Hoval TopGas 30 Manual

EN
Subject to modifications
Hoval products must be installed and commis-
sioned only by appropriately qualified experts.
These instructions are intended exclusively for
the specialist. Electrical installations may only
be carried out by a qualified electrician.
Technical information
Installation instructions
4 205 254 / 03 - 05/10
Gas condensing boiler
TopGas®(30,35,45,50,60)
for natural and liquid gas
Wall-mounted gas boilers TopGas®(30,35,45,
50,60) according to DIN 4702, DIN EN 483 and
DIN EN 677 are suitable and approved as heat
producers for hot water heating systems with
a permissible flow temperature of up to 85°C).
They are designed for a flexibly reduced opera-
tion in heating systems according.
Rated output levels at 40/30°C and
natural gas
5/6-TopGas®(30) 6,8 - 30,1 kW
5/6-TopGas®(35) 6,8 - 35,0 kW
5/6-TopGas®(45) 11,1 - 45,0 kW
5/6-TopGas®(50) 12,8 - 52,9 kW
5/6-TopGas®(60) 12,8 - 60,7 kW

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4 205 254 / 03
Table of contents
1. Important Information.......................................................................................................... 4
1.1 Symbols ................................................................................................................................................... 4
1.2 Guarantee ................................................................................................................................................ 4
1.3 Other instructions ................................................................................................................................... 4
1.4 Safety instructions.................................................................................................................................. 4
1.5 Regulations, official approvals .............................................................................................................. 5
1.6 Transport and storage ............................................................................................................................5
2. Technical details .................................................................................................................. 6
2.1 Technical Data......................................................................................................................................... 6
2.2 Dimensions.............................................................................................................................................. 7
2.3 Boiler flow resistance.............................................................................................................................8
2.4 Short description of the automatic firing unit BIC 335........................................................................ 8
2.5 Control of the boiler................................................................................................................................ 9
2.6 Adjustable parameters ......................................................................................................................... 11
3. Installation .......................................................................................................................... 13
3.1 Description of the Hoval TopGas®....................................................................................................... 13
3.1.1 Diaphragm expansion tank...................................................................................................................... 13
3.1.2 Boiler casing............................................................................................................................................ 13
3.1.3 Gas fittings .............................................................................................................................................. 13
3.1.4 Automatic gas firing unit and heating controller ...................................................................................... 13
3.1.5 Heating circulation pump......................................................................................................................... 13
3.1.6 Hot water supply ..................................................................................................................................... 13
3.1.7 Scope of supply....................................................................................................................................... 13
3.1.8 TopGas®component designation ............................................................................................................ 14
3.2 Boiler installation room........................................................................................................................ 15
3.3 Installing the boiler ............................................................................................................................... 15
3.4 Hydraulic connection............................................................................................................................ 15
3.4.1 Protection planning guidelines for the hydraulic connection ................................................................... 15
3.4.2 Boil-dry safeguard................................................................................................................................... 15
3.4.3 Gravity brake........................................................................................................................................... 15
3.4.4 Minimum flow rate ................................................................................................................................... 15
3.4.5 To be provided by customer .................................................................................................................... 16
3.4.6 Hydraulic interconnection........................................................................................................................ 16
3.5 Flue gas connection, chimney and condensate pipeline.................................................................. 17
3.5.1 Waste gas pipelines in compliance with building construction law.......................................................... 17
3.5.2 Project planning guidelines for exhaust gas systems.............................................................................. 17
3.5.3 Installation examples for room-air-dependent operation......................................................................... 18
3.5.4 Exhaust gas system for room-air-independent operation........................................................................ 19
3.5.5 Attic heating center ................................................................................................................................. 19
3.5.6 Wall penetration ...................................................................................................................................... 19
3.5.7 Connection of pipelines........................................................................................................................... 20
3.5.8 Condensate draining and neutralisation.................................................................................................. 20
3.5.9 Gas connection ....................................................................................................................................... 20
3.6 Electrical connection ............................................................................................................................ 20
3.6.1 Electrical connection regulations............................................................................................................. 20
3.6.2 Electrical connection (grid) 230 V, 50 Hz................................................................................................. 21
3.6.3 Boiler control / electrical connection diagram.......................................................................................... 21
3.6.4 Connection of the heating controller ....................................................................................................... 21
3.6.4.1 TopTronic® RS-OT ......................................................................................................................................................21
3.6.4.2 TopTronic®T/N ...........................................................................................................................................................21

3
4 205 254 / 03 Table of contents
4. Commissioning .................................................................................................................. 21
4.1 Setting the control ................................................................................................................................ 21
4.2 Water quality.......................................................................................................................................... 21
4.2.1 Heating water .......................................................................................................................................... 21
4.3 Filling and replacement water.............................................................................................................. 22
4.3.1 Filling up the system ............................................................................................................................... 23
4.3.2 Gas adjustment ....................................................................................................................................... 23
4.3.3 Bleeding the gas pipeline........................................................................................................................23
4.3.4 Commissioning........................................................................................................................................ 23
4.3.5 Gas inlet pressure................................................................................................................................... 23
4.3.6 Gas fitting ................................................................................................................................................ 23
4.3.7 Setting the gas flow rate CO2(O2) and measurement of NOx/CO content in the flue gas (flue gas
measurement)......................................................................................................................................... 23
4.3.8 Changing to a different kind of gas ......................................................................................................... 24
4.4 Handing over to the user...................................................................................................................... 25
4.4.1 Instruction the user ................................................................................................................................. 25
4.4.2 Checking the water level ......................................................................................................................... 25
4.4.3 Maintenance............................................................................................................................................ 25
5. Decommissioning .............................................................................................................. 25
6. Maintenance ....................................................................................................................... 26
6.1 Water-side leak check........................................................................................................................... 26
6.2 Refilling.................................................................................................................................................. 26
6.3 Maintenance includes:.......................................................................................................................... 26
6.4 Cleaning the heat exchanger ............................................................................................................... 26
6.5 Function check...................................................................................................................................... 26
7. Troubleshooting ................................................................................................................. 28
8. Parameter List Automatic Burner BIC 335....................................................................... 31

4
4 205 254 / 03Important information
Important Information1.
Symbols1.1
Safety information
(Instructions for the safety and protec-
tion of persons)
Warning information
(Instructions for the protection of the
heating system)
Bold type = Important information
Guarantee1.2
Important Note
Proper functioning is only guaranteed if the
operating instructions are observed and the
boiler is regularly maintained according to the
DVGW (German association of gas and water
management / ÖVGW (Austrian association
of gas and water management), respectively
SVGW (Switzerland association of gas and
water management) directives by an approved
specialist. Troubleshooting and damage repair
caused by contaminated operating media (gas,
water, combustion air), unsuitable chemical ad-
ditives to the heating water, incorrect handling,
faulty installation, inadmissible modifications
and damage due to the exercising of force are
not covered by our warranty; the same applies
to corrosion through halogen compounds, e.g.
from spray cans, paints, adhesives, solvents
and cleaning agents.
Hoval gas boilers are only to be installed by ap-
proved specialists. No modifications are to be
made to the boilers.
Other instructions1.3
Depending on the model, any further instructions are
enclosed with the individually packed components.
- Adjustment
- Accessories
Further information sources
- Hoval catalogue
- Standards, regulations
Safety instructions1.4
When working on the TopGas®the following points
need to be noted:
If you smell flue gas or gas:
no open fire or sparks,-
do not smoke,-
deflector off the heating system,-
close the gas cock,-
open doors and windows-
The system may only be placed in operation when•
all relevant standards and safety regulations have
been complied with. However, for a trial operation,
at least the following conditions must be satisfied:
- Safety valve installed (closed system)
- Control operative (connected to power supply)
- System filled with water
- Expansion tank connected
- Boiler is connected to the regulation type flue gas
pipeline
- Burner is preset
With maintenance and repair•
- Allow the gas boiler to cool.
- Deflector off the gas boiler and disconnect from
the electrical supply.
- Shut off the gas cock.
- Close the shut-off cocks of the appliance (cold
water, heating flow and return).
- Inappropriate actions on water-carrying parts of
the gas boiler can result in an outflow of hot water
and cause severe burns.
- Replace all removed covers and cladding on
completion of the repair / maintenance work.
- Do not exceed the maximum operating pressure
and temperature of the gas boiler (see identifica-
tion plate).
- Open the appliance cocks (cold water, heating
flow and return).
- Open the gas cock.

5
4 205 254 / 03 Important information
and further standards and regulations issued by
CEN, CEN ELEC, DIN, VDE, DVGW, TRD and by
the legislator.
Also to be complied with are the regulations of the
local building authorities, insurance companies and
chimney sweeping operations. When using gas as
a fuel, the regulations of the responsible gas supply
company are also to be complied with and any neces-
sary official approval obtained.
The regulations concerning condensate pipe-
lines and treatment are subject to the regula-
tions of the local water authorities and can
differ from the provisions of the technical
drainage directive ATVM251. Please obtain in-
formation on the relevant local regulations.
Transport and storage1.6
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
Regulations, official approvals1.5
The following regulations are to be complied with for
installationandoperation,in addition to therecognised
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 flow•
calculation methods
DIN EN 12828 Heating systems in buildings - Plan-•
ning 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•
(technical connection conditions of the responsi-
ble 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 -•
Methods for calculating the design heat load
OENORM 13384 Flue gas systems - Heat and•
flow calculation methods
OENORM 12828 Heating systems in buildings -•
Planning of hot water heating systems.
OENORM H5152 Calorific value burner systems.•
OENORM H5195-1 Prevention of damage through•
corrosion
M 7443, (Part 2,3,7) Gas appliances with atmos-•
pheric burners
M 7446, Heat output appliances for gaseous fuels•
M 7457, Heat output appliances with mechanically•
supported premix bat-wing burners
M 7444, Special gas boilers with burners without•
fan
M 7459, Gas appliances with gas-air compound•
controller
ÖVGW TR- Gas•
Technical provisions of the gas suppliers•
Switzerland
SN EN 12831 Heating systems in buildings - Meth-•
ods for calculating the design heat load
SN EN 13384 Flue gas systems - Heat and flow•
calculation methods
SN EN 12828 Heating systems in buildings - Plan-•
ning 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•
installation room
SWKI 88-4 Water treatment for heating, steam and•
air conditioning systems
SWKI 80-2 Technical safety regulations for heating•
systems
KRW Corrosion through halogen compounds•
Procal/FKR Plug-in electrical connections on heat-•
ing boiler and burner
Technical tank regulations TTV 1990•
EKAS - Guideline for liquid gas part 2•

6
4 205 254 / 03
Technical details
Technical details2.
Technical Data2.1
Typ (30) (35) (45) (50) (60)
•Rated heating capacity 80/60°C with natural ga 1kW 6,0-27,4 6,0-31,8 10,0-41,0 11,7-48,3 11,7-55,3
•Rated heating capacity 40/30°C with natural gas 1kW 6,8-30,1 6,8-35,0 11,1-45,0 12,8-52,9 12,8-60,7
•Rated heating capacity 80/60°C with propane gas 3kW 6,2-27,4 6,2-31,9 10,8-41,0 13,1-47,8 13,1-54,9
•Rated heating capacity 40/30°C with propane gas3kW 7,0-30,2 7,0-35,2 11,9-45,0 14,1-52,5 14,1-60,3
•Rated thermal loading with natural gas 1kW 6,4-28,3 6,4-33,0 10,6-42,5 12,2-49,9 12,2-57,3
•Rated thermal loading with propane gas 3kW 6,6-28,5 6,6-33,2 11,4-42,5 13,6-49,6 13,6-56,9
•Operating pressure, heating max./min. bar 3,0 / 1,0 3,0 / 1,0 3,0 / 1,0 3,0 / 1,0 3,0 / 1,0
•Operating temperature max. °C 85 85 85 85 85
•Boiler water contents l 4,5 4,5 4,5 6,0 6,0
•Minimum water circulation quantity l/h 300 300 350 470 470
•Boiler weight (without water content, incl. body) kg 83 83 83 89 89
•Standard level of utilization 40/30°C % 109,8 109,7 109,3 109,7 109,5
75/60°C % 106,3 106,1 105,8 105,8 105,6
•Standby heat losses at 70°C Watt 92 92 95 115 115
•Standard emission factors Nitrous oxide mg/kWh 30,2 30,2 30,2 35,0 35,0
Carbon dioxide mg/kWh 9,0 9,0 11,2 13,0 13,0
•CO2content in flue gas max./min. capacity % 9,0 / 8,8 9,0 / 8,8 9,0 / 8,8 9,0-8,8 9,0 / 8,8
•Dimensions See dimension sheet
•Connections Flow / Return Zoll Rp 1 1/4" Rp 1 1/4" Rp 1 1/4" Rp 1 1/4" Rp 1 1/4"
Gas Zoll R 3/4" R 3/4" R 3/4" R 3/4" R 3/4"
Air / flue gas Ømm C80/125 C80/125 C80/125 C80/125 C80/125
•Gas flow pressure min./ max.
Natural gas E/LL mbar 18-50 18-50 18-50 18-50 18-50
Liquid gas mbar 42-57 42-57 42-57 42-57 42-57
•Gas connection values at 0°C / 1013 mbar:
Natural gas E - (Wo = 15,0 kWh/m3) Hu = 9,97 m3/h 2,83 3,3 4,3 1,2-5,8 5,8
Natural gas LL- (Wo = 12,4 kWh/m3) Hu = 8,57 m3/h 2,84 3,9 5,0 1,4-6,7 6,7
Propane gas 3(Hu = 25,9 kWh/m3) kg/h 1,09 1,27 1,64 0,5-2,2 2,21
•Operating voltage V/Hz 230/50 230/50 230/50 230/50 230/50
•Control voltage V/Hz 24/50 24/50 24/50 24/50 24/50
•Min./max. wattage Watt 29 / 60 29 / 62 29 / 66 30 / 88 30 / 102
•Standby Watt 13 13 13 13 13
•Type of protection IP 40 40 40 40 40
•Noise level max. (room-air dependent) dB(A) 58 58 60 60 60
•Acoustic pressure level (dependent on assemly) 2dB(A) 40 - 50 40 - 50 40 - 50 40 - 50 40 - 50
•Condensate quantity (natural gas) at 40 / 30°C l/h 3,1 3,6 4,4 4,4 5,3
•Condansate pH-value ca. 5,5 ca. 5,5 ca. 5,5 ca. 5,5 ca. 5,5
•Flue gas system: requirements, values
Temperature class T120 T120 T120 T120 T120
Type of connection B23, B33, C13x, C33x, C43x, C53x, C63(x), C83x
Flue gas mass flow kg/h 49,5 57,7 74,3 81,4 100
Flue gas temperature T 80/60°C °C 67 69 75 75 79
Flue gas temperature T 40/30°C °C 45 47 52 46 49
Volume flow combustion air Nm3/h 35,4 41,3 53,1 59,4 71,6
Delivery pressure for supply air / flue gas pipeline Pa 90 95 115 120 140
1The boiler series is tested for EE/H setting. Operation is possible without resetting over the Wobbe coefficient range from 12.0 to 15,0 kWh/m3with
a factory setting to a Wobbe coefficient of 15,7 kWh/m3
2Compare with protection notes .
3TopGas®is also suitable für propone / butane (liquid gas)-mixtures

7
4 205 254 / 03 Technical details
Dimensions2.2
Distance from the side 50 mm•
Distance from the ceiling dependent on the utilised flue gas pipeline system•
In the front 500 mm•
1 Gas connection R ¾"
2 Heating flow Rp 1¼"
3 Heating return Rp 1¼"
4 Condensate drain ∅32
5 LAS flue gas supply air
connection DN 80/125
View from below
Top View Borehole drawing
6 Automatic deaeration
7 Boiler control cover
8 Safety valve
9 KFE ball valve

8
4 205 254 / 03Technical details
Boiler flow resistance2.3
Short description of the automatic fir-2.4
ing unit BIC 335
The automatic firing unit operates both without con-
troller (TTT/N) and also without room station (RS-
OT). The automatic firing unit comprises the follow-
ing functions
- PWM- fan (230V~)
- Modulating operation
- Inputs for Flow sensor
Return sensor
Flue gas sensor
Gas pressure deflector
Air pressure deflector:
(not used)
Water pressure deflector
Safety temperature limiter:
(external flue gas thermo-
stat)
HW-buffer sensor
Outdoor sensor
Locking entry:
(Burner blocking)
- Status exit „Failure“ (invertible by parameter set-
ting)
- Three-way-valve control for heating/hot water
or loading pump control (230V~exits); Exit for a
three-way-valve / HW loading pump is invertible
by a parameter.
- Collective electrode for ignition and flame guide
(Ionisation)
- Main gas valve (ev. LPG- valve) / heating room
ventilation accessable
Water-side resistance [mbar]
Flow rate [m3/h]
0
50
100
150
200
250
300
350
400
450
500
0,0 0,5 1,0 1,5 2,0 2,5 3,0 3,5 4,0 4,5 5,0 5,5
Seite 4 / 6
Boiler incl.
connection kit
Boiler only
Fuses
On the automatic firing unit theres is a mains fuse.
The breakdown of this fuse (2AT) is noticeable by an
empty display even the main deflector is on.
Ionisation flow
The value of the ionisation flow is noted on the infor-
mation level and appears as step 8. The access to
the information level is explained in chapter 2.5.
Interface to display-
OpenTherm- interface (RS-OT, TTT/N)-
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

9
4 205 254 / 03 Technical details
Control of the boiler2.5
Control elements on the boiler control panel / Basic control N4.1
Usually, no settings of the basic control have to be made by the user. All settings have been made
by the installer or by the manufacturer.
Display: temperature
Changing of
the values
Display: Mode RESET
Fault-clearance (display is
blinking, if there is a failure)
Saving of
the settings
Options, to change settings
(Parmeter) (p.ex. Calorifier
temperature)
ON/OFF Manometer
Function options
(stepwise display option)
Function
Mode 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
(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 point + Par.1 (2AB))
Fr = Frost protection is activated
Su = Summer short operation is activated

10
4 205 254 / 03Technical details
Setting of the service codes
For entering the code, press the keys „Mode“ and „Step“ simultaneously. The blinking numeral can be
changed with the „+“ and „-“ –keys.To deflector between the numerals press the „Step“- key.To confirm and
safe the total code press the „Store“- key. After 20 minutes it will be changed into the indication level.
Parameter level (constant point)
The parameter level will be signalised by a constant point behind the second sign.
If none of both keys „+“/“-„ are pressed, “P“ + the parameter number will be shown alternating and then also
the corresponding parameter value. By pressing „+“ or „-“ the parameter value can be changed.To save the
changing press the „Store“- key, which will be confirmed by blinking twice (Wait for blinking before pressing
any further keys!). If the „Store“- key won‘t be pressed, the settings are not saved.
Function
Mode indication
Parameter
Indication
Value indication
Meaning, Description
Informations-Mode
It is possible to read monetary
values from here
Point is blinking
0e.g. 45° Current flow temperature (Heating water temperature)
1e.g. 40° Current return temperature
2e.g. 60° Current temperature in water heater
3e.g. 3° Current outdoor temperature
4e.g. 55° Current flue gas temperature
5e.g. 50° Flow set value in the heating system
6e.g. 70° Flow set value in hot water operation
7e.g. 23 RPM Fan speed in hundreds
8e.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 there 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
Flow temperature
Outdoor temerature
2. Select parameter to be changed
(Step key)
3. Change setting using + - keys
4. Save (press Store key 1 x)
Automatic return to standby mode in
20 minutes or with Mode key. Other parameters only with service code

11
4 205 254 / 03 Technical details
Adjustable parameters2.6
Parameter 7 (2AH) – Set point DHW charging temperature –
Using this parameter the reference value for the DHW temperature can be set where there is no room con-
trol unit or other regulatory device installed. If a reference value is transmitted via an OT bus, the latter (value
via OT) will always override this parameter.
Parameter 8 (2AI) – Pump after-run time (DHW) –
During the time which can be set using this parameter the pump continues to run after a phase of hot water
demand. The after-run time occurs before a switchover to heating operation as well as before a switchover
to to stand-by mode (to be set at the RS-OT or control unit) or when the firing device is switched OFF. It
also occurs of course when the desired DHW value has been reached and further heating operation is not
required.
Parameter 9 (2AJ) – Legionella protection time –
The boiler is periodically heated to the temperature defined using parameter 2AF for the time period which
can be set using this parameter for protection against legionella infestation. If the parameter value is set to
0 the legionella protection function is deactivated.
Parameter 10 (2AK) – Maximum fan speed in DHW mode –
The parameter defines the maximum rpm value for the fan during DHW operation.
Parameter 18 (2BH)
– Maximum heating temperature (when minimum outside temperature has been reached) –
The value which can be set here determines the flow temperature which is to be achieved when the out-
side temperature falls below the value set using parameter 19 (2BI) (minimum outside temperature). (see
diagram 2). If the OT bus sends a reference value to the firing device, this value is limited by the value set
using parameter 18.
Parameter 19 (2BI) - Minimum outside temperature - 19 (2BI) – Minimum outside temperature –
This parameter defines the minimum outside temperature which marks the limit where the flow temperature
target is to be set at the temperature given by parameter 18 (2BH).
Parameter 20 (2BJ)
– Minimum heating temperature (when maximum outside temperature has been reached) –
If the outside temperature sensor registers 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 param-
eter 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 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 restart is delayed for the period which can be set using this parameter – irrespective of whether
the hysteresis set for the next heating demand has expired or not.
Parameter 23 (2BM) – Restart delay following heating demand during heating operation –
Immediately following the end of a heating demand phase boiler restarts are delayed. That is to say, if the
boiler is shut down on account of a reference value trigger being sent from the OT bus to the firing device, a
restart (triggered by another reference value being reached) is delayed for at least the period of time which
can be set using this parameter.

12
4 205 254 / 03
Technical details
Parameter 24 (2BN) – Pump after-run time (heating operation –
During the time which can be set using this parameter the pump continues to run after a phase of heating
demand.
Parameter 25 (2BO) – Maximum fan speed in heating operation mode –
This parameter is used to set the maximum permitted fan speed in % in heating operation mode.
Parameter 60 (2GE) – Waiting time after opening main gas valve or activation of combustion chamber
ventilator –
After a burner demand is received, the boiler start is delayed by the amount of time set using this parameter.
While this time elapses the display shows the digit ‘0’. The interval is required for the main gas valve to open
or for pre-ventilation via the combustion chamber ventilator.
Parameter 61 (2GF) - External main gas valve (possibly an LPG valve) / combustion chamber ventilator
present –
This parameter is used to indicate whether an external main gas valve or a combustion chamber ventilator
is installed.
Parameter 62 (2GG) – DHW charging (switch / pump) –
This parameter is used to indicate whether a separate pump is present for DHW charging or there is simply
a switch for accessing the main pump in use.
The setting "0" means a KKP (pump outlet) and additionally a deflector (deflector outlet) is used.The setting
"1" means, that the pump at the pump outlet (X8-5/6) is only working in HZ-mode and the DHW-pump at the
outlet X8-7/8 is getting active in the DHW-mode.
Parameter 63 (2GH) – Pump – minimum PWM value –
This parameter is used to determine the minimum permitted 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 permitted capacity of the PWM pump in %. The maxi-
mum PWM value is effective when the boiler output is at a maximum. The pump rpm-speed increases lin-
early 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.

13
4 205 254 / 03
Installation
Installation3.
Description of the Hoval TopGas3.1 ®
The heat exchanger of the Hoval TopGas®(30,35,45,
50,60) comprises a corrosion-resistant aluminum
casting, through which the heating water flows in
series-parallel fashion from bottom to top.
The combustion air is extracted by a fan through
openings in the top cladding cover from the boiler
installation room or via an air-flue gas (for room air
independent operating).
The combustion air is mixed with a defined quantity
of combustion gas before the fan by means of a gas-
air compound controller. The homogeneous gas-air
mixture is then taken to the premix bat-wing burner
for low emission combustion via a distributor.
The premix bat-wing burner comprises a high-tem-
perature resistant stainless steel mesh with optimal
protection against overheating damage.
The heat exchanger is designed in such a way that
withcorrespondinglylowsystemtemperaturestheflue
gas is cooled below the flue gas dewpoint. Through
the additional utilisation of the latent flue gas heat
(heat output utilisation) the Hoval TopGas®(30,35,
45,50,60) operates with very high efficiency.
On leaving the heat exchanger the cooled flue gas is
transferred to the flue gas pipeline system
Diaphragm expansion tank3.1.1
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 pressure must be installed by the customer.
Boiler casing3.1.2
This is of sheet steel, with a white powder-paint finish,
with easily removable front.
Gas fittings3.1.3
Honeywell VK4125V gas controller for the automatic
regulationof thegas/combustionairratio, see chapter
4.3.6.
Automatic gas firing unit3.1.4
and heating controller
Automatic firing unit BIC 335 (see chapter 2.4 for
short description).
Heating circulation pump3.1.5
The TopGas®(30,35,45,50,60) is delivered without
an installed heating circulation pump. A sufficiently
dimensioned heating circulation pump must be in-
stalled by the customer.
Hot water supply3.1.6
TheHovalTopGas®(30,35,45,50,60)canbecombined
with a service water heater (e.g. Hoval CombiVal).
The electrical connections for connecting the storage
tank sensor and filling pump must be established at
the appropriate terminals of the TopGas®controller
(see electrical connection diagram).
Scope of supply3.1.7
Manometer-
Autom. deaerator in the boiler flow-
Plastic siphon in the condensate drain line-
Water pressure deflector as a boil-dry safeguard-
Flue gas temperature sensor-
Gas connector piece ¾"-
Electrical connection cable approx. 1,5 long, with-
connector plug
Gas pressure deflector-

14
4 205 254 / 03Installation
Picture 3.1.8-1
Picture 3.1.8-2
TopGas3.1.8 ®component designation
13 14
12 15
1
2
4
7
5
9
3
10
8
11
6
1 Burner viewing window
2 Fan
3 Flue gas 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 TopTronic®control panel (optional)
15 Manometer

15
4 205 254 / 03 Installation
Boiler installation room3.2
Hoval heat output boilers series TopGas®(30,35,45,
50,60) can be combined with flue gas pipelines
which
a) extract the combustion air from the boiler instal-
lation room (room air dependent gas firing loca-
tion)
b) extract the combustion air from the outside via a
closed system (room air independent gas firing)
The boiler installation rooms must satisfy the locally
applicable regulations (firing regulation, fire service
regulations), in particular the requirements accord-
ing to:
- SVGW- guidelines
- DVGW - TRGI 86-96
must to be noted an complied with.
With room air dependent operation, care is to be taken
that the combustion air is free from impurities (dust,
building materials...) and aggressive substances
(halogens such as chlorides, fluorides etc.). The gas
boiler should not be connected to the gas supply
or put into operation whilst building work is still in
progress.
Installing the boiler3.3
The Hoval TopGas®(30,35,45,50,60) is delivered as
follows.
Carton: Boiler;claddingcomponents,installation and
operating instructions.
The boiler must not be placed on its connector
elements.
Mount the boiler to the wall at the planned location.
Distancefrom the side:atleast 5cm;distance from the
ceiling: the necessary distances are to be observed
according to the type and dimensions of the pipelines
for combustion air and flue gas.
Please note dimensions and instructions in the
drawings in chapter 2.2.
Hydraulic connection3.4
The Hoval TopGas®(30,35,45,50,60) is suitable
for flexible operation (room temperature control or
weather-supported boiler and heating control) tem-
perature limiting.
For suitable hydraulic connections, please note the
instructions in the Hoval project planning documen-
tation.
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.
Protection planning guidelines for the hy-3.4.1
draulic connection
The installation of a sludge collector in the boiler•
return is recommended (ensure correct dimension-
ing).
An adequately dimensioned expansion tank must•
be provided.
The minimum pre-pressure in the expansion tank•
must be 1,2 bar and the working pressure in the
heating boiler must be 1,5 bar.
The pump is to be connected in the boiler return•
and the expansion tank in the suction side of the
pump.
If the system pressure cannot to be reached (e.g.•
roof central heating plants), the expansion tank
must be installed in the flow line. (Note: starting
from 70°C an additional connecting tank is neces-
sary).
Plants with•
- continuous oxygen intake (e.g. underfloor heat-
ing systems without diffusion proof plastic pip-
ing) or
- intermittent oxygen intake (e.g. where frequent
refilling is necessary)
must be equipped with separate circuits.
We also recommend the conclusion of a main-
tenance contract!
Boil-dry safeguard3.4.2
To safeguard the boiler against low water levels or
waterdeficiency,a waterpressure deflector isinstalled
as standard in the flow distributor (AMP connector at
positions 1 and 3).If water pressure is lower than 1 bar
power disconnection takes place (indication „P27“).
Please check the system pressure and top up with
water as required.
Gravity brake3.4.3
It is recommended to install a gravity brake, to avoid
heat losses due to gravity circulation (particularly
importantwhen changing existing,open installations).
The gravity brake is necessary for summer operation
with indirectly heated storage water heater.
Minimum flow rate3.4.4
During the burner operation a circulation pump must
always be in operation too. The minimum flow rate
indicated in the technical data must always be pro-
vided.

16
4 205 254 / 03Installation
TopGas®(30,35,45,50,60) with water heater and
two regulated mixed circuits
Gas
Dies ist ein
unerlaubter Weg!
Gehen Sie einen
Schritt zurück oder
löschen Sie dieses
Shape!
Sie haben die
Möglichkeit ein
neues Shape zu
nehmen!!!
hovhovalhovalhoval
hovalhovalhovalhov
P
TopGas
(30-60)
PLPZUPM 5
TT
DKP
TT
DKP
RS-T
AF
TopTronic T B1VF1
TT
MK1
M
YK1
B1VF2
TT
MK2
M
YK2
B1VF2
TT
MK2
M
YK2
TT
SLP
Dies ist ein
unerlaubter
Weg!
Gehen Sie
einen Schritt
zurück oder
löschen Sie
dieses Shape!
Sie haben die
Möglichkeit ein
neues Shape
zu nehmen!!!
hovhovalhoval
hovalhovalhov
alhovalhovalho
valhovalhovalh
ovalhovalhoval
hovalhovalhov
alhovalhovalho
valhovalhovalh
ovalhovalhoval
hovalhovalhov
alhovalhovalho
valh
WW
T
KW
SF
1
Gas
Dies ist ein
unerlaubter Weg!
Gehen Sie einen
Schritt zurück oder
löschen Sie dieses
Shape!
Sie haben die
Möglichkeit ein
neues Shape zu
nehmen!!!
hovhovalhovalhoval
hovalhovalhovalhov
P
TopGas
(30-60)
PLPZUPM 5
TT
DKP
TT
DKP
TT
SLP
Dies ist ein
unerlaubter
Weg!
Gehen Sie
einen Schritt
zurück oder
löschen Sie
dieses Shape!
Sie haben die
Möglichkeit ein
neues Shape
zu nehmen!!!
hovhovalhoval
hovalhovalhov
alhovalhovalho
valhovalhovalh
ovalhovalhoval
hovalhovalhov
alhovalhovalho
valhovalhovalh
ovalhovalhoval
hovalhovalhov
alhovalhovalho
valh
WW
T
KW
SF
RS-T
AF
TopTronic T B 1
RS-T Room station
AF Outside sensor
VF1 Flow sensor 1
VF2 Flow sensor 2
SF Water heater sensor
B1 Flow temperature deflector
(if necessary)
MK1 Pump mixing circuit 1
MK2 Pump mixing circuit 2
DKP Pump for heating circuit
without mixer
SLP Water heating loading pump
M5 Boiler circuit pump
YK1 Actuator mixer 1
YK2 Actuator mixer 2
To be provided by customer3.4.5
Apressure expansiontankadaptedto heating system,
water volume and static height.
Hydraulic interconnection3.4.6
Examples
TopGas®(30,35,45,50,60) with water heater
and direct heating circuit

17
4 205 254 / 03 Installation
Flue gas connection, chimney and3.5
condensate pipeline
A pressure expansion tank adapted to heating
system, water volume and static height.
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 directives are to be complied with for flue gas
removal.
In accordance with theVKF-guidelines (edition 1993,
number 3.4.8) for Switzerland a flue gas temperature
limiting 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 approved flue gas pipelines.
Inbothcasesthecrosssectionsandmaximumlengths
based on the values for flue gas flow rate, flue gas
temperature and flow pressure available at the flue
gas connector are to be calculated according to the
table on chapter 2.1 (DIN 4705).
The calculation is normally made by means of graphs
ortablesprovidedby the manufacturerofthemoisture-
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
responsible local chimney sweeping supervisor prior
to the planning and execution of the flue gas extrac-
tion with heat output gas boilers.
Waste gas pipelines in compliance3.5.1
with building construction law
The flue gases from the Hoval TopGas®(30,35,45,
50,60) can be removed via a gas-tight, temperature
and corrosion resistant flue gas pipeline.
Only flue gas systems approved and tested by the
relevant region or province are to be connected to the
Hoval TopGas®(30,35,45,50,60) (the admissions of
individual federal states should be complied with in
Austria).The suppliers of the flue gas pipelines sup-
ply suitable boiler connectors for the transition from
the boiler to the flue gas pipeline. The flue gas con-
nector on the Hoval TopGas®(30,35,45,50,60) 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
manufacturer 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 supervi-
sor is recommended.
Your Hoval agent can supply a suitable and approved
flue gas system for your TopGas®.
Please take note of the technical information sup-
plied with your flue gas pipeline.
Project planning guidelines for exhaust3.5.2
gas systems
All applicable regional, national and state regula-•
tions are to be observed with respect to the flue
gas extraction system.
All air inlet/flue gas pipelines must have a meas-•
uring 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 shortened. Length adjustment pieces or cut to
length pieces are to be used for adjusting to the
required lengths.

18
4 205 254 / 03Installation
Installation examples3.5.3
for room-air-dependent operation
Single flue gas pipes can be shortened to the•
necessary length but must however be cleanly de-
burred before the assembly, to prevent damage to
the seal in the counter-piece.
When installing the pipes in a shaft, spacer ele-•
ments must be mounted every 2 m. For the vertical
supporting of the chimney pipeline, the very bot-
tom 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 conden-
sate to the boiler. The complete flue gas system
must be installed to prevent the accumulation of
condensate.
Falls erforderlich ist
ein Inspektions-T-
Stück einzusetzen
Verbrennungsluft
TopGas
If necessary, an inspection
T-piece has to be inserted
Combustion air

19
4 205 254 / 03 Installation
Exhaust gas system for3.5.4
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
TopGas
Falls erforderlich ist
ein Inspektions-T-
Stück einzusetzen
Verbrennungsluft
If necessary, an inspection
T-piece has to be inserted
Combustion air
Wall penetration3.5.6
(Permitted only in Austria)
TopGas
Attic heating center3.5.5
(vertical exhaust gas conduit installation)

20
4 205 254 / 03
Installation
Connection of pipelines3.5.7
Onofthe boiler installation thepipelinesareconnected
directly to the feed and the return connectors. Please
note the designations for the pipeline connectors in
chapter 2.2.
Condensate draining and neutralisation3.5.8
The condensate from heat output gas boilers is to be
transferred to the public drainage system or an own
drainage system and where prescribed, neutralised
prior to introduction.
Please comply with the instructions of the re-
sponsible local waste water authorities.
In Austria:
Please note the planning directives for heat output
firing systems in the Austrian Standard H 5152 and
in particular the ÖVGW (G 41).
It is important, already prior to planning and executing
theboilersystemtocontact theresponsibleauthorities
to plan and execute the condensate drainage accord-
ing to regulations.
The siphon drain pipe must be directed into a
funnel.
Gas connection3.5.9
The installation of the gas pipeline and first
placing in operation must be carried out by a
recognised expert.
The provisions of the 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 be installed
between the manual shut-off valve and the boiler, to
eliminate faults due to particles carried in the gas.
In Germany some regional building regulations re-
quire the installation of a thermally activated shut-off
valve directly before the boiler. Please enquire at your
local regional planning office.
It is imperative to check all gas-carry-
ing pipelines for leaks before initially
placing the boiler in operation.
Electrical connection3.6
The appliance must always be discon-
nected from the electrical supply be-
fore working on the TopGas®.
Electrical connection regulations3.6.1
All electrical installation work, in particular the protec-
tive measures are to be carried out corresponding to
the relevant regulations and any special regulations
of the local energy supplier; in particular the local
regulations must be complied with.
On installing the system, the provisions of VDE 0100
and the regulations of the responsible power supply
company are to be observed.
Accident prevention regulations
”General regulations (VBG1)”
”Electrical installations and equipment (VBG4)”