To be completed by the heating specialist:

Order No.:

Boiler type:

Set to:Natural gas H Natural gas L Liquid gas

Heating pump type:

Heating controller type:

Mixing unit type:

Separate calorifier type:Calorifier sensor Thermostat

Outdoor temperature sensorRoom temperature sensor

Combustion air supply Room Outdoor

Heating system calculation basis

Lowest outside temperature °C

Heat requirements: kW

Max. feed temperature: °C

Important telephone numbers

Heating system installer

Sanitation plumbing installer

Electrical system installer

Fuel supplier

Chimney sweep

Operating instructionsTopGas® (80)

4 203 413 / 01 Subject to changes

Hoval LTDNorthgateNewarkNottinghamshire NG24 1JNPhone: 01636 672 711Fax: 01636 673 532

Hoval ExportAustrasse 70Principality of LiechtensteinPhone: +423 399 2400Fax: +423 399 2618Export@hoval.com

4 203 413 / 012Safety information

In the case of danger:

• Turn off the fuel (gas) supply and switch off theelectrical supply!

If you smell flue gas or gas:

Do not smokeNo open fire or sparks(e.g. avoid switching on or off lights and electricalappliances)Switch off the heating systemClose the gas cockOpen doors and windows

Notify the heating firm/contact installer

Comply with the safety instructions of the gassupplier (see gas meter) and the heatingspecialist!

Maintain the air supply in the boilerinstallation room (window):Intake and outlet air openings mustnot be closed, otherwise there is nodirect supply of combustion air. Closedintake air openings result in incompletecombustion and possible toxic effects.

Intended purpose:The TopGas® (80) heating boiler is only to beoperated with the fuels stated in the Tech.Information / Installation instructions. Theheat produced must be transported withheating water . All boiler covers must be inplace during operation!

Dear Hoval customerWith the Hoval TopGas® (80) you have acquired astate-of-the-art product manufactured to the highestquality standards.

Compliance with all applicable laws, regulations andstandards is necessary for the correct installation andoperation of your Hoval TopGas® (80), in particular theregulations of the responsible energy supplier. Forqueries please contact your installer or your nearestHoval customer after-sales service agent.

The assembly and installation of the boiler is only to becarried out by the trained staff of a licensed installer.Before commissioning, an installation check is to becarried out and the system is to be cleared for operationby the specialist.

To ensure safe and fault-free service, operate yourHoval TopGas® (80) only according to these operatinginstructions.

The Hoval TopGas® (80) may only be used for thepurposes and fuels for which it is suitable on the basisof its design, and for which it has been cleared byHoval.

Do not carry out any changes to the system, otherwiseall claims under the guarantee will be waived.Conversion kits are to be supplied and installed by alicensed installer or the Hoval after-sales service.

With proper handling your Hoval system will guaranteeyou a comfortable domestic climate for many years.

General information

Information for the safety and protection ofpersons

Instructions for the protection of the heatingsystem

Important information

4 203 413 / 01 3

Checks prior to commissioningA new system is only to be placed in operation whenit has been cleared for operation by the heating installer.

Filling the heating systemThe heating system is filled with mains water accordingto the instructions of the installer. All air must be bledfrom the system. Check the pressure at the pressuregauge or hydrometer.

Filling the separately installed calorifierFill the calorifier according to the instructions of theinstaller. The boiler can also be operated when thecalorifier is not filled.

Safety valvesThe heating system and the hot water system are to beprotected against excessive over-pressure by safetyvalves.

Filling pump (boiler with separate calorifier)The speed and flow control must correspond with therequirements of the separate calorifier. Settings aremade by the heating specialist.

Heating pumpsThe speed and flow control must correspond with therequirements of the system. Settings are made by theheating specialist.

Electrical connectionThe electrical connection is to be made by an electrician.The circuit diagram is inside the cover of the controller.

Precautionary information:

Corrosion protectionDo not use any sprays, solvents, cleaning agentscontaining chlorine, adhesives etc. in the vicinity of theboiler. These substances can cause corrosion in theboiler and the flue gas system.

Check the water levelCheck the system water level at regular intervals(page 9).

Filling the Heating SystemThe water condition of the heating system watermust be as detailed in our Installation Instructionsmanual. The TopGas® (80) boiler has an aluminiumsilicon alloy heat exchanger. The use of chemicalwater additives is not allowed. If the fill-up andmake-up water volume exceed the volume, accord-ing to installation instructions, sections 4.2.2 and4.2.5, suitable water treatment or system separationis required. In the case of system separation the useof chemical water additives in the boiler circuit isalso not allowed.

The TopGas® (80) boiler is only suitable for usewith a sealed system.

GeneralHoval gas boilers TopGas® (80) are fitted with automaticcontrol and safety systems. They are normally inoperation from the start to the end of the heatingperiod. During this time the necessary boilertemperature is set with the automatic heating controller.

If the boiler is also used for water heating, the boilerremains switched on for the whole year.

Fuel

The boiler is only to be operated with thetype of gas indicated on the rating plate.Setting the gas type is carried out by theinstaller.

General information

4 203 413 / 014 Important information

Important information Erection and assembly instructions• The installer has handed you the installation

instructions. Look after this important technicaldocument in order that it can be referred to later onsite by the after-sales service fitter.

If you smell gas, close the gas shut-offcock before the meter and call your gassupplier immediately!

To prevent the occurrence of toxic flue gases thecombustion air must be allowed to flow unobstructedto the boiler. Therefore the envisaged opening (in thecase of room air dependent operation) (e.g. cellarwindow) must never be closed. Also the boiler itselfmust not be closed off.

Always keep the boiler installation room clean andswitch off the burner before carrying out cleaning, asdust laden combustion air can cause problems.

FaultsFor your safety the burner switches off automatically inthe case of burner faults, excessively low gas pressure,gas supply failure or of the maximum permissibleboiler temperature is exceeded. First make severalattempts to ignite the boiler after a waiting period ofaround 5 minutes, by pressing the reset button on theboiler control panel, If this is unsuccessful, contactyour after-sales service or heating installer.

Important note!

Proper function is only guaranteed if theoperating instructions are observed andboiler and burner are regularly maintainedby a specialist.

Faults and damage caused by installation in unsuitablerooms, e.g. hobby rooms, workshops etc.), alsocontaminated operating media (gas, water, combustionair), unsuitable chemical additives to the heating water,incorrect handling, faulty installation and damage dueto the exercising of force are not covered by ourguarantee; the same applies to corrosion throughhalogen compounds, e.g. from spray cans, paints,adhesives, solvents and cleaning agents.

4 203 413 / 01 5Preparations for commissioningIn the case of a newly installed system, commissioningmay only be carried out by a specialist. The installationcheck must be carried out in full.

• Place main switch to O• Open the shut-off valve in the heating feed and

return.• Make sure there is a supply of air (fresh air) to the

boiler installation room by opening the boiler roomwindow (only applies for room dependent operation).

• Open the shut-off valve in the gas pipeline to theboiler.

• Switch on the main switch outside the boiler room(where installed). Often the heating system has afurther danger switch which only switches off theburner).

• In the case of TopGas® (80) the odour trap (siphon)in the condensate drain line is to be filled with waterbefore commissioning.

Commissioning

Included with these instructions are operatinginstructions for the boiler control (page 7,8) withan illustration of the control panel and detailedinformation. These operating instructions forthe boiler control are to be complied with.

• Place the main switch to I• If a fault lamp lights, please turn to the section

”Faults” on page 4

Decommissioning• Place the main switch to O• Close the gas shut-off cock• In the case of a long break, e.g. during holidays, you

can switch off the heating system.• If there is a risk of frost, speak to your heating

specialist about suitable preventive measures; frostagents are never to enter the boiler circuit.

Commissioning / decommissioningBoiler cleaning

Maintenance and checkingSee page 9 for maintenance and checking information.

4 203 413 / 016 Control

Boiler controlUser-dependent settings (e.g. room temperature) are made at the TopTronic® RS-30 or TopTronic® 1B/133B.This is preferably installed in the living room (RS 30) or in the boiler (TopTronic® 1B/133B). If no TopTronic® isinstalled, these settings are made to the basic control. The control panel for the basic control is behind the frontcladding. The main switch (0/I) for placing the boiler out of operation is also in the control panel, behind the frontcladding.

Normally no settings have to be made to the basic control by the user. All settings are made by theinstaller or at the factory.

5

1

6

3

4 2

TopTronic® RS 30 in the living room

See the special operating instructions for theTopTronic® RS 30.

1 LCD display2 Button for increasing corrections3 Button for decreasing corrections4 Button for heating program5 Reduction program6 Information button

TopTronic®-RS 30

Main switchControlpanel

Pressuregauge

4 203 413 / 01 7

SYSTEM

Legend Function

1

2*

10

3

- Controls the internal boiler functionsSettings and changes are only to be carried out by the heatingspecialist. The indication flashes to display faults. To reset, fold thecover down and press the Reset button.

- Guarantees the correct room temperature whatever the outsidetemperature.

- Regulates the heating of the hot water etc.Special instructions are included for the heatingcontroller.

- Medium setting 20°CHere the room temperature can be changed by ±8°C.

Boiler operating elements

Operating elements

SYSTEM

1. Mode selection switchON/OFF

2. Basic control

3. Electronic heatingcontroller

4. Nominal setting

O = OffBoiler and burner are inoperative

Attention:No anti-freeze

I = OnBoiler operating

* also supplied withoutelectronic heating controller

45 6 9

7

8

4 203 413 / 018

5. Setpoint value "Reduced”

6. Program switch

7. Interrogating andprogramming buttons

8. Display field

9. Operating instructions

10. Room station

Legend Function

Boiler operating elements

- The desired night-time room temperature can be set here.Medium setting 14°C ±6°C

The heating program can be selected here:

Heating and hot water filling ”OFF”.Frost protection guaranteed

The room temperature night-time setting is also effectiveduring the day.Hot water according to clock program 2.

Automatic controlled operation according to theswitching times set for the 1st program(daytime interim reduction)

Automatic controlled operation according to theswitching times set for the 2nd program (normal setting)

Automatic controlled operation according to theswitching times set for the 3rd program (longer operatingtime)

The room temperature is not reduced in the nightHot water according to clock program 2

Summer operation: Heating ”OFF” Frost protection, hotwater filling is effective corresponding to clock program2.

Manual operation for the specialist. Burner andcirculation pump are operating. No supply to mixingvalve, hot water filling remains in operation.

Settings such as time of day and values can be interrogated here.Settings are made according to the special operating instructions.

Displayed alternately here is the present time, current boiler temperatureand where applicable, the calorifier temperature.

Quick reference operating instructions for heating controller only (3).

OptionalPermits operation of the heating controller (3) in the living room. Whena room station is connected, settings 5-6-7 are replaced by the settingsat the room station.

3

2

1

4 203 413 / 01 9Maintenance and checking

Maintenance and checking

Normally the work described below is carriedout by the specialist during the annualmaintenance. Nevertheless, carry out thefollowing checks in the course of the year andwhere necessary, also carry out the workdescribed.

Check the water levelIf the system water level is too low (can be read fromthe pressure gauge), notify your installer or top up thewater yourself.

Topping up the heating system• No power is to be supplied to the boiler! (disconnect

from the mains supply)• The shut-off valves for the heating feed and return

must be open• The connection between the boiler filling / draining

cock and the water cock is established with a filledhose (no air must be allowed to enter the heatingsystem); for safe disconnection, this must beunscrewed after filling.

• The water quality must satisfy the criteria detailedon page 4.

• Introduce the water slowly, check the water level atthe pressure gauge (your installer will inform you ofthe filling pressure of your system)

• Keep the bleed valves on radiators open until onlywater flows out.

Complete filling and draining is to be carried out by theheating specialist.

Attention:Never add cold water to a hot system.

Boiler and burnerHave the burner and boiler plus any neutralisationsystem periodically inspected and maintained – DIN4756 recommends at least an annual check. Thismaintenance is especially important for a high efficiencyboiler such as this Hoval TopGas®, in order to achieveoptimal annual efficiency. You can take out amaintenance contract with your heating installer or theresponsible after-sales organisation.

Maintenance of the neutralisation system

The local regulations of the responsiblecommunal waste water authority must becomplied with.

If the condensate from your boiler is neutralised beforeentering the drain system, this system must beperiodically cleaned and filled with new granulate.Comply with the instructions for your neutralisingsystem.

Before the start of the heating period, checkwhether the siphon of the condensate line isfilled.

Hot water supplyRegular checks extend the life and improve theprofitability of any flow type or separately installedcalorifier. Cleaning will remove any suspendedparticles. This work is carried out by the maintenanceservice.

In areas with a high lime content the calorifier or flowtype heater should be periodically delimed (once peryear) in the interest of an economical hot water supply.Do not use metal tools for deliming. The installation ofa water softener system is recommended in areas witha high lime risk.

4 203 413 / 0110

Please note! In the event of operating faults, carry outthe checks according to the abovechecklist.

If you are unable to rectify the fault,please contact your heating installeror the Hoval after-sales service.

Fault Check / cause Rectification See page

Gas boiler - current available - check the fuses. Switch on the main ordoes not emergency-off switchstart

- is the gas shut-off cock open - open

- does a number flash on the basic control - make a note of the number- press the Reset button- inform your after-sales service, stating

the flashing number

- is gas available - enquire from gas supplier

Radiators do - are the shut-off valves in the - opennot become heating feed and return openwarm

- is ”OFF” displayed on - press the ”-” button until the OFF sign goes out in thethe basic control display 7

- is the TopTronic® timer correctly set - check according to the separate operating instructionsfor the heating controller

- check the heating system water - replenish water and bleed air from the heating system 9level or pressure

- are the radiator valves open - open

- the heating circulation pump is not running - open sealing screwturn end of the shaft vigorously with a screwdriveruntil the resistance is reduced

- the mixing element does not open - open by hand; call after-sales serviceautomatically

No - the filling pump is not running - open sealing screwhot water turn end of the shaft vigorously with a screwdriver

until the resistance is reduced

- is there air in the filling line - where necessary, bleed manually- actuate automatic venting by hand

Fault checklist

4 203 413 / 01 11How to save energy!

The room temperatures andheating system operating timeshave a decisive influence onfuel consumption.

A 1°C lower room temperatureyields a fuel saving of up to 6%.So note the following tips:

• Avoid room temperatures ofover 20°C and set your heatingsystem accordingly.

• It is worthwhile closing theradiator valves in unused roomsproviding there is no risk of frostand no damage to the buildingstructure or furnishings isanticipated.

• Heat recycling takes place in themain living rooms through bodyheat, television sets, chimneysand also solar radiation. Thesecannot be compensated with aweather dependent control. It isworthwhile installing individualthermostatic radiator valves inthese rooms.

When there is a draught, it’snot only unpleasant but it alsomeans a loss of heat energy.

So you’ll save fuel if you . . .

• Keep doors and windowsclosed in the winter

• Close flue flaps when the fire isout

• Use kitchen and bathroom fansonly when steam and odourshave to be extracted

• Ventilate for short periods, butfrequently.

• Seal doors and windows toavoid permanent leakagelosses.

Keep in valuable heat withinsulation.

Utilise these possibilities and . . .

• Close door and window shuttersat night

• Make sure heating and hotwater pipes in unheated roomsare insulated.

The lowest possible radiatortemperature prevents unneces-sary heat loss.So radiators must always beable to transfer their heat to theroom unhindered. Avoid there-fore:

• Covered radiators

• Windowsills which allow no heatto pass through because theyare occupied by objects.

Savings are also possible withhot water systems.

• Set the calorifier temperature aslow as possible. Find the lowestpossible temperature setting atwhich sufficient hot water is stillavailable.

• If your system includes a hotwater circulation pump, it’sworthwhile switching this off atnight with a timer clock.

4 203 413 / 0112 Maintenance contract

Maintenance contract

The Hoval After-Sales Maintenance Contract

To ensure fault-free and cost-effective operation ofyour new heating system, we recommend that youtake out a Hoval After-Sales Maintenance Contract.With this agreement the Hoval After-Sales Servicemakes all the timing arrangements for thenecessary annual maintenance.In the period April to October, after prior agreement,your boiler will be thoroughly checked, its valuesmeasured and set up for optimal operation.Any repairs will be carried out at once with youragreement.

A maintenance contract carries a wide range ofbenefits

• Your guarantee period is extended when you takeout a maintenance contract.

• Your heating system is always optimally set, savingheating costs and protecting the environment.

• High level of operating reliability, since any faultsare detected early in the course of maintenanceand can be rectified.

• The optimal setting and regular maintenance extendthe service life of your system.

• The attractive lump sum price. Apart from anynecessary spares, nothing extra has to be paid forthe maintenance.

Date Text:

Enter checks, inspections, fuel purchases etc. here