United KingdomHoval Ltd.NorthgateNewarkNottinghamshire NG24 1JNPhone +44 1636 67 27 11Fax +44 1636 67 35 32

ExportHoval AktiengesellschaftAustrasse 70LI-9490 VaduzPrincipality of LiechtensteinPhone +423 399 24 00Fax +423 399 24 11

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! .................................... 31.1 Important addresses and telephone numbers....................................................................................................................31.2 Key to symbols used ...........................................................................................................................................................31.3 System data .........................................................................................................................................................................41.4 Calculation basis .................................................................................................................................................................4

2. Safety instructions .................................................................................................................................. 52.1 Cautionary notes .................................................................................................................................................................52.2 Intended use ........................................................................................................................................................................5

3. Customer service .................................................................................................................................... 6

4. Functional principle of the heating system ........................................................................................... 7

5. Commissioning ....................................................................................................................................... 85.1 Checks prior to operation ...................................................................................................................................................85.2 Switching on ........................................................................................................................................................................8

6. Heating system control ........................................................................................................................... 96.1 Boiler controller ...................................................................................................................................................................96.2 The operating elements of the RS-OT heating regulator ................................................................................................. 116.3 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

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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

iNote: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!

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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

TO GET THE MOST OUT OF YOUR HEATING SYSTEM, READ THE OPERATING INSTRUCTIONS THOROUGHLY!

4 4 213 892 / 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 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.

SAFETY INSTRUCTIONS

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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 modifications 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 efficiency 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 ServiceIf 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 find the addresses on the last page.

CUSTOMER SERVICE

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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.

Calorifier It holds a reserve of domestic hot water for consumption (e.g. for showering).

Heating controllerMaintains the desired room temperature optimally and fuel-efficiently, independent of the outside temperature.

Boiler controller Controls and monitors the operation of the boiler.

Radiator, underfloor heating Releases the heat of the heating water into the room.

Heating pumpTransports the heating water from the bo-iler to the radiators and back to the boiler, where it is reheated.

Mixing valve

Adjusts the heating flow temperature by mi-xing in colder return water (water flowing 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 TTEheating controllerVersion with RS-OT heating controller

Radiators, possiblyunderfloor heating

Heating pump

Boiler

Mixing valve

Calorifier

Flue, flue gas system

The heating water heated by the boiler is supplied to the radiators or is used to heat up the hot water (calorifier).

5. Commissioning

i • Commissioning of a newly installed system may only be carried out by a qualified 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 com-

missioning.

5.1 Checks prior to operation

Check the water level in the heating system.

i 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.

FUNCTIONAL PRINCIPLE OF THE HEATING SYSTEM

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6. Heating system control6.1 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 thevalues

Display: Mode RESETReset (display flashes in the event of a fault)

Save thesetting

Selection of the setting (parame-ter) 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

Mod

e di

spla

y

Par

amet

erdi

spla

y

Valu

e di

spla

y

Meaning, description

Sta

ndby

mod

e

Normal setting,initial setting

Cur

rent

flow

tem

pera

ture

No

disp

lay

0 = Standby, no heat demand, waiting period, main gas valve1 = Flushing2 = Ignition3 = Burner "on" in heating operation4 = Burner "on" in DHW operation5 = 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 operation8 = Pump follow-on time in DHW operation9 = Burner "off" in DHW operation

(Flow temp. > flow temp. ref. + par.1 (2AB))Fr = Frost protection is activeSu = Short summer operation is active

HEATING SYSTEM CONTROL

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Function

Mod

e di

spla

y

Par

amet

erD

ispl

ay

Valu

e di

spla

y

Meaning, description

Info

rmat

ion

mod

e

Here, you can readout current

valuesD

ot fl

ashe

s

0 e.g. 45° Current flow temperature (heating water temperature)1 e.g. 40° Current return temperature2 e.g. 60° Current temperature in the calorifier3 e.g. 3° Current outside temperature4 e.g. 55° Current flue gas temperature5 e.g. 50° Set flow value in heating operation6 e.g. 70° Set flow value in DHW operation7 e.g.23 rpm Fan speed in hundred rpm8 e.g. 4 µ A Ionisation current

HEATING SYSTEM CONTROL

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6.2 The operating elements of the RS-OT heating regulator

Settings and modifications may only be made by the heating engineer.

Key Designation Function1

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.

4 Reducedroom temperature

Set the night-time room temperature (or reduced heating operation).

5 Domestic 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.

7Information 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

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Key Designation Function

8Heating characteristics Set the heating curve

9 Operating mode selection key Select the operating modes

HolidayTurn off the heating system while you are on holiday (frost protection)

Absence Interrupt heating operation

Party Extended heating operation

AutomaticAutomatic 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)

21

34

6

75

Possible readouts:1 Active heating time 24h2 Day display3 Display of the active operating state and the clock programme4 Time5 Selected operating mode6 Date / Day / Month / Year7 Boiler temperature or room temperature

HEATING SYSTEM CONTROL

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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 modifications may only be madeby the heating engineer.

Manometer

Heat generator Living area

1

21615

14

7

8 1211

6 910

34

5

21 6 10 9

5 4 3 7 12

13

7

Position / symbol Designation Function1 Heating 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 circuitJoint operation of all heating circuits (temperature and programs identical)

HEATING SYSTEM CONTROL

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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.

3 Activeday program

Currently active day program. Only displayed if the basic programs Week 1 and Week 2 (1.8 page ?) are selected.

4 Switching 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.

5 Basic 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.

6 Operating 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.

7 Outside 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.

8 Information 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.

9 Information 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

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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 flashing? - Press Reset key - Inform customer service

- Is gas available? (either 4 or 5 flashes on the service display)

- Open gas cock - Contact the gas works

Radiators do not become warm

- Are the slide valves in the heating flow 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

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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.

Refilling the heating systemThe heating system can be filled 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 filling the heating system (highly corrosive or very hard water). Please contact a certified 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 flow and return lines must be

open.• The boiler filling and drain cock is accessible from the

underside of the boiler.• Connect a hose between the filling 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 filling to break the connection reliably.

• Slowly fill with water while checking the water level on the hydrometer or display.

• Open the bleed valves briefly after topping up until all the air has been vented from the radiator.

CHECKING THE WATER LEVEL

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ENERGY

9. How to save energyThe 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, additional heat is often genera-ted 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 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 flaps when the fire 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 sufficient 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

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10. Hoval Service / sales programmeA 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 identified 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 systemsOil- or gas-fired compact heat stations, oil-, gas- and wood-fired boilers, burners, solar energy systems (collec-tors) and heat pumps for heat generation from air, water and geothermal sources.

Heat distribution systems and building servicesCalorifiers (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.NorthgateNewarkNottinghamshire NG24 1JNPhone +44 1636 67 27 11Fax +44 1636 67 35 32www.hoval.co.uk

Principality of Liechtenstein

Hoval AktiengesellschaftAustrasse 70LI-9490 VaduzPhone +423 399 24 00Fax +423 399 24 11www.hoval.com

Switzerland

Hoval AGGeneral Wille-Strasse 201CH-8706 Feldmeilen Phone +41 44 925 61 11Fax +41 44 923 11 39www.hoval.ch

Germany

Hoval GmbHHumboldtstrasse 30DE-85609 Aschheim-DornachPhone +49 89 92 20 97-0Fax +49 89 92 20 97-77www.hoval.de

Austria

Hoval Gesellschaft mbHHovalstrasse 11AT-4614 MarchtrenkPhone +43 50 365 - 0Fax +43 50 365 - 5005www.hoval.at

Italy

Hoval s.r.l.Via XXV Aprile 1945, 13/15IT-24050 Zanica (BG)Phone +39 035 666 1111Fax +39 035 526 959www.hoval.it

France

Hoval SASParc d’Activité de la Porte SudBâtiment C - Rue du Pont au PéageFR-67118 GeispolsheimPhone +33 388 60 39 52Fax +33 388 60 53 24www.hoval.fr

Responsibility for energy and environment