Hoval TopGas 80 User manual

Subject to modi cations | EN
Technical information
Installation instructions
4 213 894 / 01 - 07/15
Hoval products must be installed and commissioned
only by appropriately qualied experts. These instruc-
tions are intended exclusively for the specialist. Elec-
trical installations may only be carried out by a qualied
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 ow
temperatures of up to 85°C.

2
4 213 894 / 01
TABLE OF CONTENTS
1. Important notes....................................................................................................................................... 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 Informationen ......................................................................................................................................................................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 Control of the boiler ..........................................................................................................................................................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
4.2 Boiler installation room.....................................................................................................................................................17
4.2.1 Installing the boiler..........................................................................................................................................................17
4.3 Hydraulic connection ........................................................................................................................................................17
4.3.1 Protection planning guidelines for the hydrau-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 ...................................................................................20
4.4.2 Project planning information for the TopGas®.................................................................................................................20
4.4.3 Natural ventilation flue example ......................................................................................................................................21
4.4.4 Flue gas system for room sealed operation.....................................................................................................................21
4.4.5 Roof heating centre concentric flue (room sealed)...........................................................................................................22
4.4.6 Wall outlet.......................................................................................................................................................................22
4.4.7 Connection of the pipes ..................................................................................................................................................23
4.4.8 Condensate draining and neutralisation ..........................................................................................................................23
4.4.9 Gas connection...............................................................................................................................................................23
4.5 Electrical connection.........................................................................................................................................................23
4.5.1 Regulations for electrical connections .............................................................................................................................24
4.5.2 Electrical connection (mains) 230 V, 50 Hz......................................................................................................................24
4.5.3 Boiler control / electrical connection diagram ..................................................................................................................24
4.5.4 Connection of the heating controller................................................................................................................................24
4.5.4.1 TopTronic®E...................................................................................................................................................................................24
4.5.4.2 TopTronic®E...................................................................................................................................................................................24

3
4 213 894 / 01
TABLE OF CONTENTS
5. Commissioning ..................................................................................................................................... 25
5.1 Setting the control.............................................................................................................................................................25
5.2 Water quality......................................................................................................................................................................25
5.2.1 Heating water..................................................................................................................................................................25
5.2.2 Filling and replacement water .........................................................................................................................................25
5.2.3 Filling up the system .......................................................................................................................................................26
5.3 Gas adjustment..................................................................................................................................................................26
5.3.1 Bleeding the gas pipeline................................................................................................................................................26
5.3.2 Commissioning ...............................................................................................................................................................26
5.3.3 Gas inlet 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
7.5 Emission measurement.....................................................................................................................................................30
8. Faults..................................................................................................................................................... 32
9. Automatic firing unit BIC 335-Parameter list ....................................................................................... 34

4
4 213 894 / 01
IMPORTANT INFORMATION
1. Important notes
The following points must be observed when performing
work on the TopGas®:
!
CAUTION
If you smell ue gas or gas
avoid naked ames 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 fol-
lowing are the minimum conditions requiring fullment:
-Safety valve installed
(closed system)
- Control in operation (connected to the mains current
supply system)
- System lled with water
- Expansion tank connected
- Boiler connected to a ue gas conduit installed in
compliance 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 ow and return).
- If work on the components of the gas condensing boi-
ler which carry water is not performed correctly, the
heating medium may escape and lead to scalding.
- After performing repair and maintenance 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 ow 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 power supply circuits must be
switched off before accessing the terminals.
1.1 On delivery
Carry out a visual inspection immediately on receiving the
boiler. If any damage is found, take the necessary steps
as dened 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 modications
- 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, ad-
hesives, 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 inst-
ructions can be found with the components!
Further sources of information:
- Hoval catalogue
-Standards, regulations

5
4 213 894 / 01
IMPORTANT INFORMATION
1.4 Regulations, official approvals
The following regulations are to be complied with for ins-
tallation and operation, in addition to the recognised rules
of the art:
Germany
• DIN EN 12831 Heating systems in buildings - Methods
for calculating the design heat load
• DIN EN 13384 Flue gas systems - Heat and ow calcu-
lation methods
• DIN EN 12828 Heating systems in buildings - Planning
of hot water heating systems.
• VDI 2035 Prevention of damage through corrosion and
scale formation in hot water heating systems.
• Firing regulation for the Federal regions
• DVGW-TRGI 86-96
• Technical regulations of gas supply enterprises
• VDE 0100 for electrical installations and the TAB (tech-
nical connection conditions of the responsible energy
supplier)
• ATV data sheet M251
• Accident prevention regulations
-VBG 1 General regulations
- VBG 4 Electric systems and equipment
Austria
• OENORM 12831 Heating systems in buildings - Me-
thods for calculating the design heat load
• OENORM 13384 Flue gas systems - Heat and ow cal-
culation methods
• OENORM 12828 Heating systems in buildings - Plan-
ning of hot water heating systems.
• OENORM H5152 Gas condensation for furnace instal-
lations
• OENORM H5195-1 Prevention of damage through cor-
rosion
• M 7443, (Part 2,3,7) Gas appliances with atmospheric
burners
• M 7446, Heat output appliances for gaseous fuels
• M 7457, Heat output appliances with mechanically sup-
ported premix bat-wing burners
• M 7444, Special gas boilers with burners without fan
• M 7459, Gas appliances with gas-air compound cont-
roller
• ÖVGW TR- Gas
• Technical provisions of the gas suppliers
Switzerland
• SN EN 12831 Heating systems in buildings - Methods
for calculating the design heat load
• SN EN 13384 Flue gas systems - Heat and ow 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 Water treatment for heating, steam and air
conditioning systems
• SWKI 80-2 Technical safety regulations for heating sys-
tems
• KRW Corrosion through halogen compounds
• Procal/FKR Plug-in electrical connections on heating
boiler and burner
• Technical tank regulations TTV 1990
• EKAS - Guideline for liquid gas part 2
and further regulations and standards prescribed by the
CEN, CEN ELEC, DIN, VDE, DVGW, TRD and by law.
The regulations of the local building authorities, insu-
rance companies and chimney inspectors must also be
taken into account. The regulations of the responsible
gas supply company are also to be complied with and
any necessary ofcial approval obtained if using gas.
Regulations governing the discharge and
treatment of condensate are subject to the
specications of the local water authorities
and may deviate from waste water guideline
ATVM251. Please contact your water autho
-
rity for details of the applicable local regula
-
tions.
1.5 Transport and storage
Please remove the packing materials and examine the
consignment for correctness, completeness and possible
transport damage.
The appliance is only to be transported and stored only in
its original packing. Interim storage of Hoval gas boilers is
only to take place in weather protected rooms and only in
the original packing. The ambient conditions for storage
must be within the following limits:
- Air temperature: -10°C - +50°C
- Air humidity: 50 - 85% relative humidity
- no condensation

6
4 213 894 / 01
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: 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 lighting symbol warns against the
danger of electrical voltage.
2.3 Informationen
Information:
Provides important information.

7
4 213 894 / 01
TECHNICAL INFORMATION
3. Technical information
3.1 Technical Data
Type (80)
•Nominal heat output 80/60°C with natural gas 1kW 15,8-72,4
•Nominal heat output 40/30 °C with natural gas 1kW 17,3-80,0
•Nominal heat output 80/60 °C propane gas 3kW 19,5-72,4
•Nominal heat output 40/30 °C propane gas3kW 21,6-80,0
•Nominal load with natural gas 1kW 16,5-75,0
•Nominal load with propane gas 3kW 20,0-75,0
•Working pressure heating maximum/minimum. bar 4,0/1,5
•Working temperature maximum °C 85
•Boiler water content l 10
•Minimum water ow l/h 800
•Boiler weight (without water content) kg 107
•Boiler efciency at 30% partial load (in acc. with EN 303)
(related to net/ gross caloric value)
% 107,0/96,4
•Normal degree of efciency (in accordance with DIN 4702 Part 8) 40/30 °C % 109,4/98,6
(related to net/gross caloric value) 75/60 °C % 106,1/95,6
•Standby losses at 70 °C Watt 95
•Norm emission factors
Nitrogen oxide NOx mg/kWh 18
Carbon monoxide CO mg/kWh 27
•CO2 content in ue gas max./min. output % 9,0/8,8
•Dimensions: see table of dimensions
•Connections
Flow/Return Inches Rp 1¼″
Gas Inches R ¾″
Flue gas/combustion air (concentrically) mm C100/150
•Gas ow 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/m3m3/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
•Standby Watt 7
•Protection rating IP 20
•Total sound power level dB(A) 63
•Sound pressure level (depending on installation conditions) 2dB(A) 53
•Condensate quantity (Natural gas) at 40/30 °C l/h 7,1
•pH-value of the condensate ca. 4,2
•Values for calculation of the chimney
Requirement ue gas system, temperature class T 120
Flue gas mass ow rate kg/h 124,5
Flue gas temperature at nominal output and operation at 80/60 °C °C 79
Flue gas temperature at nominal output and operation at 40/30 °C °C 49
Total supply pressure for supply air and ue gas conduit Pa 140
Maximum draught/underpressure at ue gas outlet Pa - 50
1Data related to Hu. The boiler series is tested for EE/H-settings. With a factory setting of the Wobbe coefficient of 15.0 kWH/m3operation at a
Wobbe coefficient of 12.0 up to 15.7 kWh/m3 is possible without new settings.
2See also notes at Engineering
3Data related to Hu

8
4 213 894 / 01
TECHNICAL INFORMATION
3.2 Boiler-flow resistance
0
50
100
150
200
250
300
0.0 1.0 2.0 3.0 4.0 5.0 6.0
m3/h
mbar
Boiler only
Boiler incl.
connection set
Maximum residual overpressure 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 ow
mbar =Flow resistance

9
4 213 894 / 01
TECHNICAL INFORMATION
3.3 Dimensions
Dimensions in mm
• Sideways 50 mm
• Space to ceiling dependent on the ue gas system
• Front 500 mm
Massliste R000459-4
2-TopGas (80) 15.07.2014
01
1 Gas connection R 3/4"
2 Flow Rp 1 1/4"
3 Return Rp 1 1/4"
4 Condensat drain D 32
5 LAS Flue Gas C 100/150
6 Cover control panel
7 Safety valve
8 Ball valve
65
135
216
413
455
10052080
View from botton
265
560
700
565
View from top 5
930
1027010 270
96060
620
1308
60
17
3
61
4
8
7
2
273
g. 01
1Gas connection R ¾″
2Heating ow Rp 1¼″
3Heating return Rp 1¼″
4 Condensate drain DN 32
5LAS ue gas/combustion air connection C 100/150
6 Cover control panel
7Safety valve
8 Ball valve
View from bottom
View from top

10
4 213 894 / 01
TECHNICAL INFORMATION
3.4 Short description of the automatic firing
unit BIC 335
The automatic ring unit operates both without controller
(TTE) and also without room station (RS-OT). The auto-
matic ring unit comprises the following functions
- PWM- fan (230V~)
- Modulating operation
- Inputs for Flow sensor
Return sensor
Flue gas sensor
Gas pressure deector
Air pressure deector:
(not used)
Water pressure deector
Safety temperature limiter:
(external ue gas thermostat)
HW-buffer sensor
Outdoor sensor
Locking entry:
(Burner blocking)
- Status exit „Failure“ (invertible by parameter setting)
- Three-way-valve control for heating/hot water or loa-
ding pump control (230V~exits); Exit for a three-way-
valve / HW loading pump is invertible by a parameter.
- Collective electrode for ignition and ame 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 pump
(230V ~): 10 min
-After-run time three-way valve / HW-loading pump: 2 min
- Restart locking after a heat demand: 2 min
- Restart locking after a temperature blocking: 2 min
Fuses
On the automatic ring unit theres is a mains fuse. The
breakdown of this fuse (2AT) is noticeable by an empty
display even the main deector is on.
Ionisation ow
The value of the ionisation ow is noted on the informati-
on level and appears as step 8. The access to the infor-
mation level is explained in 3.5.