Hoval TopGas 80 Installation Instructions Manual Download Page 1

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Subject to modifi cations |

Technical information

Installation instructions

4 213 894 / 01 - 07/15

Hoval products must be installed and commissioned

only by appropriately qualified experts. These instruc

tions are intended exclusively for the

specialist

. Elec

trical installations may only be carried out by a qualified

electrician.

These instructions apply to the following ty

pes:

41-TopGas

(80)

17,3 - 80,0 kW

TopGas

(80)

Gas condensing boiler

for natural and liquid gas

TopGas

(80) wall-hung gas condensing boilers in ac-

cordance 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.

Summary of Contents for TopGas 80

Page 1: ...list Elec trical installations may only be carried out by a qualified electrician These instructions apply to the following ty pes 41 TopGas 80 17 3 80 0 kW TopGas 80 Gas condensing boiler for natural and liquid gas TopGas 80 wall hung gas condensing boilers in ac cordance with DIN 4702 DIN EN 483 and DIN EN 677 are designed and approved for use as heat generators for hot water heating systems wit...

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

Page 3: ...pressure 26 5 3 4 Gas fitting 26 5 3 5 Setting the gas flow rate 27 5 4 Changing to a different kind of gas 28 5 5 Handing over to the user 28 5 5 1 Instruction the user 28 5 5 2 Checking the water level 28 5 5 3 Maintenance 28 6 Decommissioning 29 7 Maintenance 30 7 1 Checking the water connections for leakage 30 7 2 Maintenance includes 30 7 3 Cleaning the heat exchanger 30 7 4 Function check 30...

Page 4: ...tenance work reat tach 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 hea ting 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 po le switch WARNING All electric pow...

Page 5: ...ings Methods for calculating the design heat load SN EN 13384 Flue gas systems Heat and flow calcu lation methods SN EN 12828 Heating systems in buildings Planning of hot water heating systems Requirements of the VKF Cantonal Fire Insurance As sociation Fire service regulations SVGW directives gas guiding standard G1 SNV271020 Aeration and ventilation of the boiler ins tallation room SWKI 88 4 Wat...

Page 6: ...ble 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 ligh...

Page 7: ...Flue gas combustion air concentrically mm C100 150 Gas flow pressure minimum maximum Natural gas E LL mbar 18 50 Propane gas LPG mbar 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 1 65 7 5 Propane gas 3 Hu 25 9 kWh m3 m3 h 0 77 2 90 Operation voltage V Hz 230 50 Control voltage V Hz 24 50 Minimum maximum electrical power consumption Watt 23 130 Standb...

Page 8: ...essure TopGas 80 with connection set AS32 TG UPM2 32 60 m3 h mbar 0 100 200 300 400 500 600 700 0 0 1 0 2 0 3 0 4 0 5 0 6 0 TopGas 80 mit AS32 und UPM2 32 60 Maximum residual overpressure TopGas 80 with connection set 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 6 0 TopGas 80 mit AS32 und UPM GEO 32 85 m3 h mbar m3 h Volume flow mbar Flow resistance ...

Page 9: ...sat d 5 LAS Flue Ga 6 Cover contro 7 Safety valve 8 Ball valve 6 5 1 3 5 216 413 4 5 5 100 520 80 View from botton 2 6 5 560 700 5 6 5 View from top 5 9 3 0 10 270 10 270 9 6 0 6 0 620 1 3 0 8 6 0 1 7 3 6 1 4 8 7 2 2 7 3 fig 01 1 Gas connection R 2 Heating ﬂow Rp 1 3 Heating return Rp 1 4 Condensate drain DN 32 5 LAS flue gas combustion air connection C 100 150 6 Cover control panel 7 Safety valve...

Page 10: ...s Exit for a three way valve HW loading pump is invertible by a parameter Collective electrode for ignition and flame guide Ioni sation Main gas valve ev LPG valve heating room venti lation 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 pum...

Page 11: ...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 flow Temp flow temp set point blockage Offset ZH 7 Pump after run time in heating operation 8 Pump after run time in hot water operation 9 Burner off on hot water operation flow Temp flow temp set...

Page 12: ...ed in hundreds 8 e g 4 µ A Ionisation flow Parameter Mode Settings can be changed in this mode Point appears P 7 60 Hot water set value if threre is no TopTronic attached Procedure P 18 80 Max Flow temperature during heating operation 1 Select parameter Mode press Mode key 2 x Parameter P 7 and setting appear alternate Par 18 Further parameters only with service code 2 Select parameter to be chan ...

Page 13: ...his parameter the heating demand is cancelled At the point where the parameter value is reached the system targets the minimum heating temperature which has been set using parameter 20 2BJ Parameter 22 2BL Restart delay following temperature blocking in heating operation mode When the boiler is shut down on account of a temperature limit being exceeded i e a set point plus offset the boiler restar...

Page 14: ...ximum per mitted capacity of the PWM pump in The maximum PWM value is effective when the boiler output is at a ma ximum The pump rpm speed increases linearly between minimum and maximum boiler output Parameter 65 2GJ Three way valve inversion This parameter can be used to invert the outlet for the three way valve wiring ...

Page 15: ...system 4 1 1 Diaphragm expansion tank Depending on the hydraulic situation of the system an adequately dimensioned diaphragm expansion tank with an inlet pressure of at least 0 3 bar above the static pres sure 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 ...

Page 16: ...r 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: ...le operation room temperature control or weather supported boiler and heating control temperature limiting For suitable hydraulic connections please note the inst ructions in the Hoval project planning documentation 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 4 3 1 Protec...

Page 18: ...height 4 3 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: ... Datei Version Blatt Hydr Verbindungshinweise Notice Nota Remarque 1 4 1 24 03 2015 BDDE030 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 Actuat...

Page 20: ... pipeline Only flue gas systems approved and tested by the relevant region or province are to be connected to the Hoval TopGas 80 the admissions of individual federal states should be complied with in Aus tria The suppliers of the flue gas pipelines supply sui table boiler connectors for the transition from the boiler to the flue gas pipeline The flue gas connector on the Hoval TopGas 80 has a con...

Page 21: ...n inspection T piece is to attach combustion air fig 06 4 4 4 Flue gas system for room sealed operation DO O V HU IRU G HU O L FK L VW HL Q Q VSHN W L RQ VŁ 7Ł 6WFN HL Q XVHW HQ 9HU EU HQ Q XQ JV Ł O XIW 7RS DV fig 07 NOTE The condensate from the exhaust gas sys tem must not be discharged through the boi ler The condensate must be discharged from the exhaust pipe before the boiler through a siphon...

Page 22: ...ns T Stück einzusetzen Verbrennungsluft if necessary an inspection T piece is to attach combustion air fig 08 4 4 6 Wall outlet TopGas fig 09 NOTE The condensate from the exhaust gas sys tem must not be discharged through the boi ler The condensate must be discharged from the exhaust pipe before the boiler through a siphon ...

Page 23: ...relevant national regulations SVGW directives ÖVGW directives DVGW TRGI 86 96 DIN 4750 as well as local regulations of gas supply enterprises 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 b...

Page 24: ... be installed directly adjacent to the boiler maximum 1m 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 disconnected from the electrical supply The ap...

Page 25: ...rally 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 desalina ted and or be treat ed with inhibitors The stipulations of EN 14868 must be observed In order to maintain a high level of boiler effi ciency and to avoid overheating of the heati ng surfaces the values given in the table 1 should ...

Page 26: ...n and bleeding problems are often caused by refilling or topping up Drain trap at the condensate drain must be filled with water 5 3 Gas adjustment Compliance with the maximum permissible li mit values for CO and NOx must be verified through measurement at the installation location 5 3 1 Bleeding the gas pipeline Open the gas shut off value and bleed the air from the pipeline up to the gas fitting...

Page 27: ... 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 key Check the CO2 O2 content of the flue gas It has to be between CO2 8 5 8 8 O2 5 9 5 5 Vol dry Correct this value if necessary by turning the chocke bolt C of the Venturi 5 3 4 Next c...

Page 28: ...an speed of rotation according to the list of parameters Adaptation for Liquid Gas Parameters 35 41 H Set the CO2 O2 content according to 4 3 5 at rat ed and minimum output to CO2 9 9 10 2 O2 5 9 5 5 Vol dry 5 5 Handing over to the user 5 5 1 Instruction the user Obtain from the user a written confirmation that he has received adequate instruction in the correct operating and maintenance of the sy...

Page 29: ...on for several weeks Clean the boiler heating surfaces and have your boiler servicing agent apply a conservation agent Your chim ney sweep technician will eagerly consult you Where there is a frost hazard drain your system in ac cordance with the instructions of your heating installer or add frost according to the instructions of the heating installer ...

Page 30: ...Unscrew the threaded of the supply pipeline to the gas solenoid valve fig 15 Remove fan Detach the screw mounted burner plate fig 15 Remove the burner plate and bat wing burners fig 16 und fig 18 Wet clean the heat exchanger do not use steel wire brushes fig 17 The inspection opening must be closed during wet cleaning Clean the condensate drain After cleaning assemble in reverse order The entire g...

Page 31: ... screw connection Bolting burner plate Burner plate Mounting opening Plug connections fig 15 fig 16 fig 17 fig 18 Fan must be remove first fig 16 The cleaning cover below is for visual control only and must be closed during cleaning process Bfig 17 ...

Page 32: ... more than 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 rang...

Page 33: ...ng of the 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 sec 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 S...

Page 34: ...M 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 fol...

Page 35: ...rval 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 temperature bloc...

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Page 38: ...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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