Hoval TopGas classic 35 Manual

Subject to modi cations | EN
Technical information
Installation instructions
4 219 316 / 00 - 03/20
Hoval products may only be installed and commissi-
oned by appropriately qualied experts. These ins-
tructions are intended exclusively for the specialist.
Electrical installation must be performed by a licensed
electrical company.
TopGas® classic (35,45,50,60,80,100,120) wall-mount-
ed gas condensing boilers in accordance with
EN 15502-1/ 15502-2-1 are designed and approved for
use as heat generators for hot water heating systems
with per mis si ble ow temperatures of up to 85 °C. They
are de sig ned for continuously controlled reduced oper-
ation in heating systems.
TopGas®classic (35,45,50,60,80,100,120)
Wall-mounted gas condensing boilers
for natural gas and liquid gas
Nominal output ranges at 50/30 °C
and natural gas
47-TopGas® classic (35) 7.4 - 34.9 kW
47-TopGas® classic (45) 9.1 - 44.3 kW
47-TopGas® classic (50) 16.0 - 52.0 kW
47-TopGas® classic (60) 12.8 - 60.3 kW
47-TopGas® classic (80) 14.8 - 79.1 kW
47-TopGas® classic (100) 20.7 - 100.0 kW
47-TopGas® classic (120) 22.9 - 120.5 kW

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TABLE OF CONTENT
1. Important notes....................................................................................................................................... 4
1.1 General safety instructions.................................................................................................................................................4
1.2 Explanation of the symbols ................................................................................................................................................4
1.2.1 Warnings ..........................................................................................................................................................................4
1.2.2 Warning symbols...............................................................................................................................................................4
1.2.3 Information........................................................................................................................................................................5
1.3 On delivery...........................................................................................................................................................................5
1.4 Guarantee ............................................................................................................................................................................5
1.5 Instructions..........................................................................................................................................................................5
1.6 Transport and storage.........................................................................................................................................................5
1.7 Regulations, standards, ordinances to be complied with for proper use......................................................................................................6
2. Technical information ............................................................................................................................. 7
2.1 Description of the Hoval TopGas®classic ..........................................................................................................................7
2.1.1 Diaphragm expansion tank................................................................................................................................................7
2.1.2 Boiler casing.....................................................................................................................................................................7
2.1.3 Gas valve..........................................................................................................................................................................7
2.1.4 Gas automatic function device and heating regulator ........................................................................................................7
2.1.5 Heating circulation pump...................................................................................................................................................7
2.1.6 Hot water supply ...............................................................................................................................................................7
2.1.7 Scope of delivery ..............................................................................................................................................................7
2.1.8 TopGas®classic component designation ...........................................................................................................................8
2.2 Meaning of the data on the data plate ................................................................................................................................9
2.3 Technical data for TopGas®classic (35-120) ....................................................................................................................10
2.4 Dimensions TopGas®classic (35-80) ................................................................................................................................12
2.5 Dimensions TopGas®classic (100,120).............................................................................................................................13
2.7 Flow resistance on the heating water side.......................................................................................................................14
2.6 Brief description of the functions of automatic function device BIC 335 .......................................................................14
2.8 Heating system control .....................................................................................................................................................15
2.9 Parameters to be set .........................................................................................................................................................17
3. Installation............................................................................................................................................. 19
3.1 Boiler installation room.....................................................................................................................................................19
3.1.1 Installing the boiler..........................................................................................................................................................19
3.2 Hydraulic switching...........................................................................................................................................................19
3.2.1 Engineering guidelines for the hydraulic switching...........................................................................................................19
3.2.2 Water pressure guard for water shortage protection ........................................................................................................19
3.2.3 Gravity brake ..................................................................................................................................................................20
3.2.4 Minimum water circulation volume...................................................................................................................................20
3.2.5 To be provided on site.....................................................................................................................................................20
3.2.6 Hydraulic integration .......................................................................................................................................................20
3.2.7 Connection of the pipes ..................................................................................................................................................22
3.3 Flue gas connection, chimney and condensate discharge .............................................................................................22
3.3.1 Flue gas conduits approved under building law ...............................................................................................................22
3.3.2 Air/Flue gas pipe.............................................................................................................................................................23
3.3.3 Project planning instructions, flue gas systems ...............................................................................................................24
3.3.4 Room air-independent installation ...................................................................................................................................24
3.3.5 Design examples for room air dependent operation.........................................................................................................25
3.3.6 Design examples for room air independent operation......................................................................................................26
3.4 Condensate discharge and neutralisation........................................................................................................................30
3.5 Gas connection..................................................................................................................................................................30
3.6 Electrical connection.........................................................................................................................................................30
3.6.1 Regulations for electrical connections .............................................................................................................................31
3.6.2 Electrical connection (mains) 230 V, 50 Hz......................................................................................................................31
3.6.3 Boiler controller/electrical connection diagram ................................................................................................................31
3.6.4 Connecting the heating regulator ....................................................................................................................................31
3.6.4.1 TopTronic®RS-OT ..........................................................................................................................................................................31
3.6.4.2 TopTronic®E...................................................................................................................................................................................31

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TABLE OF CONTENT
4. Commissioning ..................................................................................................................................... 32
4.1 Setting the controller.........................................................................................................................................................32
4.2 Water quality......................................................................................................................................................................32
4.2.1 Heating water..................................................................................................................................................................32
4.2.2 Filling and replacement water .........................................................................................................................................32
4.2.3 Filling the system............................................................................................................................................................33
4.3 Venting the gas pipe..........................................................................................................................................................33
4.4 Switching on......................................................................................................................................................................33
4.5 Gas inlet pressure .............................................................................................................................................................33
4.6 Gas adjustment..................................................................................................................................................................34
4.6.1 Gas valve........................................................................................................................................................................34
4.6.2 TopGas®classic (35-80)..................................................................................................................................................34
4.6.2.1 Setting the gas flow rate CO2(O2) and measurement of NOx/CO content in the flue gas (flue gas measurement) ...........................34
4.6.2.2 Changing to a different type of gas .................................................................................................................................................35
4.6.3 TopGas®classic (100,120) ..............................................................................................................................................36
4.6.3.1 Setting the gas flow rate CO2(O2) and measurement of NOx/CO content in the flue gas (flue gas measurement) ...........................36
4.6.3.2 Changing to a different type of gas .................................................................................................................................................37
4.7 Handover to the operator ..................................................................................................................................................38
4.7.1 Instructions for the operator ............................................................................................................................................38
4.7.2 Checking the water level.................................................................................................................................................38
4.7.3 Maintenance ...................................................................................................................................................................38
5. Decommissioning ................................................................................................................................. 39
6. Maintenance .......................................................................................................................................... 40
6.1 Checking the water connections for leakage ...................................................................................................................40
6.2 Refilling..............................................................................................................................................................................40
6.3 Maintenance comprises ....................................................................................................................................................40
6.4 Cleaning the heat exchanger ............................................................................................................................................40
6.5 Function check ..................................................................................................................................................................41
6.6 Emission measurement.....................................................................................................................................................41
7. Faults..................................................................................................................................................... 42
7.1 Blocking actions................................................................................................................................................................42
7.2 Locking actions .................................................................................................................................................................42
8. Parameter list for BIC 335 automatic function device......................................................................... 44
8.1 TopGas®classic (35,45,50,60,80,100,120) automatic function device .............................................................................44

44 219 316 / 00
IMPORTANT NOTES
1. Important notes
1.1 General safety instructions
The following points must be observed when performing
work on the TopGas®classic:
!
CAUTION
If you smell ue gas or gas
• avoid naked ames and
the occurrence of sparks,
• do not smoke,
• take the system out of operation,
• close the gas shut-o󰀨 valve,
• Open windows and doors
• The system may only be placed in operation if all the
relevant standards and safety regulations have been
complied with. However, for trial operation, the follow-
ing are the minimum conditions requiring fullment:
- Safety valve installed (closed system)
- Control in operation (connected to the mains current
supply system)
- System lled with water
- Expansion tank connected
- Boiler connected to a ue gas conduit installed in
compliance with the relevant regulations.
- Burner preset.
• When performing maintenance and repairs
- Allow the gas condensing boiler to cool down.
- Switch o󰀨 the gas condensing boiler and disconnect it
from the power supply.
- Close the gas shut-o󰀨 valve.
- Close all cut-o󰀨 valves on the unit
(cold water, heating ow and return).
- If work on the components of the gas condensing boi-
ler which carry water is not performed correctly, the
heating medium may escape and lead to scalding.
- After performing repair and maintenance work, reat-
tach all cover plates which were removed.
- Do not exceed the maximum operating pressure and
operating temperature (see data plate) for the gas
condensing boiler.
- Open all cut-o󰀨 valves on the unit (cold water, heating
ow and return).
- Open gas shut-o󰀨 valve.
WARNING
The heat generator can only be de-energised
by disconnection from the mains (e.g. all-
pole switch).
WARNING
All electric power supply circuits must be
switched o󰀨 before accessing the terminals.
1.2 Explanation of the symbols
1.2.1 Warnings
!
DANGER
... indicates a situation of immediate danger
which will lead to serious or fatal injuries if
not avoided.
!
WARNING
... indicates a situation of possible danger
which can lead to serious or fatal injuries if
not avoided.
!
CAUTION
... indicates a situation of possible danger
which can lead to minor or slight injuries if
not avoided.
NOTICE
... indicates a situation of possible danger
which can lead to damage to property if not
avoided.
1.2.2 Warning symbols
The following warning signs are combined for the warn-
ing notes with signal words CAUTION, WARNING and
DANGER.
!
General warning of a danger zone.
«Warning: dangerous electrical voltage» as a
warning for accident prevention.
Ensures that people do not come into contact
with electrical voltage. The danger sign with
the black lighting symbol warns against the
danger of electrical voltage.
«Warning of hot surface» sign for indicating
safety.
Indicates dangers of injury and burns on hot
surfaces.
Incorrect handling of potentially explosive
substances can lead to serious damage, po
-
tentially fatal injuries and incalculable costs.
Danger: Substances with a corrosive e󰀨ect on
skin, eyes and respiratory organs; can cause
irritation.
Handling: Do not inhale vapours and avoid
contact with skin and eyes.

54 219 316 / 00
IMPORTANT NOTES
Warning of cutting injuries:
Avoid cutting injuries. Clearly indicate the dan
-
ger of cutting on sharp-edged parts to avoid
serious and costly injuries.
1.2.3 Information
Information:
Provides important information.
Follow the instructions for use.
Requirements to comply with the instructions.
Tool:
Which tools and other equipment are required.
§
Provides important information. Refers to
standards and directives.
1.3 On delivery
Carry out a visual inspection immediately on receiving the
boiler. If any damage is found, take the necessary steps
as dened in the delivery contract. The respective risk
carrier bears the cost of repairs.
1.4 Guarantee
The warranty does not cover defects attributable to:
• Failure to comply with these instructions
• Failure to comply with the operating instructions
• Incorrect installation
• Impermissible modications
• Incorrect handling
• Contaminated operating materials (gas, water, combus-
tion air)
• Unsuitable chemical additives to the heating water
• Damage caused by the application of force
• Corrosion by halogen compounds (e.g. paints, adhe-
sives, solvents)
• Corrosion caused by not observing the required water
quality
1.5 Instructions
All instructions relevant to your system can be found in
the Hoval system manual! In exceptional cases, the in-
structions can be found with the components!
Further sources of information:
• Hoval catalogue
• Standards, regulations
1.6 Transport and storage
On receipt of the unit, please remove the packaging and
check that the delivery is complete, consistent with your
order and has not been damaged in transit.
The unit should always be transported and stored in the
original packaging. Interim storage of Hoval condensing
boilers may only take place in the original packaging and
in locations protected against the elements. The ambient
conditions during storage must comply with the following
limit values:
• Air temperature: -10 °C - +50 °C
• Air humidity: 50-85 % relative humidity
• condensation-free

64 219 316 / 00
IMPORTANT NOTES
1.7 Regulations, standards, ordinances to be
complied with for proper use
The locally applicable heating system regulations must
be followed when planning, installing and operating the
gas heat generator:
• The regulations of the local building authorities, insur-
ance companies, chimney sweeps and the state/can-
ton. etc. must also be taken into account.
• The regulations of the responsible gas supply company
are to be complied with if using gas.
• Regulations governing the discharge and treatment of
condensate are subject to the specications of the local
water authorities.
• Approval by the authorities may be required for instal-
lation.
The standards, guidelines and ordinances listed for the
specic countries are relevant for the installation and op-
eration of the gas heat generator. The list is intended as
an aid. It is not complete. The currently applicable regula-
tions must be observed.
Germany §
• DIN EN 12828 Heating systems in buildings - Design
of hot water heating systems
• DIN EN 12831 Energy e󰀩ciency of buildings - Method
for calculation of the design heat load
• DIN EN 13384 Flue gas systems – Calculation meth-
ods in heat and ow engineering
• DIN EN 14868: Protection of metallic materials against
corrosion - Guidance on the assessment of corrosion
likelihood in closed water circulation systems
• DIN EN 50156; VDE 0116: Electrical equipment of
combustion plants and associated facilities
• DIN VDE 0100 Erection of low-voltage installations
(for electrical installation and the TAB (technical con-
nection requirements of the relevant energy supply
company))
• VDI 2035 Prevention of damage in hot water / heating
systems by corrosion and the formation of scale in
closed hot water heating systems.
• Rules for gas established by DVGW (in particular
DVGW-TRGI Technical rules for gas installations)
• Firing ordinance of the federal states
• Technical specications of the gas supply companies
• Worksheet DWA-A 251 Condensate from condensing
boilers
The regulations of the local water authorities could
deviate from the rules in this worksheet.
• Accident prevention regulations
- DGUV Regulation 1 Accident prevention regulations
- Guidelines for prevention
- DGUV Regulation 4 Accident prevention regulations
- Electrical installations and equipment
Austria §
• ÖNORM EN 12828 Heating systems in buildings - De-
sign of hot water heating systems
• ÖNORM EN 12831 Energy e󰀩ciency of buildings -
Method for calculation of the design heat load
• ÖNORM EN 13384 Flue gas systems - Heat and ow
calculation methods
• ÖNORM EN 14868: Protection of metallic materials
against corrosion - Guidance on the assessment of
corrosion likelihood in closed water circulation systems
• OVE 50156: Electrical equipment of combustion plants
and associated facilities
• ÖNORM H 5152 Caloric plants - Planning guidelines
• ÖNORM H 5170 Heating systems - Requirements
with respect to building and safety technology, re and
environmental protection
• ÖNORM H 5195-1 Heat transfer uid for building tech-
nology - Prevention of damage by corrosion and the
formation of scale in closed hot water heating systems
• ÖVGW rules for gas
• Technical specications of the gas supply companies
• SNT regulations
Switzerland §
• SN EN 12828+A1;SIA 384.101+A1 Heating systems in
buildings - Design of hot water heating systems
• SN DIN EN 12831 Energy e󰀩ciency of buildings -
Method for calculation of the design heat load
• SN EN 13384;SIA 384.42x Flue gas systems - Heat
and ow calculation methods
• SN EN 14868: Protection of metallic materials against
corrosion - Guidance on the assessment of corrosion
likelihood in closed water circulation systems
• SN EN 50156: Electrical equipment of combustion
plants and associated facilities
• SWKI 91-1 Aeration and ventilation of the boiler room
• SWKI 93-1 Safety engineering installations for heating
systems
• SWKI BT102-01 Water quality for building services
systems
• SVGW rules for gas
• Swiss re protection regulations (BSV) of the VKF
(Association of Cantonal Fire Insurers)
• Regulations of the cantonal and local re authorities
• Water Protection Regulation (GSchV)
• EKAS - Guidelines for liqueed gas
Other countries §
For all other countries of destination, the locally applicable
country-specic regulations must be observed.

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TECHNICAL INFORMATION
2. Technical information
2.1 Description of the Hoval TopGas®classic
The heat exchanger of the Hoval TopGas®classic com-
prises a corrosion-resistant aluminum casting, through
which the heating water ows in series-parallel fashion
from bottom to top. A fan draws in combustion air through
openings in the top casing cover from the installation
room or via an air-ue gas system (for room air independ-
ent operation).
A predened quantity of fuel gas is mixed with the com-
bustion air in front of the fan via a combined gas and air
control. The homogeneous fuel gas/air mixture is then
fed to the pre-mix surface burner via a distributor for low-
emission combustion.
The pre-mix surface burner is made from high-tempera-
ture stainless steel mesh which is optimally protected
against damage through overheating.
The design of the heat exchanger is such that the ue gas
is cooled to below the ue gas dew point at correspond-
ingly low system temperatures. As a result of additional
exploitation of the latent ue gas heat (caloric value uti-
lisation), the Hoval TopGas®classic operates with very
high levels of e󰀩ciency. After leaving the heat exchanger,
the cooled ue gas is fed to the ue gas system.
2.1.1 Diaphragm expansion tank
Depending on hydraulic conditions, a su󰀩ciently dimen-
sioned diaphragm expansion tank with a pre-pressure at
least 0,3 bar higher than the hydrostatic pressure on-site
must be installed.
2.1.2 Boiler casing
In sheet steel, white powder-coated, front sections easily
removable.
2.1.3 Gas valve
Gas controlled system Honeywell VK4125V + VK4615 for
automatic regulation of the gas/combustion air ratio, see
chapter 4.6.1.
2.1.4 Gas automatic function device and heating
regulator
Automatic function device BIC 335 (for brief description,
see chapter 2.7).
2.1.5 Heating circulation pump
The Hoval TopGas®classic is delivered without an in-
stalled heating circulation pump. A su󰀩ciently dimen-
sioned heating circulation pump must be installed on site.
2.1.6 Hot water supply
The Hoval TopGas®classic can be combined with a DHW
calorier (e.g. Hoval CombiVal).
The calorier sensors and the loading pump must be
connected at the corresponding terminals of the Hoval
TopGas®classic controller (see electrical connection dia-
gram in the boiler).
2.1.7 Scope of delivery
- Pressure gauge
- Autom. air vent in the boiler ow
- Plastic siphon in condensate drain
- Water pressure switch as protection against water
shortage
- Flue gas temperature sensor
- Gas connection R ¾″
- Electrical connecting cable, length approx. 1.5 m, with plug
- Gas pressure monitor

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TECHNICAL INFORMATION
2.1.8 TopGas®classic component designation
Fig. 01
3
6
2
9
5
4
8
1
10
11
7
Fig. 02
13 14
12 15
1. Sound absorber
2. Fan
3. Flue gas supply air connection
4. Water pressure switch
5. Flue gas temperature sensor
6. Flow temperature sensor
7. Return temperature sensor
8. Ignition/ionisation electrode
9. Heat exchanger
10. Gas valve
11. Gas pressure monitor
12. ON/OFF switch
13. Control panel automatic function device
14. Control module TTE (optional)
15. Pressure gauge

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TECHNICAL INFORMATION
2.2 Meaning of the data on the data plate
6
7
10
11
3
4
5
12
8
9
1
2
1Manufacturer
2Subsidiaries
3Boiler type (left) and production date (right)
4Boiler type (left) and serial No. (right)
5Performance features:
• Pn: Boiler nominal heat output
• Pn (80/60°C): Nominal heat output at 80/60°C
• Pn (50/30°C): Nominal heat output at 50/30°C
• Qn (Hi) Nominal heat input
(related to net caloric value NCV)
• Qn (Hs) Nominal heat input
(related to gross caloric value GCV)
• V (H2O) Boiler water content (V(H2O))
• PMS Max. heating operating pressure (PMS)
• PT Test pressure (PT)
• Tmax Max. operating temperature (Tmax)
• TS Safety temperature (TS)
6Boiler construction type
7Type of gas set
8Gas supply pressure depending on the gas device category and
the country of destination
• Column 1: Country of destination
• Column 2: Gas device category
• Column 3: Gas supply pressure
9Electric supply
• Nominal voltage / type of supply
• Type of protection
• Max. power consumption
10 NOx class and authoritative standard
11 Product ID number / registration number
12 Designations

10 4 219 316 / 00
TECHNICAL INFORMATION
2.3 Technical data for TopGas®classic (35-120)
Type (35) (45) (50) (60)
• Nominal heat output at 80/60 °C, natural gas kW 6.9-31.7 8.3-39.8 14.6-48.3 11.9-54.1
• Nominal heat output at 50/30 °C, natural gas kW 7.4-34.9 9.1-44.3 16.0-52.0 12.8-60.3
• Nominal heat output at 80/60 °C, propane 2) kW 9.5-32.5 10.4-41.5 - 14.1-56.6
• Nominal heat output at 50/30 °C, propane 2) kW 10.5-36.3 11.45-45.8 - 15.5-61.1
• Nominal heat input with natural gas 1) kW 6.9-33.0 8.5-42.4 15.0-49.0 11.7-56.9
• Nominal heat input with propane 2) kW 9.8-33.0 10.7-42.1 -14.5-57.7
•Heating operating pressure min./max. (PMS) bar 1/4 1/4 1/4 1/4
• Test pressure (PT) bar 6666
• Operating temperature max. (Tmax) °C 85 85 85 85
• Boiler water content (V(H20)) l 4.0 4.0 5.4 5.4
• Flow resistance boiler z-value see diagram
•Minimum circulation water quantity l/h 300 350 390 470
• Boiler weight (without water capacity, incl. casing) kg 96 96 116 116
•Boiler e󰀩ciency at 80/60 °C in full-load operation (NCV/GCV) %97.6/88.1 95.7/86.3 97.2/87.7 97.0/87.5
•Boiler e󰀩ciency at 30 % partial load (EN 15502) (NCV/GCV) %107.4/96.6 107.3/96.8 107/96.6 107.3/96.8
•Room heating energy e󰀩ciency
- without control ηs %92 92 92 92
- with control ηs %94 94 94 94
- with control and room sensor ηs %96 96 96 96
• NOx class (EN 15502) 6666
• Nitrogen oxide emissions (EN 15502) (GCV) NOx mg/kWh 23.9 27.4 21.8 23.4
• Content of CO2 in the ue gas minimum/maximum output %8.7/9.0 8.8/8.9 9/8.8 8.8/8.8
• Heat loss in standby mode Watt 95 95 105 105
• Dimensions see table of dimensions
•Gas ow pressure minimum/maximum
- Natural gas E/LL mbar 17.4-50 17.4-50 17.4-50 17.4-50
- Propane mbar 37-50 37-50 37-50 37-50
• Gas connection value at 15 °C/1013 mbar:
- Natural gas E (Wo = 15.0 kWh/m3) NCV = 9.97 kWh/m3m3/h 0.7-3.3 0.9-4.3 1.5-4.9 1.2-5.7
- Natural gas LL (Wo = 12.4 kWh/m3) NCV = 8.57 kWh/m3m3/h 0.8-3.9 1.0-4.9 1.8-5.7 1.4-6.6
- Propane 2) (NCV = 25.9 kWh/m3) m3/h 0.4-1.3 0.4-1.6 - 0.6-2.2
• Operation voltage V/Hz 230/50 230/50 230/50 230/50
• Electrical power consumption min./max. Watt 24/74 24/78 23/68 23/78
• Stand-by Watt 6666
• Type of protection IP 40D 40D 40D 40D
• Permitted ambient temperature during operation °C 5-40 5-40 5-40 5-40
• Sound power level
- Heating noise (EN 15036 Part 1) (room air dependent) dB(A) 61 61 63 63
• Condensate quantity (natural gas) at 50/30 °C l/h 3.7 4.3 4.5 5.4
• pH value of the condensate 4-6 4-6 4-6 4-6
• Construction type B23, C13(x), C33(x), C53(x), C63(x), C93(x)
• Flue gas system
- Temperature class T120 T120 T120 T120
- Flue gas mass ow at nominal heat load (dry) kg/h 52.5 66.4 76.1 88.4
- Flue gas mass ow at lowest nominal heat load (dry) kg/h 10.5 13 23.3 17.8
- Flue gas temperature at nominal output and operation 80/60 °C °C 57.7 59.4 57.6 58.9
- Flue gas temperature at nominal output and operation 50/30 °C °C 36.7 40.5 36.3 38.6
- Flue gas temperature at lowest nominal heat load and operation 50/30 °C °C 28.8 28.9 29.4 29.4
- Maximum permitted temperature of the combustion air °C 50 50 50 50
- Volume ow rate combustion air Nm3/h 42.9 54.2 62.4 72.4
- Maximum supply pressure for supply air and ue gas line Pa 120 120 140 140
- Maximum draught/depression at ue gas outlet Pa -50 -50 -50 -50
1) Data related to NCV. The boiler series is tested for EE/H-settings. With a factory setting of the Wobbe coe󰀩cient of 15.0 kWh/m3operation at a
Wobbe coe󰀩cient of 12.0 up to 15.7 kWh/m3is possible without new settings.
2) Data related to NCV. TopGas®classic can also be operated with propane.

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TECHNICAL INFORMATION
Type (80) (100) (120)
• Nominal heat output at 80/60 °C, natural gas kW 13.4-71.8 18.6-91.2 20.7-109.7
• Nominal heat output at 50/30 °C, natural gas kW 14.8-79.1 20.7-100.0 22.9-120.5
• Nominal heat output at 80/60 °C, propane 2) kW 18.4-73.7 22.9-90.4 23.7-107.6
• Nominal heat output at 50/30 °C, propane 2) kW 20.3-79.9 25.3-100.0 26.1-120.0
• Nominal heat input with natural gas 1) kW 13.8-75.8 19.2-93.7 21.1-114.0
• Nominal heat input with propane 2) kW 19.0-74.4 23.7-93.0 24.6-111.5
•Heating operating pressure min./max. (PMS) bar 1/4 1/4 1/4
• Test pressure (PT) bar 666
• Operating temperature max. (Tmax) °C 85 85 85
• Boiler water content (V(H20)) l 5.4 7.0 7.0
• Flow resistance boiler z-value see diagram
•Minimum circulation water quantity l/h 550 800 800
• Boiler weight (without water capacity, incl. casing) kg 116 130 130
•Boiler e󰀩ciency at 80/60 °C in full-load operation (NCV/GCV) %96.3/86.8 97.8/88.2 98.6/88.9
•Boiler e󰀩ciency at 30 % partial load (EN 15502) (NCV/GCV) %107.8/97.3 107.6/97.0 106.1/95.8
•Room heating energy e󰀩ciency
- without control ηs %92 92 91
- with control ηs %94 94 93
- with control and room sensor ηs %96 96 95
• NOx class (EN 15502) 666
• Nitrogen oxide emissions (EN 15502) (GCV) NOx mg/kWh 29.0 27.8 31.1
• Content of CO2 in the ue gas minimum/maximum output %8.8/8.8 8.8/8.8 9.2/8.8
• Heat loss in standby mode Watt 105 115 115
• Dimensions see table of dimensions
•Gas ow pressure minimum/maximum
- Natural gas E/LL mbar 17.4-50 17.4-50 17.4-50
- Propane mbar 37-50 37-50 37-50
• Gas connection value at 15 °C/1013 mbar:
- Natural gas E (Wo = 15.0 kWh/m3) NCV = 9.97 kWh/m3m3/h 1.4-7.6 1.9-9.4 2.1-11.4
- Natural gas LL (Wo = 12.4 kWh/m3) NCV = 8.57 kWh/m3m3/h 1.6-8.8 2.2-10.9 2.5-13.3
- Propane 2) (NCV = 25.9 kWh/m3) m3/h 0.7-2.9 0.9-3.6 0.9-4.3
• Operation voltage V/Hz 230/50 230/50 230/50
• Electrical power consumption min./max. Watt 23/116 22/150 22/214
• Stand-by Watt 666
• Type of protection IP 40D 40D 40D
• Permitted ambient temperature during operation °C 5-40 5-40 5-40
• Sound power level
- Heating noise (EN 15036 Part 1) (room air dependent) dB(A) 63 63 63
• Condensate quantity (natural gas) at 50/30 °C l/h 7.1 8.9 10.3
• pH value of the condensate 4-6 4-6 4-6
• Construction type B23, C13(x), C33(x), C53(x), C63(x), C93(x)
• Flue gas system
- Temperature class T120 T120 T120
- Flue gas mass ow at nominal heat load (dry) kg/h 124 152 187
- Flue gas mass ow at lowest nominal heat load (dry) kg/h 20.9 29.2 32
- Flue gas temperature at nominal output and operation 80/60 °C °C 62.7 62.6 66.8
- Flue gas temperature at nominal output and operation 50/30 °C °C 43.9 43.2 46
- Flue gas temperature at lowest nominal heat load and operation 50/30 °C °C 30 29.8 30.3
- Maximum permitted temperature of the combustion air °C 50 50 50
- Volume ow rate combustion air Nm3/h 102 125 153
- Maximum supply pressure for supply air and ue gas line Pa 140 140 140
- Maximum draught/depression at ue gas outlet Pa -50 -50 -50
1) Data related to NCV. The boiler series is tested for EE/H-settings. With a factory setting of the Wobbe coe󰀩cient of 15.0 kWh/m3
operation at a Wobbe coe󰀩cient of 12.0 up to 15.7 kWh/m3is possible without new settings.
2) Data related to NCV. TopGas®classic can also be operated with propane.

12 4 219 316 / 00
TECHNICAL INFORMATION
2.4 Dimensions TopGas®classic (35-80)
Measurements (mm)
• Lateral clearance 50 mm
• Distance from ceiling depending on exhaust ue system used
• Front 500 mm
View from bottom
1 Gas connection R ¾″
2 Flow R 1¼″
3 Return R 1¼″
4 Condensate drain DN 40
5LAS ue gas/combustion air connection C100/150
6 Cover control panel
7Safety valve
8 Ball valve

134 219 316 / 00
TECHNICAL INFORMATION
2.5 Dimensions TopGas®classic (100,120)
Measurements (mm)
• Lateral clearance 50 mm
• Distance from ceiling depending on exhaust ue system used
• Front 500 mm
View from bottom
1 Gas connection R ¾″
2 Flow R 1½″
3 Return R 1½″
4 Condensate drain DN 40
5LAS ue gas/combustion air connection C100/150
6 Cover control panel

14 4 219 316 / 00
TECHNICAL INFORMATION
2.6 Brief description of the functions
of automatic function device BIC 335
The automatic function device can be operated without
controller (TTE) and without room station (RS-OT) and
therefore comprises the following functions:
- PWM fan (230 V~)
- Modulating operation
- Inputs for:
- Flow sensor
- Return sensor
- Flue gas sensor
- Gas pressure switch
- Air pressure switch (not used)
- Water pressure switch
- Safety limit thermostat
- DHW tank sensor
- Outdoor sensor
- Inhibiting input (burner blocking)
- Status output "Fault"
(can be inverted via parameter setting)
- Three-way valve control for heating/DHW or charging
pump control (230 V~outputs); output for three-way valve
/DHW charging pump can be inverted via a parameter.
- Common electrode for ignition and ame monitoring
(ionisation)
- Allows control of main gas valve (possibly LPG valve)/
boiler room fan
- Interface to display
- OpenTherm interface (RS-OT, TTE)
- RS 232 interface to PC
- Start attempts: 4
- Safety period: 5 sec
- Ignition period: 5 sec
- Pre-ventilation period: 20 sec
- Main/heating pump follow-on time (230 V ~): 10 min
- Three-way valve/DHW charging pump follow-on time:
2 min
- Restart interlock after heat demand: 2 min
- Restart interlock after temperature blocking: 2 min
Fuses
The automatic function device is equipped with a mains
fuse. If this fuse (2AT) blows, the display will remain dark
although the main switch is turned on.
Ionisation current
The ionisation current value is displayed in the Informa-
tion level on sub-level 8. Access to the information level
is explained in Chapter 2.8.
2.7 Flow resistance on the heating water side
TopGas®classic (35,45)
0
50
100
150
200
250
300
0.0 1.0 2.0 3.0 4.0 5.0
Volume ow rate (m3/h)
Flow resistance (mbar)
TopGas®classic (50,60,80)
Volume ow rate (m3/h)
Flow resistance (mbar)
0
50
100
150
200
250
300
350
400
450
0.0 2.0 4.0 6.0 8.0
TopGas®classic (100,120)
Volume ow rate (m3/h)
Flow resistance (mbar)
0
50
100
150
200
250
300
0.0 2.0 4.0 6.0 8.0 10.0

154 219 316 / 00
TECHNICAL INFORMATION
2.8 Heating system control
Operating elements on the boiler control panel / basic controller G04.4
The basic controller can be upgraded with an RS-OT (G04.4) or a TopTronic®
E ZE1 heating controller set.
Normally, the user does not need to set the basic controller.
All settings have been made by the installer or the manufacturer.
Function
Mode indication Parameter indication Value indication
Meaning, description
Standby mode
Normal position,
Start position
current ow temperature
no indication
0 = Standby, no heat demand, waiting period, main gas valve
1 = Rinsing
2 = Ignition
3 = Burner "on" in heating operation
4 = Burner "on" in hot water operation
5 = Air pressure switch open (no air pressure switch tted)
6 = Burner "o󰀨" in heating operation
(ow temp. > ow temp. set + parameter 11 (2BA))
7= Pump follow-on time in heating operation
8 = Pump follow-on time in hot water mode
9= Burner "o󰀨" in DHW operation
(ow temp. > ow temp. set + parameter 1 (2AB))
Fr = Frost protection is active
Su = Short summer operation is active
Display: temperature
Changing of
the values
Display: mode RESET
Fault clearance (display is
blinking, if there is a failure)
Saving of
the settings
Selection of the setting
(parameter) to be changed
(e.g. calorier temperature)
ON/OFF Manometer
Function selection
(step by step selection on the display)

16 4 219 316 / 00
TECHNICAL INFORMATION
Entering the service code
To set the code, the "Mode" and "Step" keys must be
pres sed at the same time. The digit which ashes can
be changed using the "+" and "-" keys. The "Step" key
is used to switch between the digits. The complete code
is con r med and saved with the "Store" key. The screen
automatically switches back to the display level after 20
minutes.
Function
Mode indication Parameter indication Value indication
Meaning, description
Information Mode
It is possible
to read current values
from here
Point is blinking
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° Flow temperature set value in heating operation
6e.g. 70° Flow temperature set value in domestic hot water
mode
7 e.g.23 RPM Fan speed in hundred rpm
8 e.g. 4 µ A Ionisation current
Parameter Mode
Settings can be changed
in this mode.
Point appears
P. 7 60 = Set value, DHW charging
if there is no TopTronic®attached
Procedure: P. 18 80 = Maximum heating temperature (at minimum
outdoor temperature) during heating operation
1. Select parameter mode
(press mode key twice)
The parameter (P.7) and the
setting value are displayed
alternately.
Parameter 18
Flow temperature
Outside
temperature
Further parameters only with service code
2. Select the parameter
to be changed (step key)
3. Change setting using + - keys
4. Save
(press store key once)
Return to standby mode
automatically after 20 minutes
or by pressing mode key.
Parameter level (constant dot)
Parameter level is indicated by a constant dot after the
second character.
If neither the "+" or the "-" key is pressed, "P" + parameter
number and then the corresponding parameter value are
displayed alternately. The corresponding parameter value
can be changed by pressing the "+" or "-" key. Changes
ma de are saved by pressing "Store" and are conrmed
by the display ashing twice - (wait for this ashing signal
before pressing another key!). If the "Store" key is not
pressed, the setting is not applied.

174 219 316 / 00
TECHNICAL INFORMATION
2.9 Parameters to be set
Parameter 7 (2AH) – set value, DHW charging –
• Operation without controller:
Set value is used as DHW set value for the automatic
function device.
• Operation with RS-OT:
Set value cannot be increased by RS-OT, but it can be
decreased.
• Operation with TTT/N or TTT-WEZ:
Set value can be increased from TTT/N or TTT-WEZ up
to the value of parameter 9 (2AJ). The DHW setpoint
temperature can also be reduced below the value set in
the parameters here.
Parameter 8 (2AI) – pump follow-on time for DHW –
Here, you can dene the follow-on time for the pump after
the end of DHW demand.
The after-run time runs out before the change to heating
mode and the change to standby mode (RS-OT, TTT/N
or TTT-WEZ) or OFF mode (automatic function device).
Parameter 9 (2AJ) – anti-legionella period –
Periodic heating to the temperature set under Parameter
5 (2AF) takes place to realise anti-legionella protection.
The interval at which this takes place must be set here. At
a setting of 0, the anti-legionella function is deactivated.
Parameter 10 (2AK) – Maximum fan speed in DHW
mode –
This parameter denes the maximum speed of the fan in
DHW operation.
Parameter 18 (2BH) – Maximum heating temperature
(at minimum outside temperature) –
The value set here denes the ow temperature applied
when the outside temperature falls below the "minimum
out side temperature" specied in Parameter 19 (2BI) or
if no outside sensor is connected. If the OT bus transmits
a set value to the automatic function device, this value is
li mi ted by the value dened here.
Parameter 19 (2BI) – minimum outside temperature –
This parameter denes the minimum outside temperatu-
re, i.e. if the outside temperature falls below this value,
the ow temperature should equal the temperature de-
ned under parameter 18 (2BH).
Parameter 20 (2BJ) – minimum heating temperature
(at maximum outside temperature) –
If the outside sensor measures the value set under pa-
rameter 21 (2BK), the parameterised minimum heating
temperature is applied. If the temperature measured by
the outside sensor is above the parameterised value, the
heat demand is reset.
Parameter 21 (2BK) – maximum outside temperature –
If the maximum outside temperature dened here is ex-
ceeded, heat demand is no longer applied. As soon as
the parameterised value is reached, the minimum heating
temperature dened under parameter 20 (2BJ) is applied.
Parameter 22 (2BL) – switching delay after tempera-
ture block during heating operation –
After shutdown of the boiler as a result of a temperature
ele vation, i.e. after a set value plus the set o󰀨set is excee-
ded, start-up of the boiler in response to a future heat
de mand is delayed for a time dened with this parameter,
independent of whether the value is within the hysteresis.
Parameter 23 (2BM) – switching delay after heat de-
mand in heating operation –
Directly following a heat demand, renewed start-up of the
boiler is delayed. This means that if the set value to the
automatic ring device is reset via the OT bus and the
boiler switched o󰀨 as a result, the downtime of the boiler
when a new set value is applied is at least equal to the
time set here.
Parameter 24 (2BN) – pump follow-on time heating
operation –
The time set here denes the pump follow-on time after
the end of heating operation.
Parameter 25 (2BO) – maximum fan speed in heating
operation –
This parameter denes the maximum fan speed which
can be applied in heating operation in %.
Parameter 60 (2GE) – Waiting period after opening of
the main gas valve or activation of the boiler room fan –
If a burner request is pending, boiler start-up is delayed
by the time set here. During this waiting period, which is
required for opening the main gas valve or for pre-ventila-
tion via the boiler room fan, the display reads "0".
Parameter 61 (2GF) - external main gas valve
(possibly LPG valve) / boiler room fan present –
This parameter denes whether an external main gas val-
ve or a boiler room fan is connected.

18 4 219 316 / 00
TECHNICAL INFORMATION
Parameter 62 (2GG) – DHW charging (switch / pump) –
This parameter denes whether a pump is present for
DHW charging or whether only a switch is in use in addi-
tion to the main pump.
The setting "0" means a KKP (pump output) and additio-
nally a switch (switch output) is used. The setting "1"
means, that the pump at the pump output (X8-5/6) is only
working in heating mode and the DHW pump at the out-
put X8-7/8 is getting active in the DHW mode.
Parameter 63 (2GH) – pump – minimum PWM value –
This parameter species the minimum permissible out-
put of the PWM pump in %. The minimum PWM value is
applied in the case of minimum boiler output. The pump
speed increases in linear manner between minimum and
maximum boiler output.
Parameter 64 (2GI) – pump - maximum PWM value –
This parameter species the maximum permissible out-
put of the PWM pump in %. The maximum PWM value is
applied in the case of maximum boiler output. The pump
speed increases in linear manner between minimum and
maximum boiler output.
Parameter 65 (2GJ) – three-way valve inverted –
The output for controlling the three-way valve can be in-
verted via this parameter.
Parameter 66 (2EO) – Air pressure switch tted –
Setting this parameter species whether air pressure
switches are installed for monitoring the air channels in
the boiler or not.
0 no air pressure switches are installed
1 air pressure switches are installed

194 219 316 / 00
INSTALLATION
3. Installation
3.1 Boiler installation room
Hoval condensing boilers in the series TopGas®classic
can be combined with ue gas con duits which
a) draw in combustion air from the installation room
(room-air dependent gas ring system)
b) draw in combustion air from outside via a closed
system (room-air-independent gas ring system)
The boiler installation rooms must comply with the rele-
vant local regulations (ring ordinance, regulations of the
re prevention authority). In particular, the stipulations of:
- DVGW-TRGI
must be observed and complied with.
In the case of room air dependent operation, it must be
ensured that the combustion air is free of contamination
(dust, building materials,...) and aggressive substances
(halogens such as chloride, uoride etc.). Gas boilers
should not be connected to the mains gas supply or put
into operation until all construction work in the installation
room is completed.
3.1.1 Installing the boiler
The Hoval TopGas®classic is delivered as follows.
Box: Boiler; casing parts; installation
and operating instructions.
NOTE
The boiler must not be placed on its connec-
tor elements.
The boiler is mounted in the desired position on the wall.
Side clearance: at least 5 cm; distance from the ceiling:
the required clearance for the type and dimensions of the
lines for combustion air and ue gas must be observed.
Please note dimensions and instructions in
the drawings in the chapters 2.4 and 2.5.
3.2 Hydraulic switching
The Hoval TopGas®classic is designed for continuously
controlled operation (room temperature control/weath-
er-controlled boiler and heating circuit control) without
lower temperature limit.
Please observe the notes in the conguration documents
of the responsible Hoval companies with respect to the
appropriate hydraulic switching.
NOTE
When modernising an old heating system
with an open expansion tank, this is to be
converted to a «closed» heating system
with a diaphragm expansion tank and safety
valve.
3.2.1 Engineering guidelines for the hydraulic
switching
• Installation of a sludge collector in the boiler return is
recommended (observe the correct dimensioning).
• An adequately dimensioned expansion tank must be
provided.
• The minimum pre-pressure in the expansion tank must
be 1,2 bar and the working pressure in the boiler must
be 1,5 bar.
• The pump is to be connected in the boiler return and the
expansion tank in the suction side of the pump.
• If the system pressure cannot to be reached (e.g. roof
central heating plants), the expansion tank must be in-
stalled in the boiler ow. (Note: starting from 70 °C an
additional in-line vessel is necessary).
• Plants with
-continuous oxygen intake (e.g. underoor heating
systems without di󰀨usion-proof plastic piping) or
-intermittent oxygen intake (e.g. requiring frequent
topping-up)
must be equipped with separate circuits.
We also recommend the conclusion of a main
-
tenance contract!
3.2.2 Water pressure guard for water shortage
protection
To protect the boiler against excessively low water pres-
sure/water level, a water pressure switch is mounted on
the return distributor as standard (AMP connectors at po-
sitions 1 and 3). The boiler is switched o󰀨 if the water
pres sure falls below 1 bar ("P27" is shown on the dis-
play). Please check the system pressure and top up with
water if necessary.

20 4 219 316 / 00
INSTALLATION
3.2.3 Gravity brake
It is recommended to install a gravity brake, to avoid heat
losses due to gravity circulation (particularly important
when changing existing, open installations). The gravity
brake is necessary for summer operation with indirectly
heated storage tank calorier.
3.2.4 Minimum water circulation volume
During the burner operation a circulation pump must always
be in operation. The minimum water circulation volume in-
dicated in the technical data must always be provided.
3.2.5 To be provided on site
A pressure expansion tank appropriate for the heating
system, water volume and hydrostatic pressure.
3.2.6 Hydraulic integration
Examples
TopGas®classic (100,120)
Gas boiler with
- free-standing calorier
- 1 direct circuit
Hydraulic schematic BDDE020
1
A
B
D
E
C
F
2 3 4 5 6 7 8 9
123456789
A
B
D
E
C
F
BDDE020.dwg
Achtung ! Für die Installation muss das anlagenbezogene Schema verwendet werden!
Attention! This is just a schematic. For installation please use the detail-plan!
Attenzione! Per la messa in opera, utilizzare le schema dettagliato!
Attention! Pour la réalisation pratique de l'installation, il faut utiliser le schéma détaillé!
Datum:
Datei:
Version:
Blatt:
Hydr. Verbindungshinweise /
Notice / Nota / Remarque:
14.1
BDDE020 Name:
18.10.2015
. . .
T
P
TopGas classic ³ 35
T T
B1
BA
RS
-OT
M 5
SLP
T
T
BW
RS-OT Room station (OpenTherm)
B1 Flow temperature guard (if required)
BA Outdoor sensor
BW Calorier sensor
SLP Calorier charging pump
M5 Boiler circuit pump