safety boundry thermostat STB is ...

Page 33: ...7 16 P2BF maximum gradient for flow temperature minimum capacity 1 C s OEM 3 17 P2BG continuous pump operation in heating operation mode OEM 0 18 P2BH max heating temperature at min outside temperature 1 C BE 85 19 P2BI minimum outside temperature 1 C HF 10 20 P2BJ min heating temperature at max outside temperature 1 C HF 20 21 P2BK maximum outside temperature 1 C HF 20 22 P2BL restart delay follo...

Page 34: ...0 P2FE interval 3 1s OEM 30 51 P2FF maximum output during interval 3 1 OEM 52 52 P2FG interval 4 1s OEM 30 53 P2FH maximum output during interval 4 1 OEM 68 54 P2FI interval 5 1s OEM 30 55 P2FJ maximum output during interval 5 1 OEM 83 Further settings 56 P2GA malfunction relay functionality configuration 0 open 1 closed OEM 1 57 P2GB line voltage selection 0 L L 1 L N OEM 1 58 P2GC flue gas tempe...

Page 35: ...35 4 213 893 01 ...

Page 36: ...Type Serial number Year of manufacture Place Date System installer System user Confirmation The user owner of the system herewith confirms that he has received adequate instruction in the operating and maintenance of the installation received and taken note of the operating and maintenance instructions and where applicable other documents con cerning the heat generator and any further components an...

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