Hoval TopGas 80 User manual

Technical Information
Installation Instructions
EN
4 207 803 / 01 - 11/09 Subject to modifications
Gas condensing boiler
TopGas®(80)
for natural and liquid gas
Wall-mounted gas boilers TopGas®(80) accord-
ing 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 de-
signed for a flexibly reduced operation in heating
systems according.
Hoval gas boilers are only to be installed and
placedinoperationby technicians;theseinstruc-
tions are therefore intended for the specialist.
Electrical installation work is only to be carried
out by an electrician.
Rated output levels at 40/30°C and
natural gas
2-TopGas®(80) 17,3 - 80,0 kW

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Contents
1. General 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 Information ..................................................................................... 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 hydrau-lic 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 Examples of 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 information for the TopGas®............................................................. 17
3.5.3 Natural ventilation flue example................................................................................... 18
3.5.4 Flue gas system for room sealed operation................................................................. 19
3.5.5 Roof heating centre concentric flue (room sealed)...................................................... 19
3.5.6 Wall outlet.................................................................................................................... 20
3.5.7 Connection of pipelines ............................................................................................... 21
3.5.8 Condensate draining and neutralisation...................................................................... 21
3.5.9 Gas connection............................................................................................................ 21
3.6 Electrical connection ................................................................................................ 21
3.6.1 Electrical connection regulations................................................................................. 21
3.6.2 Electrical connection (mains) 230 V, 50 Hz ................................................................. 22
3.6.3 Boiler control / electrical connection diagram.............................................................. 22
3.6.4 Connection of the heating controller............................................................................ 22
3.6.4.1 TopTronic® RS-OT ........................................................................................................ 22
3.6.4.2 TopTronic®T/N ............................................................................................................. 22

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Contents
4. Commissioning ............................................................................................. 22
4.1 Setting the control..................................................................................................... 22
4.2 Water quality .............................................................................................................. 22
4.2.1 Heating water .............................................................................................................. 23
4.2.2 Filling and replacement water...................................................................................... 23
4.2.3 Filling up the system.................................................................................................... 24
4.3 Gas adjustment.......................................................................................................... 24
4.3.1 Bleeding the gas pipeline ............................................................................................ 24
4.3.2 Commissioning............................................................................................................ 24
4.3.3 Gas inlet pressure ....................................................................................................... 24
4.3.4 Gas fitting .................................................................................................................... 24
4.3.5 Setting the gas flow rate .............................................................................................. 25
4.3.6 Changing to a different kind of gas.............................................................................. 25
4.4 Handing over to the user .......................................................................................... 26
4.4.1 Instruction the user...................................................................................................... 26
4.4.2 Checking the water level.............................................................................................. 26
4.4.3 Maintenance................................................................................................................ 26
5. Decommissioning ......................................................................................... 27
6. System maintenance and cleaning.............................................................. 27
6.1 Water-side leak check ............................................................................................... 27
6.2 Refilling ...................................................................................................................... 27
6.3 Maintenance includes:.............................................................................................. 27
6.4 Cleaning the heat exchanger.................................................................................... 27
6.5 Function check .......................................................................................................... 27
7. Faults.............................................................................................................. 29
8. Automatic firing unit BIC 335-Parameter list .............................................. 32

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1. General Information
1.1 Symbols
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
1.2 Guarantee
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
approved specialists. No modifications are to
be made to the boilers.
1.3 Other instructions
Depending on the model, any further instructions are
enclosed with the individually packed components.
- Adjustment
- Accessories
Further information sources
- Hoval catalogue
- Standards, regulations
1.4 Safety instructions
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.
1. General Information

4 207 803 / 01
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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 regu-
lations of the local water authorities and can
differ from the provisions of the technical drain-
age directive ATVM251. Please obtain informa-
tion on the relevant local regulations.
1.6 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
1.5 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 flow
calculation methods
• DIN EN 12828 Heating systems in buildings - Plan-
ning of hot water heating systems.
• VDI 2035 Prevention of damage through cor-
rosion 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
flow calculation methods
•OENORM 12828 Heating systems in buildings
- Planning of hot water heating systems.
•OENORM H5152 Brennwert
- Feuerungsanlagen
•OENORM H5195-1 Prevention of damage through
corrosion
•M 7443, (Part 2,3,7) Gas appliances with atmo-
spheric burners
•M 7446, Heat output appliances for gaseous fu-
els
•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
1. General Information
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

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2. Technical Information
2.1 Technical Data
2.Technical Information
Type (80)
• Nominaloutput80/60°Cwithnaturalgas1kW 15,8 - 72,4
• Nominaloutput40/30°Cwithnaturalgas1kW 17,3 - 80,0
• Nominaloutput80/60°Cwithpropanegas3kW 19,5 - 72,4
• Nominaloutput40/30°Cwithpropanegas3kW 21,6 - 80,0
• Nominalloadwithnaturalgas1kW 16,5 - 75,0
• Nominalloadwithpropanegas3kW 20,0 - 75,0
• Workingpressureheatingmaximum/minimum  bar 4,0/1,5
• Workingtemperaturemaximum  °C 85
• Boilerwatercontent    l 10
• Minimumwaterow    l/h 800
• Boilerweight(withoutwatercontent)  kg 107
• Standardefciency(DIN4702,part8) 40/30°C % 109,4
• (relatedtonet/grosscaloricvalue) 75/60 °C % 106,1
• Stand-bylossat70°C   Watt 95
• Standardemissionrate
Nitrogen oxides mg/kWh 18
Carbon monoxide mg/kWh 27
• ContentofCO2in the exhaust gas maximum/minimum output % 9,0 / 8,8
• Dimensions: seetableofdimensions
• Connections
Flow/Return Inches Rp 1¼"
Gas Inches R ¾"
Flue gas/combustion air (concentrically) mm C100 / 150
• Gasowpressureminimum/maximum
Natural gas E/LL mbar 18 - 50
Propane gas mbar 37 - 50
• Gasconnectionvalueat0°C/1013mbar::
Natural gas E - (Wo = 15,0 kWh/m3) Hu= 9,97 kWh/m3 m3/h 1,65 - 7,5
Propane gas 3(Hu= 25,9 kWh/m3) m3/h 0,77 - 2,90
• Operationvoltage    V/Hz 230/50
• Controlvoltage    V/Hz 24/50
• Minimum/maximumelectricalpowerconsumption  Watt 23/130
• Stand-by     Watt 7
• IPrating(integralprotection)  IP 20
• Soundpowerlevel    dB(A) 63
• Soundpressurelevel(dependingoninstallationconditions)2dB(A) 53
• Condensatequantity(naturalgas)at40/30°C  l/h 7,1
• pHvalueofthecondensate   ca.4,2
• Valueforchimneycalculation
Requirement flue gas system, temperature class T 120
Flue gas mass flow kg/h 124,5
Flue gas temperature at operation 80/60 °C °C 79
Flue gas temperature at operation 40/30 °C °C 49
Feed pressure total at the combustion air/flue gas pipe Pa 140
Maximum draught / depression at flue gas outlet Pa -50
1Data related to Hu. The boiler series is tested for EE/H-settings. With a factory setting of the Wobbe coefficient of 15.0 kWH/m3operation at a
Wobbe coefficient of 12.0 up to 15.7 kWh/m3is possible without new settings.
2See also notes at „Engineering“.
3Data related to Hu.

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2.Technical Information
2.2 Dimensions
Measurements (mm)
• 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 Rp ¾"
2 Heating flow Rp 1¼"
3 Heating return Rp 1¼"
4 Condensate drain DN 40
5 LAS Flue gas-/combustion
air connection C 100/150
6 Cover control panel
7 Safety valve
8 Ball valve
View from bottom
View from top

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0
50
100
150
200
250
300
0.0 1.0 2.0 3.0 4.0 5.0 6.0
2.3 Boiler flow resistance
2.Technical Information
Water-side resistance [mbar]
Flow rate [m3/h]
2.4 Short description of the automatic firing
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
Boiler incl. con-
nection 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 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

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2.Technical Information
2.5 Control of the boiler
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 blin-
king, if there is a failure)
Saving of the
settings
Options, to change settings
(Parmeter) (p.ex. Calorifier
temperature)
ON/OFF Manometer
Function
Standby-Mode
Normal position,
Start position
no indication
Value indication
current flow temperature
Mode indication
Function options (stepwise
display option)
Parameter Indication
Meaning, Description
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

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2.Technical Information
Meaning, DescriptionFunction
Value indica- tion
Mode indication
Parameter Indication
0 z.B. 45° Current flow temperature
(Heating water temperature)
1 z.B. 40° Current return temperature
2 z.B. 60° Current temperature in water heater
3 z.B. 3° Current outdoor temerature
4 z.B. 55° Current flue gas temperature
5 z.B. 50° Flow set value in the heating system
6 z.B. 70° Flow set value in hot water operation
7 z.B.23 RPM Fan speed in hundreds
8 z.B. 4 µ A Ionisation flow
It is possible to read monetary values
from here
Informations-Mode
Point is blinking
Point appears
Settings can be changed in this mode.
Procedure:
1. Select parameter Mode
(press Mode key 2 x)
Parameter (P.7) and setting appear
alternate
2. Selectparametertobechanged (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.
Parameter-Mode
P.7 60 = Hot water set value
if threre is no TopTronic®attached.
P.18 80 = Max. Flow temperature during heating ope
ration
Par. 18
Setting of the service codes
For entering the code, press the keys „Mode“ und „Step“ simultaneously. The blinking numeral can be chan-
ged 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 coresponding 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 pessing
any further keys!). If the „Store“- key won‘t be pressed, the settings are not saved.

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2.Technical Information
2.6 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 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.

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2.Technical Information
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 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 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.

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3. Installation
3.1 Description of the Hoval TopGas®
The heat exchanger of the Hoval TopGas®(80) com-
prisesacorrosion-resistantaluminumcasting,through
whichthe heating waterflowsin 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
withcorrespondingly lowsystem temperaturesthe flue
gas is cooled below the flue gas dewpoint. Through
the additional utilisation of the latent flue gas heat
(heat output utilisation) the Hoval TopGas®(80) op-
erates with very high efficiency. On leaving the heat
exchanger the cooled flue gas is transferred to the
flue gas pipeline system
3.1.1 Diaphragm expansion tank
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.
3.1.2 Boiler casing
This is of sheet steel, with a white powder-paint finish,
with easily removable front.
3. Installation
3.1.3 Gas fittings
Honeywell VK4125V gas controller for the automatic
regulation of the gas/combustion air ratio, see sec-
tion 4.3.4.
3.1.4 Automatic gas firing unit and heating control-
ler
Automatic firing unit BIC 335
(see 2.4 for short description).
3.1.5 Heating circulation pump
The TopGas®(80) is delivered without an installed
heating circulation pump. A sufficiently dimensioned
heating circulation pump must be installed by the
customer.
3.1.6 Hot water supply
The Hoval TopGas®(80) can be combined with a ser-
vice 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 in the boiler).
3.1.7 Scope of supply
- Manometer
- Autom. deaerator in the boiler flow
- Plastic siphon in the condensate drain line
- Water pressure deflector as a boil-dry safe-
guard
- Flue gas temperature sensor
- Gas connector piece 3/4”
- Electrical connection cable approx. 1,5 long, with
connector plug
- Gas pressure deflector

4 207 803 / 01
14
3. Installation
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
Figure 3.1.8-2
3.1.8 TopGas®component designation
13 14
12 15
Figure 3.1.8-1
8
1
7
5
4
3
6
2
9
10
11

4 207 803 / 01
15
3.2 Boiler installation room
Hoval heat output boilers series TopGas®(80) 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.
3.3 Installing the boiler
The Hoval TopGas®(80) is delivered as follows.
Carton: Boiler;claddingcomponents,installationand
operating instructions.
The boiler must not be placed on its connector
elements.
Mount the boiler to the wall at the planned location.
Distancefromtheside:at least 5 cm;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 section 2.2.
3.4 Hydraulic connection
The Hoval TopGas®(80) is suitable for flexible opera-
tion (room temperature control or weather-supported
boiler and heating control) temperature 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.
3.4.1 Protection planning guidelines for the hydrau-
lic 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.
roofcentralheating plants), the expansiontank must
be installed in the flow line.(Note:starting from 70°C
an additional connecting tank is necessary).
•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!
3.4.2 Boil-dry safeguard
To safeguard the boiler against low water levels or
waterdeficiency, a waterpressure deflector is installed
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.
3.4.3 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.
3.4.4 Minimum flow rate
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.
3. Installation

4 207 803 / 01
16
3. Installation
TopGas®(80) with water heater and two regulated
mixed circuits
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
3.4.5 To be provided by customer
Apressure expansiontank adaptedtoheatingsystem,
water volume and static height.
3.4.6 Examples of hydraulic interconnection
TopGas®(80) with water heater and direct heating
circuit
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)
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
M5
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
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)
M5

4 207 803 / 01
17
3.5 Flue gas connection, chimney and
condensate pipeline
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 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.
Inbothcasesthecrosssectionsandmaximum lengths
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 page 6 (DIN 4705).
The calculation is normally made by means of graphs
ortablesprovided bythemanufacturer of the moisture-
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.
3.5.1 Waste gas pipelines in compliance with build-
ing construction law
The flue gases from the Hoval TopGas®(80) can be
removed via a gas-tight, temperature and corrosion
resistant flue gas pipeline. Only flue gas systems ap-
proved and tested by the relevant region or province
are to be connected to the Hoval TopGas®(80) (the
admissions of individual federal states should be
complied with in Austria). The suppliers of the flue
gas pipelines supply suitable boiler connectors for the
transition from the boiler to the flue gas pipeline.The
flue gas connector on the Hoval TopGas®(80) has a
concentric flue gas connection ø 100/150 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.
3.5.2 Project planning information for the TopGas®
• Allapplicableregional,nationalandstateregula-
tions are to be observed with respect to the flue
gas extraction system.
• Allairinlet/uegaspipelinesmusthaveamea-
suring 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.
Single flue gas pipes can be shortened to the
necessary length but must however be cleanly
deburred before the assembly, to prevent damage
to the seal in the counter-piece.
3. Installation

4 207 803 / 01
18
3.5.3 Natural ventilation flue example
3. Installation
• Wheninstallingthepipesinashaft,spacerele-
ments must be mounted every 2 m.For the vertical
supporting of the chimneypipeline, the very bottom
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.
To pGas
Ve rbrennungsluft
Falls erforderlich ist
ein Inspektions-T-
Stück einzusetzen
The condensate from the exhaust gas
system must not be discharged through
the boiler.The condensate must be dis-
charged from the exhaust pipe before
the boiler through a siphon.
if necessary an
inspection-T-piece is
to attach
combustion air

4 207 803 / 01
19
3. Installation
3.5.5 Roof heating centre concentric flue (room
sealed)
3.5.4 Flue gas system for room sealed operation
TopGas
Falls erforderlich ist
ein Inspektions-T-
Stück einzusetzen
Verbrennungsluft
if necessary an
inspection-T-piece
is to attach
combustion air
To pGas
Falls erforderlich ist
ein Inspektions-T-
Stück einzusetzen
Verbrennungsluft
combustion air
if necessary an
inspection-T-piece is
to attach
The condensate from the exhaust gas
system must not be discharged through
the boiler. The condensate must be dis-
charged from the exhaust pipe before the
boiler through a siphon.

4 207 803 / 01
20
3.5.6 Wall outlet
3. Installation
TopGas