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
74 213 892 / 01

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

6.2 The operating elements of the RS-OT heating regulator
Settings and modications may only be made
by the heating engineer.
Key Designation Function
1
Main switch
I = ON - Boiler is in operation
0 = OFF - Boiler and burner are shut down
! Caution: No frost protection
2
Manometer Displays the water pressure in the heating system.
3Daytime room temperature Set the day room temperature.
4Reduced
room temperature
Set the night-time room temperature
(or reduced heating operation).
5Domestic hot water tempe-
rature
Set the domestic hot water temperature.
Manual hot water re-charging.
6
Push & Turn button Change the values by turning. Acknowledge the values by pres-
sing. Select functions by pressing and turning.
7
Information key • Show operating data on the display.
• Return to the basic display without saving the values.
1 2
3
4
5
9
8
6
7
i
For a detailed description of the heating
controller RS-OT, refer to the separate
operating instructions.
10
HEATING SYSTEM CONTROL
114 213 892 / 01

Key Designation Function
8Heating characteristics Set the heating curve
9Operating mode selection key Select the operating modes
 Holiday
Turn off the heating system while you are on holiday (frost
protection)
 Absence Interrupt heating operation
Party Extended heating operation
 Automatic
Automatic heating operation in accordance with the set hea-
ting times = normal heating operation
Summer only DHW; Heating Off
 Heating Continuous heating
 Reduced Continuous reduced heating
 Standby System off - frost protection active
10 Display The basic display shows the day of the week, date and time
as well as the current boiler temperature or room tempera-
ture (room station)
2
1
3
4
6
7
5
Possible readouts:
1 Active heating time 24h
2 Day display
3 Display of the active operating state and the clock
programme
4 Time
5 Selected operating mode
6 Date / Day / Month / Year
7 Boiler temperature or room temperature
HEATING SYSTEM CONTROL
12 4 213 892 / 01

6.3 Operating elements of the TopTronic®E heating regulator (optional)
i
For a detailed description of the control module, refer to the brief
description TopTronic®E control module
or the operating instructions TopTronic®E control module comfort.
Main switch TopTronic®E
Settings and modications may only be made
by the heating engineer.
Manometer
Heat generator Living area
1
2
16
15
14
7
8 12
11
69
10
3
4
5
2
1610 9
5 4 3 7 12
13
7
Position / symbol Designation Function
1Heating circuit If a house is divided into individual heating areas, the heating circuit
refers to each individually adjustable portion. Each heating circuit can
have individual settings assigned to it, such as basic program, day and
week program as well as room temperature. If no name is shown, then
there is only one heating circuit.
Operation
heating circuits
Display of the joint or individual operation of all heating and domestic
hot water circuits.
Individual operation of every individual heating
circuit
Joint operation of all heating circuits (temperature
and programs identical)
HEATING SYSTEM CONTROL
134 213 892 / 01

2 Room temperature Displaying the current room temperature – in room control modules
and systems with room air sensor – in the selected heating circuit.
Adaptation of the temperature by increasing or reducing the preset
temperature (1.7.1 page ?). Display of the required room temperature
in systems without room air sensor.
3Active
day program
Currently active day program. Only displayed if the basic programs
Week 1 and Week 2 (1.8 page ?) are selected.
4Switching cycle The diagram shows the course of the day (room temperature vertical,
time horizontal) of the active basic program or the assigned day
program. The vertical line represents the current status.
5Basic program Assignment of the basic program for the particular situation (e.g. week
programs, Constant, Holiday Until). The basic program is used as the
operating mode of the heating circuit.
6Operating status Currently active operating status
No display – correct operation
Alarm message
display
Selection and display of alarm messages
Display authorisation level. If no level is displayed,
the control is in level 0 - your operating level.
7Outside
temperature
Display of the current outside temperature (only displayed if there is
a outdoor temperature sensor). In addition, the phase of the moon is
displayed at night.
In connection with the TopTronic®E online, the current weather is dis-
played.
8Information active
heat generator
Displays the current temperature in the active heat generator. If a solar
plant is installed, the collector temperature is also displayed. If the
heat generator/solar plant is currently active, this is indicated by an
orange colour.
9Information Detailed information about the system
10 Phase of the
moon, time and
date
Display of the current time and date. In connection with the TopTronic®
E online, the current phase of the moon is displayed.
11 Hot water Shows the current domestic hot water temperature if necessary.
12 Main menu This operating element accesses the main menu.
13 Present Immediate heating starts, the "All day" day program → (1st day pro-
gram) is activated.
14 Absent Used for quickly switching over if you will be absent for a few hours.
15 Week program Back to the week program
16 Special symbols = summer mode
= frost protection when pump on
= screed drying
HEATING SYSTEM CONTROL
14 4 213 892 / 01

7. Checklist in case of faults
Fault Inspection/cause Remedy See
Page
Gas boiler does
not start
- Is power supply present? - Check fuses
- Check mains plug
- Press On/Off key
(so that LED lights up)
- Is the gas cock open? - Open
- Is the service display ashing? - Press Reset key
- Inform customer service
- Is gas available?
(either 4 or 5 ashes on the service display)
- Open gas cock
- Contact the gas works
Radiators do
not become
warm
- Are the slide valves in the heating ow and
return open?
- Open
- Is the On/Off key set to "OFF"?
(LED dark)
- Switch on
- Press On/Off key
(so that LED lights up)
9
- Have the heating times been set correctly? - Check as described in operating instruc-
tions for the heating controller
- Check the water level / pressure - Top up and vent heating system 16
- Are the radiator valves open? - Open
- The heating circulating pump is not run-
ning
- Open locking screw
- Turn end of shaft vigorously with a scr-
ewdriver until there is no longer resistan-
ce
- Mixer does not open automatically - Open by hand; call Customer Service
No hot water - The charging pump is not running - Unscrew locking screw
- Turn end of shaft vigorously with a scr-
ewdriver until there is no longer resistan-
ce
- Is there air in the charging pipe? - Possibly vent manually
- Operate automatic air vent by hand
i
Please use the above checklist when carrying out the checks in the case of malfunctions.
If you are unable to remedy the fault, please call your heating contractor or Hoval Customer Service.
CHECKLIST IN THE EVENT OF FAULTS
154 213 892 / 01

8. Checking the water level
The water pressure in the system should be read
off the pressure gauge (installed externally).
If the water pressure is too low (less than 1 bar),
inform your installer or top it up with water.
Relling the heating system
The heating system can be lled and topped up with nor-
mal mains water. In exceptional cases, the water quali-
ty may vary a lot and it might not always be suitable for
lling the heating system (highly corrosive or very hard
water). Please contact a certied specialist company in
such cases.
Follow the procedure below
• Use On/Off to switch off device (LED dark), water
pressure is displayed!
• The shut-off valves in the ow and return lines must be
open.
• The boiler lling and drain cock is accessible from the
underside of the boiler.
• Connect a hose between the lling cock and the water
tap:
- Fill the hose with water before establishing the
connection to prevent any air from entering the he-
ating system.
- Unscrew the hose again after lling to break the
connection reliably.
• Slowly ll with water while checking the water level on
the hydrometer or display.
• Open the bleed valves briey after topping up until all
the air has been vented from the radiator.
CHECKING THE WATER LEVEL
16 4 213 892 / 01

ENERGY
9. How to save energy
The room temperatures and the operating periods of
the heating system have a signicant inuence on
fuel consumption.
Lowering the room temperature by 1ºC will result in a
fuel saving of up to 6 %. For this reason, bear in mind
the following tips:
• Avoid room temperatures above 20ºC and adjust your
heating system accordingly.
• It pays to turn the radiators off in unused rooms, as long
as there is no risk of frost and no moisture damage to
the building structure or furniture is to be expected.
• In the main living areas, additional heat is often genera-
ted by people, televisions, re places, tiled stoves and
also direct sunlight. These cannot be compensated for
by a weather-dependent regulator. It may therefore be
worth installing a remote control (RS 30) or room air
sensor or tting thermostatic radiator valves in these
rooms.
Draughts in the home are not only unpleasant, but
also indicate that heating energy is being lost.
And so you can save fuel if you...
• Keep the doors and windows closed in winter.
• Close the chimney aps when the re is out.
• Operate kitchen and bathroom ventilation fans only
when vapours and smells need to be extracted.
• Only ventilate for short periods, but frequently.
• Seal doors and windows to prevent constant leakage
losses.
Insulation will help retain precious heat.
Take advantage of these possibilities and...
• Close the window and door shutters at night.
• Make sure that heating and hot water pipes are insula-
ted in unheated rooms.
Keeping the temperature of the radiators as low as
possible will prevent unnecessary heat losses.
For this reason, it is important to ensure that the ra-
diator can release its heat into the room without any
obstructions. You should therefore avoid:
• Covered radiators
• Windowsills that do not let air through because they are
cluttered with objects.
Savings are also possible for water heating.
• Set the hot water temperature as low as possible. Find
out at what temperature there is still sufcient hot water
available.
• If you have installed a hot water circulation pump, it is
worth switching it off during the night with a timer.
HOW YOU CAN SAVE ENERGY
174 213 892 / 01

10. Hoval Service / sales programme
A maintenance contract has several advantages
• Your heating system is always optimally adjusted - this
saves heating costs and is good for the environment.
• High operating reliability, because in the course of
maintenance, possible causes of a malfunction can be
identied and resolved early.
• Optimum settings and regular maintenance increase
the service life of your heating system even further.
• The attractive all-inclusive price.
Hoval specialists are well equipped and will offer you
reliable service.
To place a work order, please call the regional service
operations manager; he works closely with the local ser-
vice engineers. This will ensure that a service visit takes
place promptly.
With our range of products, we can offer you solu-
tions for new buildings or conversions of any size.
Hoval’s modern and future-proof system technolo-
gy includes:
Heat generation systems
Oil- or gas-red compact heat stations, oil-, gas- and
wood-red boilers, burners, solar energy systems (collec-
tors) and heat pumps for heat generation from air, water
and geothermal sources.
Heat distribution systems and building services
Caloriers (boilers), radiators, heating walls, convector
heaters, low temperature heating elements, heating and
ventilation controllers, circulation pumps, as well as pla-
stic/concrete oil tanks.
Heat recovery and industrial ventilation systems
HOVAL SERVICE / SALES PROGRAMME
18 4 213 892 / 01

194 213 892 / 01

United Kingdom
Hoval Ltd.
Northgate
Newark
Nottinghamshire NG24 1JN
Phone [phone]
Fax [phone]
www.hoval.co.uk
Principality of Liechtenstein
Hoval Aktiengesellschaft
Austrasse 70
LI-9490 Vaduz
Phone [phone]
Fax [phone]
www.hoval.com
Switzerland
Hoval AG
General Wille-Strasse 201
CH-8706 Feldmeilen
Phone [phone]
Fax [phone]
www.hoval.ch
Germany
Hoval GmbH
Humboldtstrasse 30
DE-85609 Aschheim-Dornach
Phone [phone]
Fax [phone]
www.hoval.de
Austria
Hoval Gesellschaft mbH
Hovalstrasse 11
AT-4614 Marchtrenk
Phone [phone] - 0
Fax [phone] - 5005
www.hoval.at
Italy
Hoval s.r.l.
Via XXV Aprile 1945, 13/15
IT-24050 Zanica (BG)
Phone [phone]
Fax [phone]
www.hoval.it
France
Hoval SAS
Parc d’Activité de la Porte Sud
Bâtiment C - Rue du Pont au Péage
FR-67118 Geispolsheim
Phone [phone]
Fax [phone]
www.hoval.fr
Responsibility for energy and environment