Hoval TopGas 80 User manual

To be completed by the heating specialist:
Order No.:
Boiler type:
Set to:
Natural gas H Natural gas L Liquid gas
Heating pump type:
Heating controller type:
Mixing unit type:
Separate calorifier type:
Calorifier sensor Thermostat
Outdoor temperature sensor
Room temperature sensor
Combustion air supply Room Outdoor
Heating system calculation basis
Lowest outside temperature °C
Heat requirements: kW
Max. feed temperature: °C
Important telephone numbers
Heating system installer
Sanitation plumbing installer
Electrical system installer
Fuel supplier
Chimney sweep
Operating instructions
TopGas
®(80)
4 203 413 / 00 Subject to changes
Hoval LTD
Northgate
Newark
Nottinghamshire NG24 1JN
Phone: [phone]
Fax: [phone]
Hoval Export
Austrasse 70
Principality of Liechtenstein
Phone: [phone]
Fax: [phone]
[email protected]

4 203 413 / 00
2
Safety information
In the case of danger:
• Turn off the fuel (gas) supply and switch off the
electrical supply!
If you smell flue gas or gas:
Do not smoke
No open fire or sparks
(e.g. avoid switching on or off lights and
electrical appliances)
Switch off the heating system
Close the gas cock
Open doors and windows
Notify the heating firm/contact installer
Comply with the safety instructions of the
gas supplier (see gas meter) and the
heating specialist!
Maintain the air supply in the
boiler installation room
(window):
Intake and outlet air openings
must not be closed, otherwise
there is no direct supply of
combustion air. Closed intake air
openings result in incomplete
combustion and possible toxic
effects.
Intended purpose:
The TopGas®(80) heating boiler is
only to be operated with the fuels
stated in the Tech. Information / In-
stallation instructions. The heat
produced must be transported with
heating water . All boiler covers must
be in place during operation!
Dear Hoval customer
With the Hoval TopGas®(80) you have acquired a
state-of-the-art product manufactured to the highest
quality standards.
Compliance with all applicable laws, regulations and
standards is necessary for the correct installation and
operation of your Hoval TopGas®(80), in particular the
regulations of the responsible energy supplier. For
queries please contact your installer or your nearest
Hoval customer after-sales service agent.
The assembly and installation of the boiler is only to be
carried out by the trained staff of a licensed installer.
Before commissioning, an installation check is to be
carried out and the system is to be cleared for operation
by the specialist.
To ensure safe and fault-free service, operate your
Hoval TopGas®(80) only according to these operating
instructions.
The Hoval TopGas®(80) may only be used for the
purposes and fuels for which it is suitable on the basis
of its design, and for which it has been cleared by
Hoval.
Do not carry out any changes to the system, otherwise
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 domestic climate for many years.
General information
Information for the safety and protection of
persons
Instructions for the protection of the heating
system
Important information

4 203 413 / 00
3
Safety valves
The heating system and the hot water system are to be
protected against excessive over-pressure by safety
valves.
Filling pump (boiler with separate calorifier)
The speed and flow control must correspond with the
requirements of the separate calorifier. Settings are
made by the heating specialist.
Heating pumps
The speed and flow control must correspond with the
requirements of the system. Settings are made by the
heating specialist.
Electrical connection
The electrical connection is to be made by an electrician.
The circuit diagram is inside the cover of the controller.
Precautionary information:
Corrosion protection
Do not use any sprays, solvents, cleaning agents
containing chlorine, adhesives etc. in the vicinity of the
boiler. These substances can cause corrosion in the
boiler and the flue gas system.
Check the water level
Check the system water level at regular intervals
(page 9).
Filling the heating system
Normally the system can be filled and replenished with
mains water. In exceptional cases water can be
unsuitable for the heating system (highly corrosive or
high lime content). In such cases contact your approved
specialist.
General
Hoval gas boilers TopGas®(80) are fitted with automatic
control and safety systems. They are normally in
operation from the start to the end of the heating
period. During this time the necessary boiler
temperature is set with the automatic heating controller.
If the boiler is also used for water heating, the boiler
remains switched on for the whole year.
Fuel
The boiler is only to be operated
with the type of gas indicated on
the rating plate. Setting the gas
type is carried out by the installer.
Checks prior to commissioning
A new system is only to be placed in operation when
it has been cleared for operation by the heating installer.
Filling the heating system
The heating system is filled with mains water according
to the instructions of the installer. All air must be bled
from the system. Check the pressure at the pressure
gauge or hydrometer.
Filling the separately installed calorifier
Fill the calorifier according to the instructions of the
installer. The boiler can also be operated when the
calorifier is not filled.
General information

4 203 413 / 00
4Important information
Important information Erection and assembly instructions
• The installer has handed you the installation
instructions. Look after this important technical
document in order that it can be referred to later on
site by the after-sales service fitter.
If you smell gas, close the gas shut-
off cock before the meter and call
your gas supplier immediately!
To prevent the occurrence of toxic flue gases the
combustion air must be allowed to flow unobstructed
to the boiler. Therefore the envisaged opening (in the
case of room air dependent operation) (e.g. cellar
window) must never be closed. Also the boiler itself
must not be closed off.
Always keep the boiler installation room clean and
switch off the burner before carrying out cleaning, as
dust laden combustion air can cause problems.
Faults
For your safety the burner switches off automatically in
the case of burner faults, excessively low gas pressure,
gas supply failure or of the maximum permissible
boiler temperature is exceeded. First make several
attempts to ignite the boiler after a waiting period of
around 5 minutes, by pressing the reset button on the
boiler control panel, If this is unsuccessful, contact
your after-sales service or heating installer.
Important note!
Proper function is only guaranteed
if the operating instructions are
observed and boiler and burner are
regularly maintained by a specialist.
Faults and damage caused by installation in unsuitable
rooms, e.g. hobby rooms, workshops etc.), also
contaminated operating media (gas, water, combustion
air), unsuitable chemical additives to the heating water,
incorrect handling, faulty installation and damage due
to the exercising of force are not covered by our
guarantee; the same applies to corrosion through
halogen compounds, e.g. from spray cans, paints,
adhesives, solvents and cleaning agents.

4 203 413 / 00
5
Preparations for commissioning
In the case of a newly installed system, commissioning
may only be carried out by a specialist. The installation
check must be carried out in full.
• Place main switch to O
• Open the shut-off valve in the heating feed and
return.
• Make sure there is a supply of air (fresh air) to the
boiler installation room by opening the boiler room
window (only applies for room dependent operation).
• Open the shut-off valve in the gas pipeline to the
boiler.
• Switch on the main switch outside the boiler room
(where installed). Often the heating system has a
further danger switch which only switches off the
burner).
• In the case of TopGas®(80) the odour trap (siphon)
in the condensate drain line is to be filled with water
before commissioning.
Commissioning
Included with these instructions are
operating instructions for the boiler control
(page 7,8) with an illustration of the control
panel and detailed information. These
operating instructions for the boiler control
are to be complied with.
• Place the main switch to I
• If a fault lamp lights, please turn to the section
”Faults” on page 4
Decommissioning
• Place the main switch to O
• Close the gas shut-off cock
• In the case of a long break, e.g. during holidays, you
can switch off the heating system.
• If there is a risk of frost, speak to your heating
specialist about suitable preventive measures; frost
agents are never to enter the boiler circuit.
Commissioning / decommissioning
Boiler cleaning
Maintenance and checking
See page 9 for maintenance and checking information.

4 203 413 / 00
6Control
Boiler control
User-dependent settings (e.g. room temperature) are made at the TopTronic®RS-30 or TopTronic®1B/133B.
This is preferably installed in the living room (RS 30) or in the boiler (TopTronic®1B/133B). If no TopTronic®is
installed, these settings are made to the basic control. The control panel for the basic control is behind the front
cladding. The main switch (0/I) for placing the boiler out of operation is also in the control panel, behind the front
cladding.
Normally no settings have to be made to the basic control by the user. All settings are
made by the installer or at the factory.
5
1
6
3
42
TopTronic®RS 30 in the living room
See the special operating instructions for the
TopTronic®RS 30.
1 LCD display
2 Button for increasing corrections
3 Button for decreasing corrections
4 Button for heating program
5 Reduction program
6 Information button
TopTronic®-RS 30
Main switch
Control
panel
Pressure
gauge

4 203 413 / 00
7
SYSTEM
Legend Function
1
2*
10
3
- Controls the internal boiler functions
Settings and changes are only to be carried out by the heating
specialist. The indication flashes to display faults. To reset, fold the
cover down and press the Reset button.
- Guarantees the correct room temperature whatever the outside
temperature.
- Regulates the heating of the hot water etc.
Special instructions are included for the heating
controller.
- Medium setting 20°C
Here the room temperature can be changed by ±8°C.
Boiler operating elements
Operating elements
SYSTEM
1. Mode selection switch
ON/OFF
2. Basic control
3. Electronic heating
controller
4. Nominal setting
O = Off
Boiler and burner are inoperative
Attention:
No anti-freeze
I= On
Boiler operating
* also supplied without
electronic heating controller
4
569
7
8

4 203 413 / 00
8
5. Setpoint value
"Reduced”
6. Program switch
7. Interrogating and
programming buttons
8. Display field
9. Operating instructions
10. Room station
Legend Function
Boiler operating elements
- The desired night-time room temperature can be set here.
Medium setting 14°C ±6°C
The heating program can be selected here:
Heating and hot water filling ”OFF”.
Frost protection guaranteed
The room temperature night-time setting is also effective
during the day.
Hot water according to clock program 2.
Automatic controlled operation according to the
switching times set for the 1st program
(daytime interim reduction)
Automatic controlled operation according to the
switching times set for the 2nd program (normal setting)
Automatic controlled operation according to the
switching times set for the 3rd program (longer operating
time)
The room temperature is not reduced in the night
Hot water according to clock program 2
Summer operation: Heating ”OFF” Frost protection, hot
water filling is effective corresponding to clock program
2.
Manual operation for the specialist. Burner and
circulation pump are operating. No supply to mixing
valve, hot water filling remains in operation.
Settings such as time of day and values can be interrogated here.
Settings are made according to the special operating instructions.
Displayed alternately here is the present time, current boiler temperature
and where applicable, the calorifier temperature.
Quick reference operating instructions for heating controller only (3).
Optional
Permits operation of the heating controller (3) in the living room. When
a room station is connected, settings 5-6-7 are replaced by the settings
at the room station.
3
2
1

4 203 413 / 00
9
Maintenance and checking
Maintenance and checking
Normally the work described below is
carried out by the specialist during the
annual maintenance. Nevertheless, carry
out the following checks in the course of
the year and where necessary, also carry
out the work described.
Check the water level
If the system water level is too low (can be read from
the pressure gauge), notify your installer or top up the
water yourself.
Topping up the heating system
• No power is to be supplied to the boiler! (disconnect
from the mains supply)
• The shut-off valves for the heating feed and return
must be open
• The connection between the boiler filling / draining
cock and the water cock is established with a filled
hose (no air must be allowed to enter the heating
system); for safe disconnection, this must be
unscrewed after filling.
• The water quality must satisfy the criteria detailed
on page 4.
• Introduce the water slowly, check the water level at
the pressure gauge (your installer will inform you of
the filling pressure of your system)
• Keep the bleed valves on radiators open until only
water flows out.
Complete filling and draining is to be carried out by the
heating specialist.
Attention:
Never add cold water to a hot
system.
Boiler and burner
Have the burner and boiler plus any neutralisation
system periodically inspected and maintained – DIN
4756 recommends at least an annual check. This
maintenance is especially important for a high efficiency
boiler such as this Hoval TopGas®, in order to achieve
optimal annual efficiency. You can take out a
maintenance contract with your heating installer or the
responsible after-sales organisation.
Maintenance of the neutralisation system
The local regulations of the responsible
communal waste water authority must be
complied with.
If the condensate from your boiler is neutralised before
entering the drain system, this system must be
periodically cleaned and filled with new granulate.
Comply with the instructions for your neutralising
system.
Before the start of the heating period,
check whether the siphon of the
condensate line is filled.
Hot water supply
Regular checks extend the life and improve the
profitability of any flow type or separately installed
calorifier. Cleaning will remove any suspended
particles. This work is carried out by the maintenance
service.
In areas with a high lime content the calorifier or flow
type heater should be periodically delimed (once per
year) in the interest of an economical hot water supply.
Do not use metal tools for deliming. The installation of
a water softener system is recommended in areas with
a high lime risk.

4 203 413 / 00
10
Please note!
In the event of operating faults, carry out
the checks according to the above
checklist.
If you are unable to rectify the
fault, please contact your
heating installer or the Hoval
after-sales service.
Fault Check / cause Rectification See page
Gas boiler -current available -check the fuses. Switch on the main or
does not emergency-off switch
start
-is the gas shut-off cock open -open
-does a number flash on the basic control -make a note of the number
-press the Reset button
-inform your after-sales service, stating
the flashing number
-is gas available -enquire from gas supplier
Radiators do -are the shut-off valves in the -open
not become heating feed and return open
warm
-is ”OFF” displayed on -press the ”-” button until the OFF sign goes out in the
the basic control display 7
-is the TopTronic®timer correctly set -check according to the separate operating instructions
for the heating controller
-check the heating system water -replenish water and bleed air from the heating system 9
level or pressure
-are the radiator valves open -open
-the heating circulation pump is not running -open sealing screw
turn end of the shaft vigorously with a screwdriver
until the resistance is reduced
-the mixing element does not open -open by hand; call after-sales service
automatically
No -the filling pump is not running -open sealing screw
hot water turn end of the shaft vigorously with a screwdriver
until the resistance is reduced
-is there air in the filling line -where necessary, bleed manually
-actuate automatic venting by hand
Fault checklist

4 203 413 / 00
11
How to save energy!
The room temperatures
and heating system
operating times have a
decisive influence on fuel
consumption.
A 1°C lower room temperature
yields a fuel saving of up to 6%.
So note the following tips:
•Avoid room temperatures of
over 20°C and set your heating
system accordingly.
•It is worthwhile closing the
radiator valves in unused rooms
providing there is no risk of frost
and no damage to the building
structure or furnishings is
anticipated.
•Heat recycling takes place in the
main living rooms through body
heat, television sets, chimneys
and also solar radiation. These
cannot be compensated with a
weather dependent control. It is
worthwhile installing individual
thermostatic radiator valves in
these rooms.
When there is a draught,
it’s not only unpleasant but
it also means a loss of
heat energy.
So you’ll save fuel if you . . .
•Keep doors and windows
closed in the winter
•Close flue flaps when the fire is
out
•Use kitchen and bathroom fans
only when steam and odours
have to be extracted
•Ventilate for short periods, but
frequently.
•Seal doors and windows to
avoid permanent leakage
losses.
Keep in valuable heat with
insulation.
Utilise these possibilities and . . .
•Close door and window shutters
at night
•Make sure heating and hot
water pipes in unheated rooms
are insulated.
The lowest possible
radiator temperature
prevents unnecessary heat
loss.
So radiators must always
be able to transfer their
heat to the room
unhindered. Avoid
therefore:
•Covered radiators
•Windowsills which allow no heat
to pass through because they
are occupied by objects.
Savings are also possible
with hot water systems.
•Set the calorifier temperature as
low as possible. Find the lowest
possible temperature setting at
which sufficient hot water is still
available.
•If your system includes a hot
water circulation pump, it’s
worthwhile switching this off at
night with a timer clock.

4 203 413 / 00
12 Maintenance contract
Maintenance contract
The Hoval After-Sales Maintenance
Contract
To ensure fault-free and cost-effective operation of
your new heating system, we recommend that you
take out a Hoval After-Sales Maintenance Contract.
With this agreement the Hoval After-Sales Service
makes all the timing arrangements for the
necessary annual maintenance.
In the period April to October, after prior agreement,
your boiler will be thoroughly checked, its values
measured and set up for optimal operation.
Any repairs will be carried out at once with your
agreement.
A maintenance contract carries a wide
range of benefits
• Your guarantee period is extended when you take
out a maintenance contract.
• Your heating system is always optimally set, saving
heating costs and protecting the environment.
• High level of operating reliability, since any faults
are detected early in the course of maintenance
and can be rectified.
• The optimal setting and regular maintenance extend
the service life of your system.
• The attractive lump sum price. Apart from any
necessary spares, nothing extra has to be paid for
the maintenance.
Date Text:
Enter checks, inspections, fuel purchases etc. here