Hoval TopGas comfort 10 User manual

EN
Subject to modifications
Operating Instructions
Hoval United Kingdom
Hoval Ltd.
Northgate
Newark
Nottinghamshire NG24 1JN
Phone [phone]
Fax [phone]
Hoval Export
Hoval Aktiengesellschaft
Austrasse 70
9490 Vaduz
Principality of Liechtenstein
Phone [phone]
Fax [phone]
Gas condensing boiler
TopGas®comfort (10,16,22)
4 205 540 / 01 - 09/10

2
4 205 540 / 01Table of contents
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 Operating elements on the boiler control panel / basic controller N4.2 ............................................ 9
6.2 The operating elements of the RS-OT heating regulator (optional) ................................................. 11
6.3 Operating elements of the TopTronic®T/N 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

3
4 205 540 / 01 To get the most out of your heating system, read the operating instructions!
1. To get the most out of your heating system, read the operating instruc-
tions!
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
i
Instruction: Prompts you to carry out an action
Result: Shows the expected reaction to your action
Note: Provides important information
Safety instructions: Indicate an immediate hazard to persons
Cautionary notes: Indicate danger to machines and installations
Energy-saving tips: Provide information on how to save energy
ENERGY

4
4 205 540 / 01To get the most out of your heating system, read the operating instructions!
1.3 System data
To be completed by the heating engineer!!
Order no.: .....................................................................
Boiler type: .....................................................................
Heating pump type: .....................................................................
Heating regulator type: .....................................................................
Mixer type: .....................................................................
Calorifier 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. flow temperature: .................................................................... °C

5
4 205 540 / 01 Safety instructions
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 flames
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 flue 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 qualified
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 flue 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.

6
4 205 540 / 01Customer service
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 com-
pleteness. Also check for possible 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 carried out by trained personnel
from a licensed installation company. Before commissioning, an installation inspection
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 instructions 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 modifications to the system, otherwise all claims under the war-
ranty will be waived. Conversion kits must be installed and the installation approved
by authorised installers or by the Hoval Customer Service.
Reliable and safe functioning of a gas boiler, as well as the achievement of optimum
efficiency and clean combustion 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 comprehensive 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 compliance with the applicable legal regulations. Non-compliance
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 functioning, please contact the nearest Hoval Customer Service
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 technician 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 find the addresses on the last page.

7
4 205 540 / 01 Functional principle of the heating system
4. Functional principle of the heating system
Components Function
Gas boiler Burns natural gas safely and in an en-
vironmentally friendly manner. Extracts
the heat from the generated combustion
gases and transfers it to the heating water.
Calorifier It holds a reserve of domestic hot water
for consumption (e.g. for showering).
Boiler control unit Controls and monitors the operation of
the boiler. Maintains the desired room
temperature optimally and fuel-efficiently,
independent of the outside temperature.
Radiator, underfloor heating Releases the heat of the heating water
into the room.
Heating pump Transports the heating water from the
boiler to the radiators and back to the
boiler, where it is reheated.
Mixing valve Adjusts the heating flow temperature by
mixing in colder return water (water flow-
ing to the radiator) to maintain the desired
room temperature, independent of the
outside temperature.
Pressure gauge Displays the hydraulic 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.

8
4 205 540 / 01Functional principle of the heating system /commissioning
5. Commissioning
Commissioning of a newly installed system may only be carried out by a quali-
fied 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 flow 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 filled with water before commissioning.
5.1 Checks prior to operation
Check the water level in the heating system.
The heating system must be filled with water and vented.
Observe the regulations regarding frost protection agents and water treatment.
Open the shut-off valves in the flow 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
i
i
Radiators, possibly
underfloor heating
Heating pump
Boiler
Mixing valve
Calorifier
Flue, flue gas system

9
4 205 540 / 01 Heating system control
6. Heating system control
6.1 Operating elements on the boiler control panel / basic controller N4.2
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 flashes in
the event of a fault)
Save the
setting
Selection of the setting
(parameter) which is to
be changed (e.g. calorifier
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 flow 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. > flow 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. > flow temp. ref. + par.1 (2AB))
Fr = Frost protection is active
Su = Short summer operation is active

10
4 205 540 / 01Heating system control
Function
Mode display
Parameter
Display
Value display
Meaning, description
Information mode
Here, you can read
out current
values
Dot flashes
0e.g. 45° Current flow temperature (heating water temperature)
1e.g. 40° Current return temperature
2e.g. 60° Current temperature in the calorifier
3e.g. 3° Current outside temperature
4e.g. 55° Current flue gas temperature
5e.g. 50° Set flow value in heating operation
6e.g. 70° Set flow value in DHW operation
7e.g.23 rpm Fan speed in hundred rpm
8e.g. 4 µ A Ionisation current
Parameter mode
Settings can be changed in this mode.
Dot appears
P. 7 60 = DHW reference value
if no TopTronic®connected
Proceed as follows: P. 1 8 80 = Max. flow temperature in heating operation
1. Select Parameter mode
(Press mode key twice).
The parameter (P.7) and the setting
value are displayed alternately. Par. 18
2. Select the parameter to be changed
(Step key)
3. Change the setting using
+ - keys
4. Save
(Press Store key once)
Return to Standby mode automati-
cally after 20 minutes or by pressing
Mode key.
Further parameters only with service code

11
4 205 540 / 01 Heating system control
6.2 The operating elements of the RS-OT heating regulator (optional)
Settings and modifications 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
2Daytime room tempera-
ture Set the day room temperature.
3Reduced
room temperature
Set the night-time room temperature
(or reduced heating operation).
4Domestic hot water tem-
perature
Set the domestic hot water temperature.
Manual hot water re-charging.
5
Push & Turn button Change the values by turning. Acknowledge the values by
pressing. Select functions by pressing and turning.
6
Information key • Show operating data on the display.
• Return to the basic display without saving the values.
7Heating characteristics Set the heating curve
1
9
2
3
4
8
7
5
6

12
4 205 540 / 01Heating system control
Key Designation Function
8
���
Operating 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 heating times = normal heating operation
Summer only DHW; Heating Off
 Heating Continuous heating
 Reduced Continuous reduced heating
 Standby System off - frost protection active
9Display The basic display shows the day of the week, date
and time as well as the current boiler temperature
or room temperature (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

13
4 205 540 / 01 Heating system control
Key Designation Function Pressure gauge
1
Main switch
I = ON - Boiler is in operation
0 = OFF - Boiler and burner are shut down
! Caution: No frost protection
2Daytime room tempera-
ture Set the day room temperature.
3Reduced
room temperature
Set the night-time room temperature
(or reduced heating operation).
4Domestic hot water tem-
perature
Set the domestic hot water temperature.
Manual hot water re-charging.
5
Push & Turn button Change the values by turning. Acknowledge the values by
pressing. Select functions by pressing and turning.
6
Information key • Show operating data on the display.
• Return to the basic display without saving the values.
7Heating characteristics Set the heating curve
6.3 Operating elements of the TopTronic®T/N heating regulator (optional)
1
54 11
9
67
8
10
Settings and modifications may only be made by
the heating engineer.
Pressure
gauge
32

14
4 205 540 / 01Heating system control
Key Designation Function
8 Operating 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 heating times = normal heating operation
Summer only DHW; Heating Off
 Heating Continuous heating
 Reduced Continuous reduced heating
 Standby System off - frost protection active
9Manual mode / emission
measurement
Only for heating engineer.
10 Display The basic display shows the day of the week, date
and time as well as the current boiler temperature
or room temperature (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
11
Brief operating instructions Special brief operating instructions are
included with the boiler controller.

15
4 205 540 / 01 Checklist in case of faults
7. Checklist in case of faults
Fault Inspection/cause Remedy See
Page
Gas boiler
does not start - Is power supply present? - Check fuses.
Turn on the main switch
- Is the gas cock open? - Open
- Is mode display "E" flashing? - Press Reset key
- Contact customer service
- Is too little gas available?
"P26" appears on the display screen - Contact the gas works
- If the water pressure is too low
"P27" appears on the display screen - Check the water level 16
Radiators do
not become
warm
- Are the slide valves in the heating flow
and return open? - Open
- Is the main switch set to "OFF"? - Set switch to Off 11
No. 1
- Is the TopTronic®T timer set correctly? - Check using operating instructions for
the heating regulator
- Check water level and pressure - Top up and vent heating system 16
- Are the radiator valves open? - Open
- The heating circulation pump is not
running
- Open locking screw
Using a screwdriver, turn the end of the
shaft sharply until the resistance de-
creases
- Mixer does not open automatically - Open it by hand;
Call Customer Service
No hot water
- The charging pump is not running
- Unscrew locking screw
Using a screwdriver, turn the end of the
shaft sharply until the resistance de-
creases
- Is there air in the charging pipe? - Possibly vent manually
- Operate automatic air vent manually
Please note!
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.

16
4 205 540 / 01Checking the water level
8. Checking the water level
If the system pressure is too low (check pressure gauge), inform your installer or top it up with
water.
Refilling the heating system
The heating system can normally be filled and topped up with mains water. In excep-
tional cases, the water quality may vary strongly and it might not always be suitable
for filling the heating system (highly corrosive or very hard water). Please contact a
certified specialist company in such cases.
Follow the procedure below
• Set main switch to "O."
• Open the shut-off valves in the ow and return lines.
• 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 heating system
- Unscrew the hose again after filling to break the connection reliably.
• Slowly ll with water while checking the water level on the hydrometer or pressure
gauge.
• Open the bleed valves briey after topping up until all the air has been vented from
the radiator.

17
4 205 540 / 01 How to save energy!
9. How to save energy!
The room temperatures and
the operating periods of
the heating system have a
significant influence 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, ad-
ditional heat is often gener-
ated by people, televisions, fire
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 fitting thermostatic
radiator valves in these rooms.
Draughts in the home are not
only unpleasant, but also in-
dicate 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 fire is out.
• Operate kitchen and bathroom
ventilation fans only when va-
pours and smells need to be
extracted.
• Only ventilate for short periods,
but frequently.
• Seal doors and windows to pre-
vent constant leakage losses.
Insulation will help retain
precious heat.
Take advantage of these pos-
sibilities and...
• Close the window and door shut-
ters at night.
• Make sure that heating and hot
water pipes are insulated in un-
heated 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 radiator 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 clut-
tered 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
sufficient hot water available.
• If you have installed a hot wa-
ter circulation pump, it is worth
switching it off during the night
with a timer.
ENERGY

18
4 205 540 / 01Hoval Service / sales programme
10. Hoval Service / sales programme
A service 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 identified and resolved
early.
• Optimum settings and regular
maintenance increase the ser-
vice life of your heating system
even further.
• The attractive all-inclusive price.
Heat generation systems
OIL- or gas-fired compact heat sta-
tions, OIL-, gas- and wood-fired
boilers, burners, solar energy sys-
tems (collectors) and heat pumps
for heat generation from air, water
and geothermal sources.
Heat distribution systems
and building services
Calorifiers (boilers), radiators,
heating walls, convector heaters,
low temperature heating elements,
heating and ventilation controllers,
circulation pumps, as well as plastic/
concrete heating oil tanks.
Heat recovery and industrial
ventilation systems
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 service engineers.This will en-
sure that a service visit takes place
promptly.
With our range of products,
we can offer you solutions
for new buildings or conver-
sions of any size.
Hoval’s modern and future-
proof system technology in-
cludes:

19
4 205 540 / 01

Conservation of Energy -
Protection of the Environment
United Kingdom
Hoval Ltd.
Northgate
Newark
Nottinghamshire NG24 1JN
Phone [phone]
Fax [phone]
www.hoval.co.uk
Switzerland
Hoval AG
General Wille-Strasse 201
CH-8706 Feldmeilen
Phone [phone]
Fax [phone]
www.hoval.ch
Germany
Hoval GmbH
Karl-Hammerschmidt Strasse 45
D-85609 Aschheim-Dornach
Phone [phone]
Fax [phone]
www.hoval.de
Austria
Hoval Gesellschaft mbH
Hovalstrasse 11
A-4614 Marchtrenk
Phone [phone] - 0
Fax [phone] - 5005
www.hoval.at
Italy
Hoval s.r.l.
Via per Azzano San Paolo, 26/28
I-24050 Grassobbio (BG)
Phone [phone]
Fax [phone]
www.hoval.it
France
Hoval SAS
6, rue des Bouleaux
F-67100 Strasbourg
Phone [phone]
Fax [phone]
www.hoval.fr