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4 213 893 / 01

MONTAGE

4.5

Flue gas connection, chimney

and condensate pipeline

NOTICE

The condensate from the exhaust gas sys-

tem must not be discharged through the boil-

er. The condensate must be discharged from

the exhaust pipe before the boiler through a

siphon.

Due to water vapour content of the flue gases with low

temperature and the resulting further condensation in the

flue, heat output boilers cannot be connected to standard

house flues.

The applicable local authority regulations and the special

regulations in the DVGW-(TRGI), ÖVGW and SVGW di

rectives are to be complied with for flue gas removal.

In accordance with the VKF-guidelines (edition 1993,

number 3.4.8) for Switzerland a flue gas temperature lim

iting device according to the above mentioned directive

must be installed in the flue gas pipeline.

There are two possibilities of flue gas removal with heat

output gas boilers:

a) The use of specially approved flue gas pipelines,

b) Use of damp-insensitive flues, approved for flue gas

temperatures starting from 40 °C, connected to the

heat output boiler in the boiler installation room via ap-

proved flue gas pipelines.

In both cases the cross sections and maximum lengths

based on the values for flue gas flow rate, flue gas tem

perature and flow pressure available at the flue gas con

nector are to be calculated according to the table on

chap ter 3.1 (DIN 4705).

The calculation is normally made by means of graphs

or tables provided by the manufacturer of the moisture-

resistant flue of the special flue gas pipeline. Often this

manufacturer performs the calculation using a computer

program specially created for the model in question.

In any case, we recommend a discussion with the re

sponsible local chimney sweeping supervisor prior to the

planning and execution of the flue gas extraction with

heat output gas boilers.

4.5.1 Waste gas pipelines in compliance

with building construction law

The flue gases from the Hoval TopGas

(35,45,60) can

be removed via a gas-tight, temperature and corrosion

resistant flue gas 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

(35,45,60) has a concentric flue

gas connection ø 80/125 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

The planning and installation instructions of the manufac-

turer together with the building construction regulations

are to be observed in the planning and execution of the

flue gas pipeline. A timely discussion with the responsible

local chimney sweeping supervisor is recommended.

Your Hoval agent can supply a suitable and approved flue

gas system for your TopGas

Please take note of the technical information supplied

with your flue gas pipeline.

4.5.2 Project planning information for the TopGas

•

All applicable regional, national and state regulations

are to be observed with respect to the flue gas extrac

tion system.

•

All air inlet/flue gas pipelines must have a measuring

orifice (already incorporated in the moduel kits). These

are to be positioned where they can be easily accessed

for measuring purposes.

• The concentric length elements cannot simply be short-

ened. Length adjustment pieces or cut to length pieces

are to be used for adjusting to the required lengths.

•

Single flue gas pipes can be shortened to the neces

sary length but must however be cleanly deburred be-

fore the assembly, to prevent damage to the seal in the

counter-piece.

•

When installing the pipes in a shaft, spacer elements

must be mounted every 2 m. For the vertical supporting

of the chimney pipeline, the very bottom element must

be permanently fixed (mounting rail or pipe clip).

• Horizontal connections must have a gradient of at least

5 cm per running metre in the direction of the boiler,

to permit unobstructed flow of the condensate to the

boiler. The complete flue gas system must be installed

to prevent the accumulation of condensate.

Содержание TopGas 35

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 35: ...35 4 213 893 01 ...

Страница 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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