Hoval CompactGas 700 User manual

Subject to modi cations | EN

Technical information

Assembly instructions

4 205 753 / 06 - 06/14

Hoval products must be installed and commissioned

only by appropriately qualied experts. These instruc-

tions are intended exclusively for the specialist. Electri-

cal installations may only be carried out by a qualied

electrician.

The gas boiler series Compact is suitable and appro-

ved for use as heat generator for water heating plants

with permitted ow temperatures up to 110 °C1). They

are designed for closed-circuit plants according to

EN 12828.

1) see section Technical data

Hoval CompactGas (700-2800)

for natural gas and liquid gas

These instructions apply to the following ty-

pes:

Nominal output at 80/60 °C and natural gas

1-CompactGas (700) 700 kW

1-CompactGas (1000) 1000 kW

1-CompactGas (1400) 1400 kW

1-CompactGas (1800) 1800 kW

1-CompactGas (2200) 2200 kW

1-CompactGas (2800) 2800 kW

24 205 753 / 06

TABLE OF CONTENTS

1. Safety notices

1.1 Key to symbols....................................................................................................................................................................4

2. Important notices

2.1 Measures on receipt of the appliance.................................................................................................................................5

2.2 Warranty...............................................................................................................................................................................5

2.3 Instructions..........................................................................................................................................................................5

2.4 Regulations, official approvals ...........................................................................................................................................5

2.4.1 Germany...........................................................................................................................................................................5

2.4.2 Austria ..............................................................................................................................................................................6

2.4.3 Switzerland.......................................................................................................................................................................6

3. Assembly

3.1 Installation, levelling ...........................................................................................................................................................7

3.2 Mounting the condensate drain ..........................................................................................................................................9

3.3 Mounting the thermal insulation.........................................................................................................................................9

3.4 Mounting the cladding and the boiler control.................................................................................................................. 11

3.5 Mounting the side shutters ...............................................................................................................................................13

3.5.1 Mounting the flexible side shutter (detail A,B,C) ..............................................................................................................13

3.5.2 Mounting the fixed side shutter (detail D) ........................................................................................................................13

4. Technical details

4.1 Description of the boiler ...................................................................................................................................................14

4.2 Technical data....................................................................................................................................................................15

4.3 Dimensions / Space required............................................................................................................................................16

4.3.1 Dimensions.....................................................................................................................................................................16

4.3.2 Base size........................................................................................................................................................................17

4.4 Flue gas and output diagrams ..........................................................................................................................................18

4.4.1 Flue gas - output diagram ...............................................................................................................................................18

4.4.2 Flue gas resistance.........................................................................................................................................................18

5. Installation

5.1 Safety notices....................................................................................................................................................................19

5.2 Requirements for boiler room...........................................................................................................................................19

5.3 Flue gas connection, flue gas pipe, dimensions of flue gas pipe ...................................................................................19

5.4 Installing the burner ..........................................................................................................................................................21

5.5 Hydraulic connection ........................................................................................................................................................21

5.5.1 Pressure maintenance ....................................................................................................................................................21

5.5.2 Hydraulic connection.......................................................................................................................................................21

5.5.3 Hydraulic schematic........................................................................................................................................................22

5.6 Gas connection..................................................................................................................................................................22

5.7 Electrical connection.........................................................................................................................................................23

34 205 753 / 06

TABLE OF CONTENTS

6. Commissioning

6.1 Safety notices....................................................................................................................................................................24

6.2 Charging with water ..........................................................................................................................................................24

6.3 Water quality......................................................................................................................................................................25

6.3.1 Heating Water.................................................................................................................................................................25

6.3.2 Filling and replacement water .........................................................................................................................................25

6.4 Venting the gas pipes........................................................................................................................................................26

6.5 Handing over the plant to the operator ............................................................................................................................26

6.6 Record - Activation of screed function.............................................................................................................................27

7. Maintenance

7.1 Information for combustion controller/chimney sweep regarding emission monitor key .............................................29

7.2 Safety notices....................................................................................................................................................................30

7.3 Venting ...............................................................................................................................................................................30

7.4 Replenishing water............................................................................................................................................................30

7.5 Cleaning.............................................................................................................................................................................31

8. Overview of settings

8.1 Table of parameters...........................................................................................................................................................32

8.2 Fault Reporting overview TopTronic®T.............................................................................................................................42

44 205 753 / 06

IMPORTANT INFORMATION

1. Safety notices

The plant must only be commissioned

when all relevant standards and safety re-

gulations have been fullled.

For test operation at least the following conditions must

be met:

- safety valve installed (closed-circuit plant)

- control unit in operation (connected to mains electricity)

- sensor for safety temperature limiter connected (= boi-

ler temperature sensor)

- plant lled with water

- expansion tank connected

- ue gas outlet with ue gas pipe connected to chimney

- burner preset

1.1 Key to symbols

Tools:

Shows which tools you will need for the

following steps.

Instructions for action:

Here you will need to undertake specic

action.

Result:

Shows the result to be expected from the

action.

Reference to standards and guidelines.

Notice:

Supplies important information.

Safety notices:

Warns of potential danger of injury.

Caution notices:

Warns of potential damage to machines

and plants.

Supplies important information.

54 205 753 / 06

IMPORTANT INFORMATION

2. Important notices

2.1 Measures on receipt of the appliance

As soon as the boiler is delivered, per-

form a visual check.

If damage should be detected, undertake

the necessary steps as detailed in the de-

livery contract.

The costs for repairs will be borne by the

respective risk taker.

2.2 Warranty

The following defects are not covered by

warranty:

- non-observance of these instructions

- non-observance of the handbook

- faulty installation

- non-approved alterations

- improper treatment

- undue force being applied

- contaminated operating media (gas, wa-

ter, combustion air)

- corrosion through halogen compounds

(e.g. paints, adhesives, solvents)

unsuitable chemical additives in the

heating water

- corrosion through non-compliance with

the water quality requirements

2.3 Instructions

All the instructions which you will need

for the operation of your plant can be

found together in the Hoval plant hand-

book. Please keep all instructions in a

safe and accessible place!

In some exceptional cases the instruc-

tions are to be found with the specic

components!

Further sources of information:

- Hoval catalogue

- standards and regulations

2.4 Regulations, official approvals

For the installation and operation of the

plant the standards and regulations listed

in sections 2.4 (see page 6) must be ob-

served.

2.4.1 Germany

• DIN EN 12831 Heating systems in buil-

dings – procedure for calculating the

standard heating load.

•

DIN EN 13384 Exhaust gas systems –

thermal and uid dynamic calculation

methods.

• DIN EN 12828 Heating systems in buil-

dings - planning of hot water systems.

• DIN 4756 Gas-red systems: design,

construction and technical safety requi-

rements, planning and execution (for

operation with gas burners).

• DIN 18160 House chimneys, require-

ments, planning and execution.

• TRD 702 Steam boiler plants with calori-

ers of the group II.

• TRD 721 Safety equipment to safegu-

ard against excess pressures / safety

valves / for group II steam boilers.

• VDI 2035 Prevention of damage by cor-

rosion and the formation of scale in hot

water systems.

• DIN 57 116 / VDI 0116 Electrical equip-

ment for ring systems.

• (VDE regulation).

• For further standards applying to Ger-

many see attachment N-430 020.

2.4.2 Austria

•

OENORM 12831 Heating installations

in buildings – procedure for calculating

the standard heating load

•

OENORM 13384 Exhaust gas systems

– procedure for heat and technical gas-

ow calculations.

•

OENORM 12828 Heating systems in

buildings: planning of hot water heating

systems.

•

ÖNorm B 8130 Open hot water, systems,

safety installations.

•

ÖNorm B 8131 Closed-circuit hot water

systems, safety, construction and tes-

ting regulations.

•

ÖNorm B 8133 Water heating systems,

technical safety requirements.

• ÖNorm B 8136 Heating systems, space

requirements and other building requi-

rements.

•

ÖNorm M 7515 Calculation of chimney

dimensions; denition of expressions,

calculation procedures.

• ÖNorm H 5171 Heating systems – tech-

nical building requirements.

• ÖVGW TR gas

64 205 753 / 06

IMPORTANT INFORMATION

2.4.3 Switzerland

SN EN 12831 Heating installations in

buildings – procedure for calculating

the standard heating load.

SN EN 13384 Exhaust gas systems –

procedure for heat and technical gas-

ow calculations.

- SN EN 12828 Heating systems in buil-

dings: planning of hot water heating

systems.

- VKF-Association of Cantonal Fire Insu-

rers.

- Regulations of the re police.

- SVGW Schweiz. Swiss Gas and Water

Federation.

SNV 27 10 20 Aeration and ventilation of

the boiler room.

- SWKI 88-4 Water treatment for heating,

steam and airconditioning plant.

- SWKI 80-2 Technical safety regulations

for heating installations.

- KRW Corrosion caused by halides.

KRW/VSO/FKR Electrical connections

on heating boilers and burners ready to

plug in.

- FCOS - Guidelines for liquid gaz, part 2

and further regulations and standards issued by CEN,

CEN ELEC, DIN, VDE, DVGW, TRD and government

authorities. The regulations issued by local buildings au-

thorities, insurers and chimney sweeps must also be ob-

served. Where gas is used as a fuel the regulations of the

local gas supplier must be observed. An ofcial licence

may be needed.

74 205 753 / 06

ASSEMBLY

3. Assembly

3.1 Installation, levelling

No special foundation plate is required for installing the

boiler (sufcient supporting capacity for the boiler must

be guaranteed); see section Technical data for operatio-

nal weight.

In the case of boiler installation in the domestic domain,

vibration absorbers are to be mounted under the boiler

plinth rails.

Space required

for mounting the thermal insulation and sheet metal clad-

ding:

is to be at least 40 cm laterally, to the left and right

side of the boiler.

If the distance from walls is less, the boiler must rst be

completely thermally insulated and cased before being

placed into the installation position designated.

Levelling

The upper edge of the boiler water jacket (boiler longitu-

dinal axis) must be levelled by means of a spirit level until

it is aligned exactly horizontally.

Mount the door liner (door cladding) before instal-

ling the burner (for heating trials, with the boiler not

yet thermally insulated).

Delivery from factory-boiler door opens to the right

However the boiler door hinges can be changed over to

enable the door to be opened to the left. This can be use-

ful when space is limited.

Boiler door hinges may only be changed

over by Hoval Service!

The boiler door must be closed when changing over the

hinges - procedure:

1. For types 1800,2200,2800 only:

Dismantle support for door positioning (5, Fig. 02)

2. Tighten the top and bottom lock nuts (1, Fig. 01) to-

wards the swing-out ange (manually).

3. Mount ange nuts (2, Fig. 01) with the hole

diagonally on the new opening side, i.e.,

- change over the bottom left and top right ange nut and

- change over the top left and bottom right ange nut.

4. Open boiler door after removing ange nuts (2 , Fig.

02) and turn back locknuts (3, Fig. 02) approx. 1-2cm.

As a result, the boiler door is pressed against the

sealing gasket without hindrance.

5. Mount the burner plug connector on the other side.

The cable must not contact any hot parts.

6. Mount door rabbet (5, Fig. 01) on the other side and

adjust it (angle of door opening 90°).

Figure shows situation as delivered

(boiler door opens to the right)

Fig. 04 Fig. 05

Position mechani-

cal jack

Figure shows situation after transformation

(boiler door opens to the left)

84 205 753 / 06

ASSEMBLY

7. For types 1800,2200,2800:

Remount support for door positioning (5, Fig. 01) on

the other side, readjust if necessary resp. level boiler

door rst!

After changing over the hinges it might be necessary to

align (level) the boiler door! (Hanging boiler door)

Procedure:

8. Open boiler door approx. 10cm.

9. Raise boiler door (20-30mm) by means of a mechani-

cal jack (or jack) by slightly loosening ange nuts (2,

Fig. 01).

Do not loosen ange nuts entirely nor remo-

ve them as the boiler door might fall down.

10. After leveling the boiler door, retighten ange nuts (8,

Fig. 02) securely.

3.2 Mounting the condensate drain

The consensate drain is to be mounted according to (Fig.

04).

Fig. 01

Fig. 02

3.3 Mounting the thermal insulation

1. Wrap the insulating mats (1,1a, Fig. 06) around the

boiler body. The insulating mat (1a, Fig. 06) has to be

applied in such a way that the large recess (1b, Fig.

06) is located at the back.

2. Fix the insulating mats (1/1a, Fig. 06) with plastic

straps and strap fasteners (2a, Fig. 06):

- Tension springs (2, Fig. 06) serve for additional -

xing (2b, Fig. 06)

- Do not overtighten the straps (reduced insulation

effect)

3. Place insulating mats (3, Fig. 06) on the boiler rear

panel and attach them to the insulating mat of the

boiler body using tension springs.

4. Wrap the insulating mat (4, Fig. 06) around the ue

gas collector ring and x it below with retaining discs

(Figure 4).

5. Wrap the insulating mat (5, Fig. 06) around the ue

gas collector and x it using retaining discs (Fig. 05).

6. Place insulating mats (6,7,8, Fig. 06) on the boiler

front and x them with retaining discs ( ).

Fig. 03

Notice

The mounting of the insulating mats (6,7,

Fig. 06) may be facilitated by cutting them

through at the narrowest section.

7. Attach the Compact Gas (1800-2800) insulating mats

(8a, Fig. 06) to the boiler door without the use of re-

taining discs.

The remaining insulating mats (20a,24, Fig. 10) are xed

with the mounting of the cladding (see Fig. 06).

94 205 753 / 06

ASSEMBLY

Fig. 06

Insulating mat may be partitioned

10 4 205 753 / 06

ASSEMBLY

3.4 Mounting the cladding and the boiler con-

trol

1. Fix bolts (20, Fig. 10) (Compact Gas (1800-2800):

incl. distance spacers) at the boiler door using he-

xagonal nuts and U-washers, then insert insulating

mat (20a, Fig. 10) into boiler door cladding (20b, Fig.

10) and mount onto boiler door (Compact Gas (1800-

2800): 2 parts boiler door claddings - mount inferior

rst).

2. Integrate burner plug (21, Fig. 10) into the left (resp.

right) side panel and lead burner cable upwards

(cable routing according to Image Fig. 10). Insert

right and left side panels (22, Fig. 10) into retaining

bracket (32, Fig. 10), attach 1 C-Clip each (29, Fig.

07) to the front of the side panels.

3. Insert rear panels (23, Fig. 10) into folded edges (22,

Fig. 10) (Compact Gas (2800): 6 pieces) of side wall.

4. Insert 2 insulating mats (24, Fig. 10) left and right in

longitudinal direction (to prevent vertical air circulati-

on).

5. Mount 2 special screws (14,Fig. 07, Fig. 10) with lock-

nut on the side panel. These are used for mounting

the control box.

6. Remove control box cover plate (11, Fig. 07). The

control panel (12a, Fig. 08) must be turned. For this

purpose the pressure lock sleeves (12b, Fig. 08, com-

press and pull away) as well as the earth screw and

serrated lock washer (12d, Fig. 08) must be removed.

Attach the control box (12, Fig. 08, Fig. 10) with the

cut-out for special screws to the cladding side panel

(22, Fig. 10) and secure with 2 self-tapping screws

Ø 3,5 x 6,5 and serrated lock washers (12c, Fig. 08).

7. Pull capillaries with immersion sensors (17, Fig. 09)

through the opening (15, Fig. 07), put it into immersi-

on sleeve (18, Fig. 09) up to the stop and secure with

retaining spring (16, Fig. 09)

Attention: the capillaries must not be

kinked!

8. Lead burner plug (21, Fig. 10) to the control and plug

in.

9. Mount cover plate (11, Fig. 07) with 3 self-tapping

screws Ø 3,5 x 6,5 and serrated lock washers (13,

Fig. 07).

10. Place walkable cover in proper sequence 26, 27, 28

on the bracket (32, Fig. 10), x front cover (30, Fig.

10) using 2 self-tapping screws (31, Fig. 10) Ø 4,8

x 50 and level with height-adjustable elbow (34, Fig.

10).

11. Afx rating plate and retainer for handbook (33, Fig.

10) to the side.

12. Mounting the side shutter see Fig. 11.

1113

Fig. 07

12c

180°

12d

12c

12b

12a

Fig. 08

Fig. 09

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