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Condensing Boilers
30-80 kW
Low-NOx wall-mounted condensing boilers
with high efficiency premix burner 6-80kW
...all you will ever need for the most advanced
heating system available.
Hoval TopGas®
• Simplicity of design
• 5:1 turndown
Applications:
TopGas condensing boilers are suitable for closed central heating and domestic
hot water primary supply systems. The condensing operation also makes
them suitable for underfloor heating installations requiring lower flow/return
temperatures. A range of matched calorifiers and Hoval pressurisation units
are available. Hoval approved flue kits are available ex-stock to assist with site
installation.
TopTronic®T controllers:
With the addition of a TopTronic®T controller a boiler circuit, mixed circuit and
calorifier primary pump can be controlled. Up to five boilers can be linked
together to provide sequence control. Additional features such as an extra mixed
circuit, solar and solid fuel can be added with optional software keys.
BMS control:
The operation of each boiler can be controlled via a 0-10V input signal (by the
addition of an optional interface module). This allows control of either the burner
firing rate or the boiler operating temperature set point.
Pre-mix burner
controller
Technical Data
Hoval TopGas 30 to 80 kW
®
30 35 45 60 80
Nominal output
at 40/30º C kW 6,8-30,1 6,8-35,0 11,1-45,0 12,8-60,7 17.3-80.0
Nominal output
at 80/60º C kW 6,0-27,4 6,0-35,0 10,0-41,0 11,7-55,3 15.8-72.4
Weight kg 83 83 83 89 107
Standard efficiency* % 109,8 109,7 109,3 109,5 109,4
Height/Width/Depth mm 950/630/465 950/630/465 950/630/465 950/630/465 940/700/585
* Standard efficiency at 40/30º C to DIN 4702 part 8
Advanced control system Hoval TopTronic®T:
For even more comfort and flexibility the standard boiler control can
be supplemented with the the optional user friendly digital Hoval
TopTronic®T controller and separate room station(s) with remote
control. With a central turn / push button and 7 keys the required
heating programs can be activated and the temperatures regulated. A
clear LCD display shows important operating information in figures and
text. With a 0-10 volt interface module providing the option of setpoint
or firing rate the control panel can be integrated with modern building
management systems.
Radiator
Record level of efficiency of more than 109%:
Low temperature boilers convert about 93% of the calorific value of gas
into usable heat. With the TopGas®, this limit is raised considerably by
using condensing technology. One of the main products of combustion
gases is water (as steam) and in the conventional boiler the heat within
this is lost through the flue. This is not the case with the TopGas®; in
condensing operation the hot steam is cooled back down to 40-50°C
thus releasing the latent heat of vapourisation for use in the heating
system. The result is as much as a 15% increase in the amount of
usable heat which dramatically increases the boiler efficiency.
Additional heat
Hoval TopGas® wall hung boilers are delivered fully equipped and can be
installed in a short period of time. All servicable components are easy to
access and can be replaced quickly and easily if required.
TopGas® 30-80
Technical data
TopGas® (30-60)
Type (30) (35) (45) (60)
• Nominal output 80/60 °C with natural gas kW 6,0-27,4 6,0-31,8 10,0-41,0 11,7-55,3
• Nominal output 40/30 °C with natural gas kW 6,8-30,1 6,8-35,0 11,1-45,0 12,8-60,7
• Nominal output 80/60 °C with propane gas 1 kW 6,6-27,4 6,6-31,9 10,8-41,0 13,1-54,9
• Nominal output 40/30 °C with propane gas 1 kW 7,3-30,2 7,3-35,2 11,9-45,0 14,1-60,3
• Nominal load with natural gas kW 6,4-28,3 6,4-33,0 10,6-42,5 12,2-57,3
• Nominal load with propane gas 1 kW 7,0-28,5 7,0-33,2 11,4-42,5 13,6-56,9
• Working pressure heating max./min. bar 3,0 / 1,2 3,0 / 1,2 3,0 / 1,2 3,0 / 1,2
• Working temperature max. °C 85 85 85 85
• Boiler water capacity l 4,5 4,5 4,5 6,0
• Min. water flow rate l/h 300 300 350 470
• Boiler weight (without water, incl. casing) kg 83 83 83 89
• Standard efficiency (DIN 4702, part 8) 40/30 °C % 109,3 / 98,5 109,1 / 98,3 109,0 / 98,2 109,0 / 98,2
75/60°C % 106,3 / 95,8 106,1 / 95,6 106,0 / 95,5 106,0 / 95,5
• Heat lossrate at 70°C Watt 95 95 95 120
• Standard emission rate Nitrogen oxides mg/kWh 30,0 30,0 30,0 35,0
Carbon monoxide mg/kWh 9,0 9,0 11,0 13,0
• Content of CO2 in the exhaust gas max./min. output % 9,0 / 8,8 9,0 / 8,8 9,0 / 8,8 9,0 / 8,8
• Dimensions See table of dimensions
• Connections Flow/return Inches Rp 1 ¼" Rp 1 ¼" Rp 1 ¼" Rp 1 ¼"
Gas Inches R ¾" R ¾" R ¾" R ¾"
Flue gas/
mm C80/125 C80/125 C80/125 C80/125
combustion air Ø
• Gas flow pressure min./max.
Natural gas mbar 18-50 18-50 18-50 18-50
Liquid gas 1 mbar 37-50 37-50 37-50 37-50
• Gas connection value at 0 °C / 1013 mbar:
Natural gas E - (Wo = 15,0 kWh/m3) Hu = 9,97 kWh/m3 m3/h 2,83 3,3 4,3 5,8
Propane gas 2 (Hu = 25,9 kWh/m3) m3/h 1,09 1,27 1,64 2,21
• Operating voltage V/Hz 230/50 230/50 230/50 230/50
• Control voltage V/Hz 24/50 24/50 24/50 24/50
• Min./max. electrical power consumption Watt 29/43 29/62 29/66 30/102
• Stand-by electrical consumption Watt 13 13 13 13
• IP rating (integral protection) IP 40 40 40 40
• Acoustic power level
- Heating noise (EN 15036 part 1) (room air dependent) dB(A) 61 61 63 63
- Exhaust noise is radiated from the mouth
dB(A) 63 63 66 66
(DIN 45635 part 47) (room air dependent/room air independent)
• Acoustic pressure level (depending on installation conditions) dB(A) 49 49 51 51
• Condensate quantity (natural gas) at 40/30 °C l/h 2,7 3,1 4,0 5,4
• pH value of the condensate ca. 4,2 ca. 4,2 ca. 4,2 ca. 4,2
• Values for flue calculation
Temperature class T120 T120 T120 T120
Flue gas mass flow kg/h 47,0 54,8 70,6 95,1
Flue gas temperature with operating conditions 80/60 °C °C 65 69 75 79
Flue gas temperature with operating conditions 40/30 °C °C 42 47 52 49
Volume flow rate combustion air Nm3/h 35,4 41,3 53,1 71,6
Excess pressure for combustion air/ flue gas system Pa 90 95 115 140
Maximum draught / depression at flue gas outlet Pa - 50 - 50 - 50 - 50
1
TopGas® can also be operated with propane/butane (liquid gas) mixtures.
Ventilation
For installations not exceeding 70 kW total nominal input (net)
refer to BS5440-2 : 2000.
Technical data
TopGas® (80)
Type (80)
Ventilation
Both high and low level ventilation is required, this should be calculated
to BS6644 : current edition.
TopGas® 30-80
Technical data
mbar
connection-set 150 Boiler incl.
mbar
250 connection-set
200 100
150 Boiler only
50 Boiler only
100
50 0
0 0,0 1.0 2,0 3,0 4,0 5,0 6,0
0,0 0,5 1,0 1,5 2,0 2,5 3,0 3,5 4,0 4,5 5,0 5,5 m3/h
m3/h
Maximum residual overpressure TopGas® (30-60) Maximum residual overpressure TopGas® (80)
with connection set AS32-TG/M13-2 with connection set AS32-TG/M14-2
500 700
450 Stage 3
600 Stage 3
400
350 500 Stage 2
Stage 2
300 400
mbar
mbar
250 Stage 1
300
200
150 Stage 1 200
100
100
50
0 0
0,5 1,0 1,5 2,0 2,5 3,0 3,5 0,0 0,5 1,0 1,5 2,0 2,5 3,0 3,5 4,0 4.5
m3/h m3/h
Maximum residual overpressure TopGas® (30-60) Maximum residual overpressure TopGas® (80)
with connection set AS32-TG/M14-2 with connection set AS32-TG/M15-2
mbar
500
mbar
200
100
0
0,5 1,0 1,5 2,0 2,5 3,0 3,5 4,0 4,5 5,0
m3/h
TopGas® 30-80
Dimensions
Clearances
• Right/Left 50 mm
• Space to ceiling dependent on the flue gas system (450mm with
Hoval horizontal wall terminal kit)
• Front 500 mm Front View
Dimensions
TopGas® (80)
(Measurements in mm)
Clearances
• Right/Left 50 mm
• Space to ceiling dependent on the flue gas system (300mm with Hoval
horizontal wall terminal kit)
• Front 500 mm
Front View
Automatic air
vent fitted inside
casing
Top View
Accessories
Accessories
Functions of Key-Modules:
Key- 2 mixing solid fuel Solar
Module circuits buffer vessel
1
2
3
4
5
6
7
Key-Module 1
1 For 2 mixing circuits.
M
Function key 1, 1 flow sensor, 2 loose plugs. 6012 154
Key-Module 2
2 For solid fuel / buffer vessel installation.
Function key 2, 3 immersion sensors, 4 loose
plugs. 6012 155
M
Key-Module 3
3 For solar plants.
Function key 3, 1 collector panel sensor, 1 6012 156
calorifier sensor, 4 loose plugs.
Key-Module 4
For 2 mixing circuits and solid fuel / buffer
4
vessel installation.
Function key 4, 1 flow sensor, 3 immersion 6012 157
M
M
sensors, 6 loose plugs.
Key-Module 5
For 2 mixing circuits and solar plants.
5 Function key 5, 1 flow sensor, 1 collector panel
M
sensor, 1 calorifier sensor, 6 loose plugs. 6012 158
Key-Module 6
For solid fuel / buffer vessel installation and
6 solar plants.
Function key 6, 1 collector panel sensor, 4
immersion sensors, 6 loose plugs. 6012 159
M
Key-Module 7
For 2 mixing circuits, solid fuel / buffer vessel
7 installation and solar plants.
M
Function key 7, 1 flow sensor, 1 collector panel
sensor, 4 immersion sensors, 8 loose plugs. 6012 160
M
Sensor type
Immersion / calorifier sensor: TypeKVT20/5/6
(L = 5m) without immersion sleeve.
flow sensor : Type VF204S with plug
Consult Hoval for specific applications collector sensor : Type PT1000 (Silicon)
TopGas® 30-80
Accessories
BMS module
BMS Module 0-10V GLT
Module for control of boiler by a building
management system using 0-10 V signals.
- For the control of firing rate or setpoint and
interrogation of firing rate or setpoint (single
boiler).
- For the control of setpoint only and
interrogation of firing rate and setpoint on
first boiler (a single BMS Module 0-10V GLT
is required with up to five boilers sequenced
by TopTronic).
- For the control of setpoint only and
interrogation of firing rates and setpoints on
individual boilers (BMS Module 0-10V GLT is
required per boiler with up to five boilers
sequenced by TopTronic).
Consisting of: BMS-Module and transformer.
Only for use with optional TopTronic. 6015 195
Accessories
Ø80
Ø124
Ø100
Connection C100/150 to 2xE100PP
For separate routing of flue gases and
combustion air.
Ø100
240
Recommendation:
115
102
152
1290
1180
Ø100
Ø150
152
102
Vertical adaptor
110
Ø152
Ø102
Vertical adaptor
Complete with condensing drain
215
100
45°
95
90
135
125
Ø152
Ø102
Accessories
200
- 45
°
Ø160
40
165
390
1220 max
140
93 degree Wall
bend terminal
Wall terminal kit (for horizontal discharge)
Comprises of vertical adaptor, 93 degree
elbow, 2 wall plates, horizontal wall
195
Wall Wall
plate Max dimension can be extended by use of
155
Vertical plate
adaptor extension pieces.
80/125 to 100/150 1)
80/125 to 100/150 adapter part not required
015 072 100
adaptor
for TopGas® 80)
2018533 1)
All items finished white RAL 9016.
Flue design TopGas® 30-80
• An adapter with sample points must be used (fitted to the boiler flue outlet connection).
• The flue gas is very cool and saturated with moisture so there will be very little or no buoyancy to pull the gases up the chimney.
• The burner fan assists with the evacuation of the flue gases so there may be slight pressurisation of the flue.
• It is permissible for the condensate from the flue system to drain back through the boiler.
• Horizontal flue sections must be inclined back to the boiler (3° minimum) to prevent condensate remaining in the flue.
• Flues must be designed to meet all current regulations / standards.
• See Technical data section for flue gas mass flow rates, temperatures, usable fan overpressure and ventilation requirements.
• The tables below are for guidance only.
29
28 15
27 TopGas 60
26 10
25
24
TopGas 60 5
23
22
21 0
20 0 1 2 3 4 5 6
19 Horizontal flue gas pipe length (m)
0 1 2 3 4
Horizontal flue gas pipe length (m)
TopGas 35
12 reducing the length by 2.5 metres and 45 degree bends
10 will reduce the length by 1.5 metres. The flue lengths
stated will have no effect on the boiler output.
8 TopGas 60
6 TopGas 30
4
2
0
0 1 2 3 4 5 6
Horizontal flue gas pipe length (m)
TopGas® 30-80
Accessories
DN kvs1
DN kvs1
40 44 6003 904
50 66 6003 905
65 100 6003 906
80 150 6003 907
1
Flow quantity in m3/h on a pressure loss of 1 bar.
consisting of:
Return:
Isolating valve R 1 ¼" with gland nut 2".
Side outlet branch with drain cock and G ¾"
connection for expansion vessel.
Flow:
Extension G 2" x L=180mm with integrated
non-return valve. Isolating valve R 1 ¼" with
gland nut 2". Side outlet branch with safety
valve (3 bar) and drain cock.
Connection sets complete with pump
Connection set type Biral Pump type
DHWS
RS-T
ATS TPV
T T T T
DKP SLP
D i e s i s t e i n
unerlaubter Weg!
G e hTopGas
en Si e e ine n
ATS
Schritt zurück oder
(30-80)
Dies ist ein
unerlaubter
TD
löschen Sie dieses
Shape! Weg! T
Gehen Sie
P
Sie haben die
Möglichkeit ein einen Schritt
neues Shape zu zurück oder
lösch en S ie
CWS n e h m e n ! ! !
hovhovalhovalhoval dieses Shape!
Hoval hovalhovalhovalhov Sie haben die
Möglichkeit ein
PressVal SF neues Shape zu
Hoval nehmen!!!
Gas hovhovalhoval
hovalhovalhova
lhovalhovalhov
alhovalhovalho
valhovalhovalh
ovalhovalhoval
hovalhovalhova
lhovalhovalhov
ATS alhovalhovalho
ATS valhovalhovalh
ovalhovalhoval
ATS h
ATS
CWS
ATS
DHWS
RS-T
ATS TPV
T T T T T T T T
DKP MK 1 MK2 SLP
D i e s i s t e i n
unerlaubter Weg! ATS
G e hTopGas
e n Si e ei ne n
Schritt zurück oder Dies ist ein TD
(30-80) unerlaubter
löschen Sie dieses
Shape!
M
YK1 M
YK2
Weg! T
Gehen Sie
P
Sie haben die
M ögl i chk ei t ei n e i n e n Sc h ri t t
neues Shape zu zurück oder
n e h m e n ! ! ! löschen Sie
CWS hovhovalhovalhoval dieses Shape!
Hoval hovalhovalhovalhov Sie hab en die
Möglichkeit ein
PressVal SF neues Shape zu
Hoval nehmen!!!
Gas hovhovalhoval
hovalhovalhova
lhovalhovalhov
alhovalhovalho
valhovalhovalh
ovalhovalhoval
hovalhovalhova
lhovalhovalhov
ATS alhovalhovalho
ATS valhovalhovalh
ATS ovalhovalhoval
h
ATS
CWS
ATS
DHWS
ATS
T T T T T T T T TPV
AAV MK 1 MK2 MK 2
3 MK4
D i eTopGas
s i s t e i n D i eTopGas
s i s t e i n
unerlaubter Weg!
G e h e n S1i e e i n e n
unerlaubter Weg!
G e h e n S2i e e i n e n
ATS
Schritt(30-80)
zurück oder Schritt(30-80)
zurück oder Dies ist ein TD
unerlaubter
löschen Sie dieses
Shape!
löschen Sie dieses
Shape! SVLF
M
YK1 M
YK2 M
YK2
YK3 M
YK4
Weg! T
Gehen Sie
P
Sie haben die
Möglichkeit ein P
Sie haben die
Möglichkeit ein einen Schritt
neu es Sh ape zu neues Shape zu zurück oder
n e h m e n ! ! ! n e h m e n ! ! ! löschen S ie
hovhovalhovalhoval hovhovalhovalhoval dieses Shape!
hovalhovalhovalhov hovalhovalhovalhov Sie haben die
Möglichkeit ein
SF neues Shape zu
nehmen!!!
Gas Gas hovhovalhoval
M5.1 M5.2
hovalhovalhova
lhovalhovalhov
alhovalhovalho
ATS SLP valhovalhovalh
SV SV ovalhovalhoval
hovalhovalhova
lhovalhovalhov
CWS alhovalhovalho
Hoval valhovalhovalh
PressVal ovalhovalhoval
ATS h
Hoval
AAV
SV
P CWS
ATS
ATS ST
Alternative
BRU1
SVLF
e-mail: service@hoval.co.uk
direct dial: 01636 593413 or 593435
Other associated products
Solkit ®
The ecological solution. Using the sun as the source
of energy for hot water: The Hoval SolKit in
combination with Hoval heat pumps offers a solution
that can meet any challenge the future may bring.
Hoval Service
For specialist commissioning, maintenance and
troubleshooting of your Hoval equipment, contact our
in-house Service and Spares Department. Make use of it
to ensure economic operation, reliability and best cost of
ownership. October 2008
By Appointment to
Her Majesty the Queen
Boiler Manufacturers & Engineers
Hoval Ltd Newark
Hoval follows a policy of continued improvement and reserves the right to change specifications without notice.