Hoval TopGas classic 35 User manual

United Kingdom
Hoval Ltd.
Northgate
Newark
Nottinghamshire NG24 1JN
Phone [phone]
Fax [phone]
Export
Hoval Aktiengesellschaft
Austrasse 70
LI-9490 Vaduz
Principality of Liechtenstein
Phone [phone]
Fax [phone]
Subject to modifi cations | EN
Operating Instructions
4 213 892 / 01 - 07/15
TopGas®classic (35,45,60,80,100,120)
Gas condensing boiler

1. To get the most out of your heating system, read the operating instructions!.................................... 3
1.1 Important addresses and telephone numbers....................................................................................................................3
1.2 Key to symbols used...........................................................................................................................................................3
1.3 System data .........................................................................................................................................................................4
1.4 Calculation basis.................................................................................................................................................................4
2. Safety instructions.................................................................................................................................. 5
2.1 Cautionary notes .................................................................................................................................................................5
2.2 Intended use ........................................................................................................................................................................5
3. Customer service.................................................................................................................................... 6
4. Functional principle of the heating system ........................................................................................... 7
5. Commissioning ....................................................................................................................................... 8
5.1 Checks prior to operation ...................................................................................................................................................8
5.2 Switching on........................................................................................................................................................................8
6. Heating system control........................................................................................................................... 9
6.1 Boiler controller...................................................................................................................................................................9
6.2 The operating elements of the RS-OT heating regulator ................................................................................................. 11
6.3 Operating elements of the TopTronic®E heating regulator (optional) ............................................................................13
7. Checklist in case of faults .................................................................................................................... 15
8. Checking the water level ...................................................................................................................... 16
9. How to save energy............................................................................................................................... 17
10. Hoval Service / sales programme......................................................................................................... 18
24 213 892 / 01
TABLE OF CONTENTS

1. To get the most out of your heating system, read the operating instructions!
These instructions will provide you with all the information you need for optimum use of your heating system.
An optimally adjusted heating system can not only save you a lot of trouble, but also a lot of money
1.1 Important addresses and telephone numbers
Heating engineer: ...................................................................
...................................................................
Plumber: ...................................................................
...................................................................
Electrician: ...................................................................
...................................................................
Chimney sweep: ...................................................................
...................................................................
Fuel supplier: ...................................................................
...................................................................
1.2 Key to symbols used
Instruction:
Prompts you to carry out an action
Result:
Shows the expected reaction to your action
i
Note:
Provides important information
Safety instructions:
Indicate an immediate hazard to persons
Cautionary notes:
Indicate danger to machines and installations
ENERGY Energy-saving tips:
Provide information on how to save energy
TO GET THE MOST OUT OF YOUR HEATING SYSTEM, READ THE OPERATING
INSTRUCTIONS THOROUGHLY!
34 213 892 / 01

1.3 System data
To be completed by the heating engineer!
Order no..: ...............................................................................................
Boiler type: ...............................................................................................
Heating pump type: ...............................................................................................
Heating regulator type: ...............................................................................................
Mixer type: ...............................................................................................
Calorier type: ...............................................................................................
DHW sensor: Yes No
Thermostat: Yes No
Type of gas: Natural gas H Natural gas L Liquid gas
Neutralisation unit: Yes No
Condensate pump: Yes No
Fresh air sensor: Yes No
Room air sensor: Yes No
Dependent on room air: Yes No
Not dependent on room air: Yes No
Number of heating circuits: 1 2
3 4
Heating circuit HC = ...............................................................................................
Heating circuit MC1 = ...............................................................................................
Heating circuit MC2 = ...............................................................................................
Heating curve value HC = ...............................................................................................
Heating curve value MC1 = ...............................................................................................
Heating curve value MC2 = ...............................................................................................
1.4 Calculation basis
Lowest outside temperature: .............................................................................................. °C
Heat demand: .............................................................................................. kW
Max. ow temperature: .............................................................................................. °C
TO GET THE MOST OUT OF YOUR HEATING SYSTEM, READ THE OPERATING
INSTRUCTIONS THOROUGHLY!
44 213 892 / 01

2. Safety instructions
In the event of danger!
Cut off the fuel (gas) and electricity supplies
If you smell gas!
Do not smoke
No open ames
Avoid the occurrence of sparks
Do not switch on the light or other electrical appliances
Open windows and doors
Close the gas shut-off valve
Notify the heating company / installing contractor
Follow the safety regulations on the gas meter
Follow the safety regulations of the heating company
If you smell ue gas!
Turn the system off
Open windows and doors
Notify the heating company
• Supply air openings
- Air inlets and outlets must not be closed. Closed supply air openings can lead to incomplete
combustion and possible poisoning.
- Exception: Your system is operated independent of room air
• Commissioning of a newly installed system may only be carried out by a qualied installer. The
complete installation inspection must be performed - see Chapter 5
2.1 Cautionary notes
• Check the water level - see Chapter 8
•
Keep the room in which the boiler is installed clean at all times and turn off the burner before
starting cleaning to avoid any faults due to dusty combustion air.
• Corrosion protection:
-
Do not use sprays, solvents, chlorine-based cleansing agents, paint, adhesives etc. in the
proximity of the boiler. Under certain circumstances, these substances can cause corrosion
inside the boiler and the ue gas system!
2.2 Intended use
i
• Intended use:
The TopGas®
boiler may only be operated with the fuels indicated in the Technical Information/
installation instructions.
The heat produced must be carried away by the heating water. All boiler openings must be
closed during operation.
SAFETY INSTRUCTIONS
54 213 892 / 01

3. Customer service
i
The following information should be read
before starting up the boiler!
Dear Customer,
With the Hoval TopGas®, you have acquired a product
manufactured according to the state-of-the-art and to the
highest quality standards.
Please ensure that the delivery is consistent with your
order and check it for completeness. Also check for pos-
sible damage incurred during transport and inform the
nearest Customer Service centre of any damage. For
insurance reasons, it will not be possible to accept any
subsequent claims.
For the correct installation and operation of your Hoval
TopGas®, all applicable laws, regulations and standards
must be complied with; in particular the regulations of the
responsible energy supply company. In case of queries,
please contact your specialist installer or the nearest
Hoval Customer Service centre.
Assembly or installation of the boiler may only be carri-
ed out by trained personnel from a licensed installation
company. Before commissioning, an installation inspecti-
on and approval of the overall installation by the installer
are required.
To guarantee safe and trouble-free operation, operate
your Hoval boiler in accordance with these operating ins-
tructions at all times.
The boiler may only be used for its intended purpose and
with fuels for which it was designed and which have been
approved by Hoval.
Do not carry out any modications to the system, other-
wise all claims under the warranty will be waived. Conver-
sion kits must be installed and the installation approved
by authorised installers or by the Hoval Customer Ser-
vice.
Reliable and safe functioning of a gas boiler, as well as
the achievement of optimum efciency and clean com-
bustion are only possible and guaranteed if the system is
serviced and cleaned at least once per year.
In the event of a fault or in the event of damage, please
contact the Hoval Customer Service to inquire about the
necessary repairs. In the meantime, shut down the unit to
avoid any damage.
With the acquisition of a Hoval unit, you also obtain com-
prehensive warranty cover, as indicated in the warranty
conditions on the warranty pass for your unit.
This warranty is, however, dependent on observance of
the operating and assembly instructions and on compli-
ance with the applicable legal regulations. Non-complian-
ce with the above will invalidate all liability and warranty
claims against Hoval.
Provided it is used correctly, your Hoval boiler will ensure
you enjoy a well heated home for many years.
Hoval Customer Service
If you have any doubts with regard to the operation of
your Hoval boiler, or if minor faults affect its correct func-
tioning, please contact the nearest Hoval Customer Ser-
vice centre. A telephone call is often all you need to solve
minor problems. Our trained Customer Service staff will
do everything in their power to help you.
If a problem cannot be solved in this way, a service techni-
cian will visit you in order to correct the damage. We hope
you will understand that, except in urgent cases, this will
not always be immediately possible.
Take advantage of the Hoval Customer Service offerings
to prolong the service life of your boiler, and inquire about
a service agreement. Your Customer Service consultant
will be pleased to advise you!
You will nd the addresses on the last page.
CUSTOMER SERVICE
64 213 892 / 01

4. Functional principle of the heating system
Components Function
Gas boiler
Burns natural gas safely and in an environ-
mentally friendly manner. Extracts the heat
from the generated combustion gases and
transfers it to the heating water.
Calorier It holds a reserve of domestic hot water for
consumption (e.g. for showering).
Heating controller
Maintains the desired room temperature
optimally and fuel-efciently, independent
of the outside temperature.
Boiler controller Controls and monitors the operation of the
boiler.
Radiator, underoor heating Releases the heat of the heating water into
the room.
Heating pump
Transports the heating water from the bo-
iler to the radiators and back to the boiler,
where it is reheated.
Mixing valve
Adjusts the heating ow temperature by mi-
xing in colder return water (water owing to
the radiator) to maintain the desired room
temperature, independent of the outside
temperature.
Pressure gauge Displays the water pressure in the heating
system.
Air vent Eliminates any air to make sure that the
system contains only heating water.
Safety valve Prevents overpressure in the system.
Diaphragm expansion tank Maintains the pressure in the system at
a constant level.
Depending on the type of heating system selected, some of the components might not be present or others
added. The heating engineer will explain the system to you.
FUNCTIONAL PRINCIPLE OF THE HEATING SYSTEM
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Boiler control
Version with TTE
heating controller
Version with RS-OT
heating controller
Radiators, possibly
underoor heating
Heating pump
Boiler
Mixing valve
Calorier
Flue, ue gas system
The heating water heated by the boiler is supplied to the radiators or is used to heat up the hot water (calorier).
5. Commissioning
i
• Commissioning of a newly installed system may only be carried out by a qualied installer. A full installation
inspection must be completed prior to start-up.
• Set the main SYSTEM switch to “0”
• Open the shut-off valves in the ow and return lines.
• Open the cut-off valve in the gas pipe to the boiler
• Switch on the main switch outside the boiler room (if present). Frequently, the heating system has an additional
emergency switch that switches off only the gas burner.
• With the TopGas®, the odour trap (siphon) in the condensate drain pipe must be lled with water before com-
missioning.
5.1 Checks prior to operation
Check the water level in the heating system.
i
The heating system must be lled with water and vented.
Observe the regulations regarding frost protection agents and water treatment.
Open the shut-off valves in the ow and return lines.
Check the fresh air supply to the heating system.
Check the settings for the operating modes.
5.2 Switching on
Open the gas cock.
Turn on the main switch.
Set the boiler control to the desired operating mode and temperature.
FUNCTIONAL PRINCIPLE OF THE HEATING SYSTEM
84 213 892 / 01

6. Heating system control
6.1 Boiler controller
i
Normally, the user does not need to set the basic controller.
All settings have been made by the installer or the manufacturer.
Display: Temp.
Change the
values
Display: Mode RESET
Reset (display ashes in the
event of a fault)
Save the
setting
Selection of the setting (parame-
ter) which is to be changed (e.g.
calorier temperature)
ON/OFF
Pressure gauge
Function selection (step by step
selection on the display)
Main switch
Function
Mode display
Parameter
display
Value display
Meaning, description
Standby mode
Normal setting,
initial setting
Current ow temperature
No display
0= Standby, no heat demand, waiting period, main gas valve
1 = Flushing
2 = Ignition
3 = Burner "on" in heating operation
4 = Burner "on" in DHW operation
5 = Air pressure switch defective (no air pressure switch in use)
6 = Burner "off" in heating operation
(Flow temp. > ow temp. ref. + blocking offset heating operation)
7 = Pump follow-on time in heating operation
8 = Pump follow-on time in DHW operation
9 = Burner "off" in DHW operation
(Flow temp. > ow temp. ref. + par.1 (2AB))
Fr = Frost protection is active
Su = Short summer operation is active
HEATING SYSTEM CONTROL
94 213 892 / 01

Function
Mode display
Parameter
Display
Value display
Meaning, description
Information mode
Here, you can read
out current
values
Dot ashes
0 e.g. 45° Current ow temperature (heating water temperature)
1 e.g. 40° Current return temperature
2 e.g. 60° Current temperature in the calorier
3 e.g. 3° Current outside temperature
4 e.g. 55° Current ue gas temperature
5 e.g. 50° Set ow value in heating operation
6 e.g. 70° Set ow value in DHW operation
7 e.g.23 rpm Fan speed in hundred rpm
8 e.g. 4 µ A Ionisation current
HEATING SYSTEM CONTROL
10 4 213 892 / 01