Hoval TopGas 35 Manual

Subject to modi cations | EN
Technical information
Installation instructions
4 213 893 / 01- 07/15
Hoval products may only be installed and commis-
sioned by appropriately qualied experts. These in-
structions are intended exclusively for the specialist.
Electrical installations may only be carried out by a
qualied electrician.
Nominal 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 ow temperatures of up to 85 °C. They are
designed for continuously controlled reduced operation
in heating systems.
TopGas®(35,45,60)
Wall-mounted condensing gas boilers
for natural and liquid gas

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TABLE OF CONTENTS
1. Important Information............................................................................................................................. 4
1.1 On delivery...........................................................................................................................................................................4
1.2 Guarantee ............................................................................................................................................................................4
1.3 Instructions .........................................................................................................................................................................4
1.4 Regulations, official approvals ...........................................................................................................................................5
1.5 Transport and storage.........................................................................................................................................................5
2. Safety instructions.................................................................................................................................. 6
2.1 Warning levels .....................................................................................................................................................................6
2.2 Warning symbols.................................................................................................................................................................6
2.3 Information ..........................................................................................................................................................................6
3. Technical information ............................................................................................................................. 7
3.1 Technical Data .....................................................................................................................................................................7
3.2 Boiler-flow resistance .........................................................................................................................................................8
3.3 Dimensions..........................................................................................................................................................................9
3.4 Short description of the automatic firing unit BIC 335 ....................................................................................................10
3.5 Heating system control .....................................................................................................................................................11
3.6 Adjustable parameters ......................................................................................................................................................13
4. Installation............................................................................................................................................. 15
4.1 Description of the Hoval TopGas®.....................................................................................................................................15
4.1.1 Diaphragm expansion tank..............................................................................................................................................15
4.1.2 Boiler casing...................................................................................................................................................................15
4.1.3 Gas fittings .....................................................................................................................................................................15
4.1.4 Automatic gas firing unit and heating controller ...............................................................................................................15
4.1.5 Heating circulation pump.................................................................................................................................................15
4.1.6 Hot water supply .............................................................................................................................................................15
4.1.7 Scope of supply ..............................................................................................................................................................15
4.1.8 TopGas®component designation.....................................................................................................................................16
4.2 Boiler installation room.....................................................................................................................................................17
4.3 Installing the boiler............................................................................................................................................................17
4.4 Hydraulic connection ........................................................................................................................................................17
4.4.1 Protection planning guidelines for the hydraulic connection.............................................................................................17
4.4.2 Boil-dry safeguard...........................................................................................................................................................17
4.4.3 Gravity brake ..................................................................................................................................................................18
4.4.4 Minimum flow rate...........................................................................................................................................................18
4.4.5 To be provided by customer ............................................................................................................................................18
4.4.6 Examples of hydraulic interconnection ............................................................................................................................18
4.5 Flue gas connection, chimney and condensate pipeline.................................................................................................20
4.5.1 Waste gas pipelines in compliance with building construction law ...................................................................................20
4.5.2 Project planning information for the TopGas®..................................................................................................................20
4.5.3 Installation examples for room-air-dependent operation ..................................................................................................21
4.5.4 Exhaust gas system for room-air-independent operation .................................................................................................21
4.5.5 Roof heating centre concentric flue (vertical exhaust gas conduit installation) .................................................................22
4.5.6 Wall penetration (permitted only in Austria) .....................................................................................................................22
4.5.7 Connection of the pipes ..................................................................................................................................................23
4.5.8 Condensate draining and neutralisation ..........................................................................................................................23
4.5.9 Gas connection...............................................................................................................................................................23
4.6 Electrical connection.........................................................................................................................................................23
4.6.1 Regulations for electrical connections .............................................................................................................................24
4.6.2 Electrical connection (mains) 230 V, 50 Hz......................................................................................................................24
4.6.3 Boiler control / electrical connection diagram ..................................................................................................................24
4.6.4 Connection of the heating controller................................................................................................................................24
4.6.4.1 TopTronic®RS-OT ..........................................................................................................................................................................24
4.6.4.2 TopTronic®E...................................................................................................................................................................................24

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TABLE OF CONTENTS
5. Commissioning ..................................................................................................................................... 25
5.1 Setting the control.............................................................................................................................................................25
5.2 Water quality......................................................................................................................................................................25
5.2.1 Heating water..................................................................................................................................................................25
5.3 Filling and replacement water:..........................................................................................................................................25
5.3.1 Filling up the system .......................................................................................................................................................26
5.4 Gas adjustment..................................................................................................................................................................26
5.4.1 Bleeding the gas pipeline................................................................................................................................................26
5.4.2 Commissioning ...............................................................................................................................................................26
5.4.3 Gas inlet pressure...........................................................................................................................................................26
5.4.4 Gas fitting .......................................................................................................................................................................26
5.4.5 Setting the 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 Cleaning the heat exchanger ............................................................................................................................................29
7.5 Function check ..................................................................................................................................................................30
7.6 Emission measurement.....................................................................................................................................................30
8. Faults..................................................................................................................................................... 31
9. Automatic firing unit BIC 335-Parameter list ....................................................................................... 33

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4 213 893 / 01
IMPORTANT INFORMATION
1. Important Information
BThe 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 follow-
ing 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
boiler which carry water is not performed correctly,
the heating medium may escape and lead to scald-
ing.
- After performing repair and 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 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-
pole 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, adhesives, 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 in-
structions can be found with the components!
Further sources of information:
- Hoval catalogue
- Standards, regulations

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IMPORTANT INFORMATION
1.4 Regulations, official approvals
The following regulations are to be complied with for
installation 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 calculation 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
(technical 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
- Methods for calculating the design heat load
• OENORM 13384 Flue gas systems
- Heat and ow calculation methods
• OENORM 12828 Heating systems in buildings
- Planning of hot water heating systems.
• OENORM H5152 Gas condensation
for furnace installations
• OENORM H5195-1 Prevention of damage
through corrosion
• 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 supported premix batwing burners
• M 7444, Special gas boilers with burners without fan
• M 7459, Gas appliances with
gas-air compound controller
• ÖVGW TR- Gas (Austrian Gas and
Water Confederation - Technical Guidelines)
• 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 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 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 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, insur-
ance 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
spe cications of the local water authorities
and may deviate from waste water guideline
ATVM251. Please contact your water author
-
ity 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
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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 Information
Information:
Provides important information.

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TECHNICAL INFORMATION
3. Technical information
3.1 Technical Data
Type (35) (45) (60)
• Nominal heat output 80/60 °C with natural gas 1kW 6,0-31,8 10,0-41,0 11,7-55,3
• Nominal heat output 40/30 °C with natural gas 1kW 6,8-35,0 11,1-45,0 12,8-60,7
• Nominal heat output 80/60 °C propane gas 3kW 6,6-31,9 10,8-41,0 13,1-54,9
• Nominal heat output 40/30 °C propane gas3kW 7,3-35,2 11,9-45,0 14,1-60,3
• Nominal load with natural gas 1kW 6,4-33,0 10,6-42,5 12,2-57,3
• Nominal load with propane gas 3kW 7,0-33,2 11,4-42,5 13,6-56,9
• Working pressure heating maximum/minimum. bar 3,0/1,0 3,0/1,0 3,0/1,0
• Working temperature maximum °C 85 85 85
• Boiler water content l 4,5 4,5 6,0
•Minimum water ow l/h 300 350 470
•Boiler weight (without water content, incl. body) kg 83 83 89
•Boiler efciency at full load at 80/60 °C
(related to net/gross caloric value) %96,4/86,8 96,5/86,9 96,5/86,9
•Boiler efciency at 30 % partial load (in acc. with EN 303)
(related to net/ gross caloric value) %107,1/96,5 106,9/96,3 106,9/96,3
•Normal degree of efciency (in accordance with DIN 4702 Part 8) 40/30 °C % 109,1/98,3 109,0/98,2 109,0/98,2
(related to net/gross caloric value) 75/60 °C % 106,1/95,6 106,0/95,5 106,0/95,5
• Standby losses at 70 °C Watt 95 95 120
• Norm emission factors Nitrogen oxide NOx mg/kWh 30,0 30,0 35,0
Carbon monoxide CO mg/kWh 9,0 11,0 13,0
• CO2 content in ue gas max./min. output %9,0/8,8 9,0/8,8 9,0/8,8
• Dimensions see table of dimensions
• Connections Flow/Return Inches Rp 1¼″ Rp 1¼″ Rp 1¼″
Gas Inches R ¾″ R ¾″ R ¾″
Air/ue gas Ø mm C80/125 C80/125 C80/125
•Gas ow 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/m3m3/h 3,3 4,3 5,8
Natural gas LL- (Wo = 12,4 kWh/m3) Hu = 8,57 kWh/m3m3/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 24/50
• Minimum/maximum electrical power consumption Watt 29/62 29/66 30/102
• Standby Watt 13 13 13
• Protection rating IP 40 40 40
• Sound power level
- Heating noise (EN 15036 part 1) (room air dependent) dB(A) 61 63 63
- Exhaust noise is radiated from the mouth
(DIN 45635 part 47) (room air dependent/room air independent dB(A) 63 66 66
• Sound pressure level (depending on installation conditions) 2dB(A) 49 51 51
• Condensate quantity (natural gas) at 40/30 °C l/h 3,1 4,0 5,4
• pH-value of the condensate ca. 4,2 ca. 4,2 ca. 4,2
•Flue gas system: requirements, values
Temperature class T120 T120 T120
Type of connection B23, C13(x), C33(x), C53(x), C63(x)
Flue gas mass ow kg/h 54,8 70,6 95,1
Flue gas temperature at nominal output and operation 80/60 °C °C 69 75 79
Flue gas temperature at nominal output and operation 40/30 °C °C 47 52 49
Volume ow rate combustion air Nm3/h 41,3 53,1 71,6
Feed pressure total at the combustion air/ue gas pipe Pa 95 115 140
Maximum draught/depression at ue gas outlet Pa - 50 - 50 - 50
1Data related to Hu. The boiler series is tested for EE/H-settings. With a factory setting of the Wobbe coefcient of 15,0 kWh/m3operation
at a Wobbe coefcient of 12,0 up to 15,7 kWh/m3is possible without new settings.
2See also notes at “Engineering”.
3Data related to Hu. TopGas®is also suitable for propane/ butane (liquid gas) mixtures.

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4 213 893 / 01
TECHNICAL INFORMATION
m3/h = Volume ow
mbar = Flow resistance
3.2 Boiler-flow resistance
0
50
100
150
200
250
300
350
400
450
500
0,0 0,51,0 1,5 2,0 2,5 3,0 3,5 4,0 4,5 5,0 5,5
Seite 4 / 6
Boiler incl.
connection set
(mbar)
Boiler only
500
450
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 32-60
0
100
200
300
400
500
600
0.0 1.0 2.0 3.0 4.0
m3/h

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TECHNICAL INFORMATION
3.3 Dimensions
Minimum clearances
Dimensions in mm
• Lateral clearance 50 mm
• Distance from ceiling depending on exhaust ue system used
• Front 500 mm
Ansicht von oben
Ansicht von unten
View from bottom
View from top
Fig. 01
1Gas connection R ¾″
2Heating ow Rp 1¼″
3Heating return Rp 1¼″
4Condensate drain Ø 32
5LAS ue gas/combustion air connection DN 80/125
6 Automatic deaeration
7 Boiler control cover
8 Safety valve
9 KFE ball valve

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TECHNICAL INFORMATION
3.4 Short description of the automatic firing unit
BIC 335
- The automatic ring unit operates both without control-
ler (TTE) and also without room station (RS-OT). The
automatic 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 load-
ing 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 (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
(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 informa-
tion level and appears as step 8. The access to the infor-
mation level is explained in chapter 3.5.

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4 213 893 / 01
TECHNICAL INFORMATION
3.5 Heating system control
Boiler control
Normally, the user does not need to set the basic controller.
All settings have been made by the installer or 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. Calorier 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 ow 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 deector defectiv (no air pressure deector in use)
6= Burner „off“ in heating operation
(ow-Temp > ow-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
(ow-Temp > ow-temp. set point + Par.1 (2AB))
Fr = Frost protection is activated
Su = Summer short operation is activated

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4 213 893 / 01
TECHNICAL INFORMATION
Setting of the service codes
For entering the code, press the keys „Mode“ und „Step“
simultaneously. The blinking numeral can be changed
with the „+“ and „-“ –keys. To deector between the nu-
merals press the „Step“- key. To conrm 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 param-
eter number will be shown alternating and then also the
coresponding parameter value. By pressing „+“ or „-“ the
parameter value can be changed. To save the changing
press the „Store“- key, which will be conrmed by blinking
twice (Wait for blinking before pessing 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
0 e.g. 45° Current ow 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 ue gas temperature
5 e.g. 50° Flow set value in the heating system
6 e.g. 70° Flow set value in hot water operation
7 e.g. 23 RPM Fan speed in hundreds
8 e.g. 4 µ A Ionisation ow
Parameter-Mode
Settings can be changed
in this mode.
Point appears
P. 7 60 = Hot water set value
if threre is no TopTronic®attached.
Procedure: P. 18 80 = Max. Flow temperature during heating operation
1. Select parameter Mode
(press Mode key 2 x)
Parameter (P.7) and setting
appear alternate
Par. 18
Flow temperature
outside temperature
Further parameters only with service code
2. Select parameter to be
changed (Step key)
3. Change setting using
+ - keys
4. Save
(press Store key 1x)
Automatic return to standby mode
in 20 minutes or with Mode key.

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4 213 893 / 01
TECHNICAL INFORMATION
3.6 Adjustable parameters
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 control
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 de-
mand. 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 ring 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 de-
ned using parameter 2AF for the time period which can
be set using this parameter for protection against le-
gionella 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 denes 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 ow
temperature which is to be achieved when the outside
temperature falls below the value set using parameter
19 (2BI) (minimum outside temperature). If the OT bus
sends a reference value to the ring device, this value is
limited by the value set using.
Parameter 19 (2BI) - Minimum outside temperature -
This parameter denes the minimum outside temperature
which marks the limit where the ow 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 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 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 be-
ing sent from the OT bus to the ring 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.
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 de-
layed 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) / com-
bustion chamber ventilator present –
This parameter is used to indicate whether an external
main gas valve or a combustion chamber ventilator is in-
stalled.

14
4 213 893 / 01
TECHNICAL INFORMATION
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 addition-
ally a deector (deector 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 WW-pump at the outlet X8-
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 effective when the boiler output is at a max-
imum. The pump rpm-speed increases linearly between
minimum and maximum boiler output.
Parameter 65 (2GJ) – Three-way valve inversion –
This parameter can be used to invert the outlet for the
three-way valve wiring.

15
4 213 893 / 01
MONTAGE
4. Installation
4.1 Description of the Hoval TopGas®
The heat exchanger of the Hoval TopGas® (35,45,60) com-
prises a corrosion-resistant aluminum casting, through
which the heating water ows in series-parallel fashion
from bottom to top.
The combustion air is extracted by a fan through open-
ings in the top cladding cover from the boiler installation
room or via an air-ue gas (for room air independent op-
erating).
The combustion air is mixed with a dened 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 emis-
sion combustion via a distributor.
The premix bat-wing burner comprises a high-tempera-
ture resistant stainless steel mesh with optimal protection
against overheating damage.
The heat exchanger is designed in such a way that with
correspondingly low system temperatures the ue gas is
cooled below the ue gas dewpoint. Through the addi-
tional utilisation of the latent ue gas heat (heat output
utilisation) the Hoval TopGas® (35,45,60) operates with
very high efciency.
On leaving the heat exchanger the cooled ue gas is
trans ferred to the ue gas pipeline system.
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 nish,
with easily removable front.
4.1.3 Gas fittings
Honeywell VK4125V gas controller for the automatic reg-
ulation of the gas/combustion air ratio, see chapter 5.4.4.
4.1.4 Automatic gas firing unit and heating controller
Automatic ring unit BIC 335 (see chapter 7.4 for short
description).
4.1.5 Heating circulation pump
The TopGas® (35,45,60) is delivered without an installed
heating circulation pump. A sufciently dimensioned heat-
ing circulation pump must be installed by the customer.
4.1.6 Hot water supply
The Hoval TopGas® (35,45,60) can be combined with a
service water heater (e.g. Hoval CombiVal).
The electrical connections for connecting the storage
tank sensor and lling pump must be established at the
appropriate terminals of the TopGas®controller (see elec-
trical connection diagram in the boiler).
4.1.7 Scope of supply
• Manometer
• Autom. deaerator in the boiler ow
• Plastic siphon in the condensate drain line
• Water pressure deector as a boil-dry safeguard
• Flue gas temperature sensor
• Gas connector piece R ¾″
• Electrical connection cable approx. 1,5 m long,
with connector plug
• Gas pressure deector

16
4 213 893 / 01
MONTAGE
4.1.8 TopGas®component designation
1
2
4
7
5
9
3
10
8
11
6
Fig. 02
1. Burner viewing window
2. Fan
3. Flue gas air inlet
4. Water pressure deector
5. Flue gas temperature sensor
6. Flow temperature sensor
7. Return temperature sensor
8. Ignition/ionisation electrode
9. Heat exchanger
10. Gas tting
11. Gas pressure deector
12. ON/OFF deector
13. Automatic ring unit control panel
14. TTE control panel (optional)
15. Manometer
13 12 14 15
Fig. 03

17
4 213 893 / 01
MONTAGE
4.2 Boiler installation room
Hoval heat output boilers series TopGas® (35,45,60) can
be combined with ue gas pipelines which
a) extract the combustion air from the boiler installation
room (room air dependent gas ring location)
b) extract the combustion air from the outside via a
closed system (room air independent gas ring)
The boiler installation rooms must satisfy the locally ap-
plicable regulations (ring regulation, re service regula-
tions), in particular the requirements according to:
- SVGW- Leitsätze
- 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, build-
ing materials...) and aggressive substances (halogens
such as chlorides, uorides etc.). The gas boiler should
not be connected to the gas supply or put into operation
whilst building work is still in progress.
4.3 Installing the boiler
The Hoval TopGas® (35,45,60) is delivered as follows.
Carton: Boiler; cladding components, installation and op-
erating instructions.
NOTICE
The boiler must not be placed on its connec-
tor elements.
Mount the boiler to the wall at the planned location. Dis-
tance from the side: at least 5 cm; distance from the
ceiling: the necessary distances are to be observed ac-
cording to the type and dimensions of the pipelines for
combustion air and ue gas.
Please note dimensions and instructions in
the drawings in section 3.3.
4.4 Hydraulic connection
The Hoval TopGas® (35,45,60) is suitable for exible 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.
4.4.1 Protection planning guidelines
for the hydraulic connection
• The installation of a sludge collector in the boiler return
is recommended (ensure correct dimensioning).
• 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 boil-
er 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 in-
stalled in the ow line. (Note: starting from 70 °C an
additional connecting tank is necessary).
• Plants with
- continuous oxygen intake (e.g. underoor heating
systems without diffusion proof plastic piping) or
- intermittent oxygen intake (e.g. where frequent rell-
ing is necessary)
must be equipped with separate circuits.
We also recommend the conclusion of a main
-
tenance contract!
4.4.2 Boil-dry safeguard
To safeguard the boiler against low water levels or wa-
ter deciency, a water pressure deector is installed as
standard in the ow distributor (AMP connector at posi-
tions 1 and 3). If water pressure is lower than 1 bar pow-
er disconnection takes place (indication „P27“). Please
check the system pressure and top up with water as re-
quired.

18
4 213 893 / 01
MONTAGE
4.4.3 Gravity brake
It is recommended to install a gravity brake, to avoid heat
losses due to gravity circulation (particularly important
when changing existing, open installations). The gravity
brake is necessary for summer operation with indirectly
heated storage water heater.
4.4.4 Minimum flow rate
During the burner operation a circulation pump must al-
ways be in operation too. The minimum ow rate indicat-
ed in the technical data must always be provided.
4.4.5 To be provided by customer
A pressure expansion tank adapted to heating system,
water volume and static height.
4.4.6 Examples of hydraulic interconnection
Gas boiler with
- Free-standing calorier
- 1 direct circuit
Hydraulic schematic BDDE020
Fig. 04
RS-OT Room station (OpenTherm)
B1 Flow temperature monitor (if required)
BA Outdoor sensor
BW Calorier 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 information required for
installation. Installation must be carried out according
to the conditions on site, dimensioning and local regu
-
lations.
- With underoor heating, a ow temperature monitor
must be installed.
-
Shut-off devices to the safety equipment (pressure
ex pansion tank, safety valve, etc.) must be secured
against unintentional closing!
- Install sacks to prevent single-pipe gravity circulation!

19
4 213 893 / 01
MONTAGE
Gas boiler with
- Free-standing calorier
- 1 direct circuit
- 1 direct circuit + 1-... mixer circuit(s)
Hydraulic schematic BDDE030
1
A
B
D
E
C
F
2 3 4 5 6 7 8 9
123456789
A
B
D
E
C
F
BDDE030.dwg
Achtung ! Für die Installation muss das anlagenbezogene Schema verwendet werden!
Attention! This is just a schematic. For installation please use the detail-plan!
Attenzione! Per la messa in opera, utilizzare le schema dettagliato!
Attention! Pour la réalisation pratique de l'installation, il faut utiliser le schéma détaillé!
Datum:
Datei:
Version:
Blatt:
Hydr. Verbindungshinweise /
Notice / Nota / Remarque:
1
4.1
...
24.03.2015
BDDE030
Name:
WG
P
TopGas >35
VF1
YK1 YK2
MK1
T T
DKP
T T
SLP
T
T
MK2
T T
B1.2VF2B1.1
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
SF Calorier sensor
DKP Pump for heating circuit without mixer
SLP Calorier loading pump
M5 Boiler circuit pump
Optional
WG Wall casing
TTE-FE HK TopTronic®E module expansion heating circuit
VF2 Flow temperature sensor 2
B1.2 Flow temperature monitor (if required)
MK2 Pump mixer circuit 2
YK2 Actuator mixer 2

20
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 ue gases with low
temperature and the resulting further condensation in the
ue, heat output boilers cannot be connected to standard
house ues.
The applicable local authority regulations and the special
regulations in the DVGW-(TRGI), ÖVGW and SVGW di-
rectives are to be complied with for ue gas removal.
In accordance with the VKF-guidelines (edition 1993,
number 3.4.8) for Switzerland a ue gas temperature lim-
iting device according to the above mentioned directive
must be installed in the ue gas pipeline.
There are two possibilities of ue gas removal with heat
output gas boilers:
a) The use of specially approved ue gas pipelines,
b) Use of damp-insensitive ues, approved for ue gas
temperatures starting from 40 °C, connected to the
heat output boiler in the boiler installation room via ap-
proved ue gas pipelines.
In both cases the cross sections and maximum lengths
based on the values for ue gas ow rate, ue gas tem-
perature and ow pressure available at the ue gas con-
nector are to be calculated according to the table on
chapter 3.1 (DIN 4705).
The calculation is normally made by means of graphs
or tables provided by the manufacturer of the moisture-
resistant ue of the special ue 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 ue gas extraction with
heat output gas boilers.
4.5.1 Waste gas pipelines in compliance
with building construction law
The ue gases from the Hoval TopGas® (35,45,60) can
be removed via a gas-tight, temperature and corrosion
resistant ue gas pipeline. Only ue 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 ue gas pipelines
supply suitable boiler connectors for the transition from
the boiler to the ue gas pipeline. The ue gas connector
on the Hoval TopGas® (35,45,60) has a concentric ue
gas connection ø 80/125 mm.
We recommend installation of the connector
piece (boiler ue gas connector vertical ue
gas pipeline) in the same diameter as the ue
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
ue gas pipeline. A timely discussion with the responsible
local chimney sweeping supervisor is recommended.
Your Hoval agent can supply a suitable and approved ue
gas system for your TopGas®.
Please take note of the technical information supplied
with your ue 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 ue gas extrac-
tion system.
• All air inlet/ue gas pipelines must have a measuring
orice (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 ue 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 xed (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 ow of the condensate to the
boiler. The complete ue gas system must be installed
to prevent the accumulation of condensate.