Hoval TopGas 35 User manual

To be fi lled in by the heating expert
:
Order No
.:
Boiler type
:
Set to
:
Natural gas H Natural gas L Liquid gas
Heating pump type
:
Heating regulation type
:
Mixing organ type
:
Ancillary water heater type
:
Water heater sensor Thermostat
Outdoor temperature sensor
Room temperature sensor
Combustion air supply
Room Outdoor
Design parameters of the heating
Lowest outdoor temperature
°C
Heat demand
: kW
Max. fl ow temperature
: °C
Important telephone numbers
Heating engineer
Sanitary installer
Electrical installer
Fuel supplier
Chimney-sweep
Natural gas H Natural gas L Liquid gas
Natural gas H Natural gas L Liquid gas
Natural gas H Natural gas L Liquid gas
Ancillary water heater type
Water heater sensor Thermostat
Room Outdoor
Room Outdoor
°C
: °C
Operating instructions
TopGas
®
(35, 45, 60)
® (35, 45, 60) ®
EN
Hoval Switzerland
Hoval Herzog AG
CH-8706 Feldmeilen
General Wille Strasse 201
Telephone 01 / 925 61 11
Fax 01 / 923 11 39
Hoval Austria
Hoval Gesellschaft mbH
A-4614 Marchtrenk
Hovalstrasse 11
Telephone 07243 / 550-400
Fax 07243 / 550-17
Hoval Germany
Hoval Hagenberger GmbH
D-85609 Aschheim Dornach
Karl Hammerschmidt Strasse 45
Telephone 089 / 92 20 97-0
Fax 089 / 550-17
Subject to change
4 204 473 / 01 - 04/05

4 204 473 / 01
2
Safety instructions
In the event of danger:
• Switch off fuel (gas) and electricity supply!
In the event of exhaust and gas smell:
Do not smoke
Avoid open fl ame and sparks
(e.g. switching lights and electrical appliances
on and off)
Disconnect the system and close the gas
cock
Open windows and doors
Inform the heating specialist/installing contrac-
tor
Follow the safety regulations of the gas supp-
ly company (see gas meters) and the heating
specialist!
Keep the air supply in the heating
system room open (windows):
Ventilation apertures should not be
closed, if no direct combustion air
fl ow takes place. Closed fl ow apertu-
res can lead to incomplete combusti-
on. This can lead to poisoning.
Intended purpose:
The TopGas
®
(of 35,45,60) boiler may only
® (of 35,45,60) boiler may only ®
be operated with the fuels indicated in the
technical information/installation guideli-
nes. The heat produced must be removed by
means of heating water. All openings of the
boiler must be closed during operation!
Dear Hoval customer
,
You have acquired in the Hoval TopGas
®
(35, 45, 60)
® (35, 45, 60) ®
a product, which has been manufactured to the latest
state of the art and the highest quality.
For regular installation and operation of your Hoval
TopGas
®
(35,45,60), you must comply with all appli-
® (35,45,60), you must comply with all appli- ®
cable laws, regulations and standards, in particular
the regulations of the responsible power supply com-
panies. For any further inquiries please contact your
specialist installer or your nearest Hoval customer
services unit.
Assembly and installation of the boiler may only be
carried out by trained personnel of a licensed instal-
lation company. Before start-up an installation check
must be carried out and the system must be cleared
by the specialist.
Please only operate your Hoval TopGas
®
(35,45,60)
® (35,45,60) ®
on the basis of these operating instructions, in order
to ensure safe and troublefree operation.
The Hoval TopGas
®
(35,45,60) may only be used for
® (35,45,60) may only be used for ®
its intended purposes and fuels, for which it is sui-
table through its mode of construction and has been
approved by Hoval.
Do not carry out any changes to the system, other-
wise all claims under the guarantee will be waived.
Conversion kits are to be supplied and installed by a
licensed installer or the Hoval after-sales service.
With proper handling your Hoval system will guarantee
you a comfortable living climate for many years
.
General Instructions
Instructions to the protection of persons
Instructions to the protection of the heating
systems
Important information

4 204 473 / 01
3
Controls before the initial start-up
A new system may only be taken into operation if it has
been cleared for operation by the heating engineer.
Filling the heating system
The heating system is fi lled with tap water according
to the instructions of the installer. The system must be
drained of air. Check the pressure at the manometer
or hydrometer.
Filling the ancillary water heater
The water heater must be fi lled on the side of the
consumption water according to the instructions of
the installer. The boiler may be taken into operation
even if the water heater is not fi lled.
Safety valves
The heating system and warm water system must be
protected with one safety valve each from inadmissible
excess pressure.
Loading pump (boiler with ancillary water hea-
ters)
The number of revolutions and capacity control must
correspond to the requirements of the ancillary tank.
To be set by the heating expert.
Heating pumps
The number of revolutions and capacity control must
correspond to the requirements of the system. They
must be set by the heating expert.
Electricity connection
The electricity connection must be made by a spe-
cialist.
Precautionary instructions:
Corrosion protection
Do not use sprays, solvents, chloric cleaning agents,
dyes, adhesives etc. in the environment of the equip-
ment. Sometimes these materials can lead to corrosion
in the boiler and in the exhaust system.
Water level control
Check the water level of the system at regular inter-
vals (page 9).
Filling the Heating System
The water condition
of the heating system water must
be as detailed in our Installation Instructions manual.
The
TopGas
®
(35, 45, 60)
® (35, 45, 60) ®
boiler has an aluminium si-
licon alloy heat exchanger. The use of chemical water
addititives is not allowed. If the fi ll-up and make-up
water volume exceed the volume, according to instal-
lation instructions, sections 4.2.2 and 4.2.5, suitable
water treatment or system separation is required. In the
case of system separ
ation the use of chemical water
additives in the boiler circuit is also not allowed.
The
TopGas
®
(35, 45, 60) boiler is only suitable
® (35, 45, 60) boiler is only suitable ®
f
or use with a sealed system.
General information
The Hoval gas boiler TopGas
®
(35, 45, 60) is equip-
® (35, 45, 60) is equip- ®
ped with automatic adjustment and safety systems.
Under normal conditions they are in operation from
the beginning of the heating season to its end. During
this time the necessary boiler temperature is set by
means of the automatic heating regulation.
If water heating is also provided through the heating
boiler, then the boiler remains switched on for the
whole year.
Fuel
The boiler may only be operated with
the kind of gas indicated on the class
identifi cation plate. To be set by the
installer.
General Instructions

4 204 473 / 01
4
Important instructions
Important instructions
Installation and assembly instruction
• The installing company has given you installation
and assembly instructions. Keep this important
technical information securely, so that if necessary
the customer service mechanic can at a later date
discover the technical details on the spot.
Please close the main blocking clock
ahead of the gas meter as soon as you
smell gas and call the faults department
of your gas supply company.
To ensure that no poisonous exhaust gases develop,
the combustion air must fl ow unhindered into the gas
boiler. Accordingly the ventilation opening provided (in
the room temperature-sensitive mode of operation)
(e.g. basement windows) may never be closed. Also
the boiler itself may not be turned off.
Always keep the room, in which your boiler is installed,
clean and turn off the burner before cleaning, since
dusty combustion air can lead to faults.
Faults
For your safety of the burner switches itself off auto-
matically in the event of faults in the burner system,
excessively low gas pressure, a gas leak or the ex-
ceeding of the maximum boiler temperature. Try fi rst
to ignite the burner several times, after approximately
5 minutes of waiting period, by operating the clearing
button (Reset) on the control panel of the boiler. If that
does not succeed, please close the gas cock and
inform your customer service or heating engineer
.
Imperative requirement!
Perfect operation is only ensured if the
operating instructions are followed and
boilers as well as burners are maintained
regularly by a specialist
.
Faults and damaged caused by installation in unsui-
table areas, e.g. hobby rooms, workshops etc., as well
as by dirty operational agents (gas, water, combus-
tion air), unsuitable chemical additives to the heater
water, inappropriate treatment, incorrect installation
and damage by force do not fall under our warranty;
this also applies to corrosion by halogen compounds
e.g. from spray cans, paints, adhesives and solution
and cleaning agents
.

4 204 473 / 01
5
Preparation for start-up
With a newly installed system the fi rst start-up may
only be carried out by a specialist. Installation checks
must be carried out in full
.
•
Set main switch to 0.
• Open the block valve in the heater fl ow and return
pipe.
• By opening the heating system room window ensure
air supply (fresh air) in the heating system room
(only applies to room air-sensitive operation).
• Open the shut-off valve in the gas pipe to the boi-
ler.
• Switch on the main switches outdoor the heating
system room (if available). Often the heating system
also has another danger switch, which only takes
the gas burner out of operation.
• With the TopGas
®
(35, 45, 60) the trap (siphon) in
the condensate exhaust pipe should be fi lled with
water before start-up
.
Start-up
Operating instructions for boiler control (pa-
ges 6 and 7) with a fi gurative representation
of the switch bay and detailed instructions are
attached to these guidelines. These operating
instructions should be followed for boiler cont-
rol
.
• Set main switch to I
• When lighting up the fault lamps please consult the
section “faults” on page 4.
Taking out of operation
• Set main switch to 0
• Close gas shut off cock
• During a longer interruption, e.g. during your vaca-
tion, you can turn the heating system off.
• If there is a danger of frost, consult your heating
engineer about suitable preventive measures, an-
tifreeze may not under any circumstances enter the
boiler circuit.
Start-Up/Taking out of Operation
/
Boiler Cleaning
Maintenance and control
Instructions on maintenance and control can be
found on page 9
.

4 204 473 / 01
6
Control
Control of the boiler
User-dependent settings (e.g. room temperature) are made to the TopTronic
®
R-S 30 and/or to the TopTronic
® R-S 30 and/or to the TopTronic ®
®
1B/133B. This is preferably in the livingroom (R-S 30) and/or to the boiler (TopTronic
®
1 B/133B). If you do
® 1 B/133B). If you do ®
not have a TopTronic
®
, these settings are made on the basic control. The control panel of the basic control is
behind the lower front lining. The main switch (O/I) for the taking of the boiler out of operation is also behind
the lower front lining in the control panel
.
Normally no settings are required by the user to the basic control. All settings will have been made
by the installer or by the manufacturer
.
5
1
6
3
4
2
TopTronic-RS 30 in the livingroom
For the operation of the TopTronic
®
R-S 30 please
® R-S 30 please ®
consult the special operating instructions
1 LCD display
2 Key for upward adjustments
3 Key for downward adjustments
4 Key for heating program
5 Key for lowering program
6 Information key
TopTronic
®
-RS 30
Main switch
Control panel
Manometer

4 204 473 / 01
7
Legend
Function
Function
Function
Function
1
2*
10
3
-
Controls the boiler’ s internal functions
Settings and changes may only be made by the heating engineer.
In the event of faults the display fl ashes.
For clearing fold the cover down and press the clearing button
- Ensures the correct room temperature for each outdoor tempera-
ture
- Regulates the heating of the water heater etc..
The heating regulator has its own special guidelines
- Central position 20°C
The room temperature can be changed here by ± 8°C
The Controls of the Boiler
Controls
SYSTEM
1. Operating selector switch;
ON/OFF
2. Basic control
3. Electronic heater radiator
4. Control setting
O = Off
Boilers and burners are
out of operation
Note:
No freeze protection
I = On
SYSTEM
I = On
SYSTEM
The boiler is in operation
* also available without elect-
ronic heating regulator
9
7
8
5
6
4

4 204 473 / 01
8
Legend
Function
Function
Function
Function
The controls of the boiler
- Here the desired room temperature for the night can be set
Central position
14°C ± 6°C
Here the heating program can be selected:
Heating and hot water load “OFF”.
Frost protection is ensured
The adjusted room temperature for the night is also ef-
fective during the day
Hot water according to clock program 2
The automatic default operation corresponds to the swit-
ching times entered for the fi rst programme
(Daytime intermediate reduction)
The automatic default operation corresponds to the swit-
ching times entered for the second programme (normal-
position)
The automatic default operation corresponds to the
switching times entered for the third programme (longer
period of operation)
The room temperature is not lowered in the night
Hot water according to clock program 2
Summer operation: Heating “OFF”
Frost protection and hot water load works according to
clock program 2
Hand operation for the specialist. Burner and heating
circulation pump are in operation. Mixing valve discon-
nected, hot water loading remains in operation
Here settings such as time can be entered and values can be que-
ried.
The setting takes place according to special operating instructions
Here the current time, the current boiler temperature and possibly
the water heater temperature are alternately displayed
Short operating instructions only for heating regulator (3)
When desired
Makes possible the operation of the heating regulator (3) in the
livingroom. If a room station is attached, the settings 5-6-7 are re-
placed by the settings on the room station.
Frost protection is ensured
The automatic default operation corresponds to the
The automatic default operation corresponds to the
The automatic default operation corresponds to the
3
The automatic default operation corresponds to the swit-
The automatic default operation corresponds to the swit-
The automatic default operation corresponds to the swit-
2
The automatic default operation corresponds to the swit-
(Daytime intermediate reduction)
The automatic default operation corresponds to the swit-
The automatic default operation corresponds to the swit-
1
5. Control setting “reduced”
6. Program switch
7. Inquiry and programming
keys
8. Display area
9. Operating instructions
10. Room station
�
The room temperature is not lowered in the night
�
The room temperature is not lowered in the night
Hot water according to clock program 2
�
Hot water according to clock program 2
�
The adjusted room temperature for the night is also ef-
�
The adjusted room temperature for the night is also ef-
Hot water according to clock program 2
�
Hot water according to clock program 2
�
Summer operation: Heating “OFF”
�
Summer operation: Heating “OFF”
Frost protection and hot water load works according to
�
Frost protection and hot water load works according to

4 204 473 / 01
9
Maintenance and Control
Maintenance and control
Normally these are carried out by the specialist
on the occasion of the annual maintenance.
Nevertheless, you should carry out the follo-
wing controls and if necessary implement the
works described
.
Check water level
With excessively low water pressure in the sys-
tem (readable at the manometer), you should
inform your installer and/or refi ll the water
.
Refi lling the heating
• The boiler must be switched off! (disconnected from
the net)
• The stop valves in the heater fl ow and return pipes
must be open.
• The connection between the boiler fi lling/emptying
cock and the tap is established through a fi lled
hose (no air should enter the heating system); this
should be unscrewed again after fi lling, in order to
interrupt the connection securely.
• The water quality must correspond to the criteria
described on page 4 of the installation guideli-
nes.
• Slowly fi ll in the water and check the water level at
the manometer (ask for the fi lling pressure for your
system from the installer).
• The bleed valves on the heating elements must be
kept open, until only water fl ows out.
Complete fi lling and emptying should be implemented
by the heating expert
.
Note:
Never fi ll cold water into the hot system
.
Boiler and burner
Have the burner and boiler as well as any neutralisation
mechanism checked and maintained periodically - DIN
4756 recommends at least one maintenance every
year. This maintenance is particularly important with
a high effi ciency boiler such as this Hoval TopGas
®
,
in order to achieve the optimal annual consumption.
You can conclude a servicing contract with your he-
ating engineer or the responsible customer service
organisation.
Maintenance of the neutralisation
The local regulations of the responsible local
waste water authority must be complied with.
If the condensate of your boiler is neutralised before
introducing in the waste water, the neutralisation
system must be periodically cleaned and fi lled with
new granulates. Follow the guidelines for your neu-
tralisation system.
Check before the start of the heating season
whether the siphon of the condensate drainage
pipe is fi lled.
Hot-water supply
Regular controls increase the life span and effi ciency
of any throughput and/or ancillary water heater. Du-
ring the cleaning submerged parts are removed. The
maintenance service will carry out this work.
In areas with calcium rich water the water heater
and/or the throughput heater - in the interest of an
economic hot-water supply - should be periodically
decalcifi ed (1 x annually). The water heater may not
be worked on with metal tools when decalcifying. With
highly calcium rich water the installation of a water
softening system is a good idea
.

4 204 473 / 01
10
Please note
the following!
In the event of operating faults please
carry out the checks in accordance with
the above checklist.
If you cannot remove the fault,
please call the heating engineer
or Hoval customer service.
Fault Check/cause Remedy See page
Gas boiler - Is there a current - Check fuses. Switch on the main and
does not if necessary emergency switches
start
- Is the gas shut off cock open - Open it
- Is a number fl ashing on the basic control - Note the number
- Press the clearing key (Reset key)
- Inform customer service indicating
the fi gure fl ashing
- Is there gas present - Contact the gas company
Radiators do - Are the blocking valves in the heating - Open them
not heat up fl ow and return pipes open
- Is “OFF” indicated on the control panel - Switch on 6
- Press the “-” key until the OFF sign
disappears in the display
- Is the time switch of the TopTronic set - Check in accordance with separate operating
correctly guidelines of the heating regulation
- Check the water level and/or - pressure - Refi ll the water and drain air from the 4
in the heating system heating system
- Are the radiator valves open - Open them
- The heating circulation pump is not - Open the plug
working Turn the shaft end with a screwdriver
fi rmly until the resistance reduces
- Mixing organ does not open automatically - Open by hand; contact customer services
No hot water - The loading pump is not working - Open the plug
Turn the shaft end with a screwdriver
fi rmly until the resistance reduces
- Air is in the loading pipe - If necessary, drain the air by hand
- Operate the automatic air drainer annually
Check list in the event of faults