Hoval CompactGas 700 Manual

Subject to modi cations | EN
Technical information
Assembly instructions
4 214 864 / 01 - 05/17
Hoval products must be installed and commissioned
only by appropriately qualied experts. These instruc-
tions are intended exclusively for the specialist. Elec-
trical installations may only be carried out by a qualied
electrician.
These instructions apply to the following types:
Nominal output at 80/60 °C and natural gas
42-CompactGas (700) 700 kW
42-CompactGas (1000) 1000 kW
42-CompactGas (1400) 1400 kW
42-CompactGas (1800) 1800 kW
42-CompactGas (2200) 2200 kW
42-CompactGas (2800) 2800 kW
42-CompactGas (3500) 3500 kW
42-CompactGas (4200) 4200 kW
Hoval CompactGas (700-4200)
for natural gas and liquid gas
The gas boiler series Compact is suitable and ap-
proved 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

1. Safety notices
1.1 General safety instructions.................................................................................................................................................4
1.2 Explanation of the symbols ................................................................................................................................................4
1.2.1 Warnings ..........................................................................................................................................................................4
1.2.2 Symbols............................................................................................................................................................................4
1.3 On delivery...........................................................................................................................................................................5
1.4 Guarantee ............................................................................................................................................................................5
1.5 Instructions..........................................................................................................................................................................5
1.6 Regulations, official approvals ...........................................................................................................................................5
1.6.1 Germany §........................................................................................................................................................................5
1.6.2 Austria § ...........................................................................................................................................................................5
1.6.3 Switzerland § ....................................................................................................................................................................6
2. Assembly
2.1 Installation, levelling ...........................................................................................................................................................7
2.2 Mounting the condensate drain ..........................................................................................................................................8
2.3 Mounting the thermal insulation.........................................................................................................................................8
2.4 Mounting the cladding and the boiler control..................................................................................................................10
2.4.1 Boiler controller TopTronic®E..........................................................................................................................................10
2.4.2 Boiler controller T0.2 / T2.2.............................................................................................................................................10
2.5 Mounting the side shutters ...............................................................................................................................................12
2.5.1 Mounting the flexible side shutter (detail A,B,C) ..............................................................................................................12
2.5.2 Mounting the fixed side shutter (detail D) ........................................................................................................................12
3. Technical details
3.1 Description of the boiler ...................................................................................................................................................13
3.2 Technical data....................................................................................................................................................................14
3.3 Dimensions / Space required............................................................................................................................................16
3.3.1 Dimensions.....................................................................................................................................................................16
3.3.2 Base size........................................................................................................................................................................17
3.4 Flue gas and output diagrams ..........................................................................................................................................18
3.4.1 Flue gas - output diagram ...............................................................................................................................................18
3.4.2 Flue gas resistance.........................................................................................................................................................18
4. Installation
4.1 Safety notices....................................................................................................................................................................19
4.2 Requirements for boiler room...........................................................................................................................................19
4.3 Flue gas connection, flue gas pipe, dimensions of flue gas pipe ...................................................................................19
4.4 Installing the burner ..........................................................................................................................................................21
4.5 Hydraulic connection ........................................................................................................................................................21
4.5.1 Pressure maintenance ....................................................................................................................................................21
4.5.2 Hydraulic connection.......................................................................................................................................................21
4.5.3 Hydraulic schematic........................................................................................................................................................22
4.6 Gas connection..................................................................................................................................................................22
4.7 Electrical connection.........................................................................................................................................................23
4.7.1 Safety measures relating to EMC-compliant assembly ....................................................................................................24
4.7.2 Recommended cable cross sections ...............................................................................................................................25
24 214 864 / 01
TABLE OF CONTENTS

5. Commissioning
5.1 Safety notices....................................................................................................................................................................25
5.2 Charging with water ..........................................................................................................................................................25
5.3 Water quality......................................................................................................................................................................26
5.3.1 Heating Water.................................................................................................................................................................26
5.3.2 Filling and replacement water .........................................................................................................................................26
5.4 Venting the gas pipes........................................................................................................................................................27
5.5 Handing over the plant to the operator ............................................................................................................................27
5.6 Record - Activation of screed function.............................................................................................................................28
6. Maintenance
6.1 Information for combustion controller/chimney sweep regarding emission monitor key .............................................30
6.2 Safety notices....................................................................................................................................................................31
6.3 Venting ...............................................................................................................................................................................31
6.4 Replenishing water............................................................................................................................................................31
6.5 Cleaning.............................................................................................................................................................................32
3
4 214 864 / 01
TABLE OF CONTENTS

1. Safety notices
1.1 General safety instructions
The system may only be placed in operation
if all the relevant standards and safety regula
-
tions have been complied with.
At least the following conditions must be satised for a
trial operation:
- Safety valve installed (system sealed)
- Control in operation (connected to the mains current
supply system)
- Sensor for safety temperature limiter connected
(= boiler temperature sensor)
- System lled with water
- Expansion vessel connected
- Flue gas connectors connected to the ue gas pipeline
at the chimney or ue.
- Burner preset.
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 off 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 Symbols
!
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 cutting injuries:
Avoid cutting injuries. Clearly indicate the dan
-
ger of cutting on sharp-edged parts to avoid
serious and costly injuries.
Incorrect handling of potentially explosive
substances can lead to serious damage, po
-
tentially fatal injuries and incalculable costs.
Description of an activity instruction.
Information:
Provides important information.
§
Provides important information.
Refers to standards and directives.
44 214 864 / 01
IMPORTANT INFORMATION

1.3 On delivery
Carrreceiving the boiler.y out a visual inspection imme-
diately on. 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, com-
bustion air)
• Corrosion by halogen compounds (e.g. paints, adhe-
sives, solvents)
• 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 Regulations, official approvals
The standards and directives stated under points 1.6.1 to
1.6.3 must be taken into account during installation and
operation of the system.
1.6.1 Germany §
- DIN EN 12831 Heating systems in buildings – proce-
dure for calculating the standard heating load.
- DIN EN 13384 Exhaust gas systems – thermal and uid
dynamic calculation methods.
- DIN EN 12828 Heating systems in buildings - planning
of hot water systems.
- DIN 4756 Gas-red systems: design, construction and
technical safety requirements, planning and execution
(for operation with gas burners).
- DIN 18160 House chimneys, requirements, planning
and execution.
- TRD 702 Steam boiler plants with caloriers of the
group II.
- TRD 721 Safety equipment to safeguard against ex-
cess pressures / safety valves / for group II steam boil-
ers.
- VDI 2035 Prevention of damage by corrosion and the
formation of scale in hot water systems.
- DIN 57 116 / VDI 0116 Electrical equipment for ring
systems.
- (VDE regulation).
- For further standards applying to Germany see attach-
ment N-430 020.
1.6.2 Austria §
- ÖNORM 12831 Heating installations in buildings – pro-
cedure for calculating the standard heating load
- ÖNORM 13384 Exhaust gas systems – procedure for
heat and technical gasow calculations.
- ÖNORM 12828 Heating systems in buildings: planning
of hot water heating systems.
- ÖNORM B 8130 Open hot water, systems, safety in-
stallations.
- ÖNORM B 8131 Closed-circuit hot water systems,
safety, construction and testing regulations.
- ÖNORM B 8133 Water heating systems, technical
safety requirements.
- ÖNORM B 8136 Heating systems, space requirements
and other building requirements.
- ÖNORM M 7515 Calculation of chimney dimen-
sions; denition of expressions, calculation proce-
dures.
- ÖNORM H 5171 Heating systems – technical building
requirements.
- ÖVGW TR gas
5
4 214 864 / 01
IMPORTANT INFORMATION

1.6.3 Switzerland §
- SN EN 12831 Heating installations in buildings – proce-
dure 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 buildings: planning of
hot water heating systems.
- VKF-Association of Cantonal Fire Insurers.
- 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 air-
conditioning plant.
- SWKI 80-2 Technical safety regulations for heating in-
stallations.
- KRW Corrosion caused by halides.
- KRW/VSO/FKR Electrical connections on heating boil-
ers 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.
64 214 864 / 01
IMPORTANT INFORMATION

2. Assembly
2.1 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 opera-
tional 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 in
-
stalling 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.
NOTICE
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, 3500, 4200 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 diago-
nally 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 (4, Fig. 02) on the other side and
adjust it (angle of door opening 90°).
3
1
2
Fig. 01
Figure shows situation after transformation
(boiler door opens to the left)
23
Fig. 02
4
5
Position mechanical jack
8
Figure shows situation as delivered
(boiler door opens to the right)
74 214 864 / 01
ASSEMBLY

2.2 Mounting the condensate drain
The consensate drain is to be mounted according to
(Fig. 03, Fig. 04).
!
CAUTION
To achieve a siphon effect, the condensate
drain hose must be routed as shown in the
drawing - ll the hose with water before com-
missioning!
Fig. 03
Fig. 04
7. For types 1800, 2200, 2800, 3500, 4200:
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. 10 cm.
9. Raise boiler door (20-30 mm) by means of a mechan-
ical jack (or jack) by slightly loosening ange nuts
(8,Fig. 02).
NOTICE
Do not loosen ange nuts entirely nor remove
them as the boiler door might fall down.
10. After leveling the boiler door, retighten ange nuts
(8,Fig. 02) securely.
2.3 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 (2, Fig. 06) and strap fasteners (2a, Fig. 06):
- Tension springs (2b, Fig. 06) serve for additional xing
- 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
(Fig. 05).
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. 05).
Fig. 05
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).
CAUTION
Danger of injury through sharp edges.
Handle the cladding panels with care
and avoid contact with sharp edges.
84 214 864 / 01
ASSEMBLY

3
2a
1
1b
2
2a 2b
5
7
8
6
4
Fig. 06
1a
8a
Insulating mat may be partitioned
94 214 864 / 01
ASSEMBLY

2.4 Mounting the cladding
and the boiler control
1. Fix bolts (20, Fig. 10) (Compact Gas (1800-2800):
incl. distance spacers) at the boiler door using hex-
agonal 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 (ca-
ble 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. 10) to the
front of the side panels. Route the condensate drain
hose through the side wall. (35, Fig. 10).
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 circulation).
2.4.1 Boiler controller TopTronic®E
5. Mount the special screws with nuts (14, Fig. 07) on the
side panel. Then hook the boiler controller (12,Fig.
07) into the side wall with the recesses for the special
screws and secure it with 4 self-tapping screws ø 3.5
x 6.5 and serrated washers (12b).
12a
12b
12
13a
12c
12c
Fig. 07
6. Pull the capillaries with the immersion sensors
(15,Fig. 09) through the opening (13a, Fig. 07) in
the side panel, insert them into the immersion sleeve
(15a, Fig. 09) as far as the stop and x in position with
retaining spring (15c, Fig. 09).
7. Plug in the burner plug.
NOTICE
The capillaries must not be folded or kinked!
8. Close the boiler controller and screw on (12c, Fig. 07),
continue with tting the casing.
2.4.2 Boiler controller T0.2 / T2.2
12
12b
12d
14
13a
Fig. 08
9. Mount the special screws with nuts (14, Fig. 08) on
the side panel. Then hook the boiler control (12, Fig.
08) onto the special screws and secure using self-
tapping screws ø 3.5 x 6.5 and serrated lock washers
(12b,Fig. 08).
10. Pull the capillaries with the immersion sensors
(15,Fig. 09) through the opening (13a, Fig. 08) in
the side panel, insert them into the immersion sleeve
(15a, Fig. 09) as far as the stop and x in position with
retaining spring (15c, Fig. 09).
11. Plug in the burner plug.
NOTICE
The capillaries must not be folded or kinked!
12. Attach cover plate to the boiler controller (12d, Fig.
08) with self-tapping screws ø 3.5 x 6.5 and serrated
lock washers.
continue with tting the casing.
13. Bring burner connector plug to the control box and
plug in (21, Fig. 10).
14. 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).
15. Afx rating plate and retainer for handbook (33, Fig.
10) to the side.
16. Mounting the side shutter see Fig. 11.
10 4 214 864 / 01
ASSEMBLY

4214864_B02 15.10.2015 / SJUL
A
21
30
26
27
28
25
22
23
23
24
20a
20b 22
22
31
33
29 32
12
20
31
14
34
15c
15
15a
35
CompactGas (1800-2800) cutaway view
Fig. 09
Fig. 10
114 214 864 / 01
ASSEMBLY

2.5 Mounting the side shutters
The cladding shutter system serves for covering the gap
between the boiler door and the side wall. The shutter at
the boiler door hinge side must be exible.
2.5.1 Mounting the flexible side shutter
(detail A,B,C)
1. Mount hinges (40, Fig. 11) on top and bottom of front
side wall using self-tapping screws Ø 3,5 x 9,5.
2. Mount side shutter (41, Fig. 11) on right half of hinge
using 2 pieces of cross-head screws (42, Fig. 11) and
distance spacers (44, Fig. 11), use 1 piece each for
top and bottom (detail A,B). Secure against extraction
using two hexagonal locknuts (41a, Fig. 11). - ! Do no
clamp the hinge!
3. Mount magnets (46, Fig. 11) on top and bottom hole
of side ends (41, Fig. 11) using hexagonal nut M10
(47,Fig. 11), U-washer (48, Fig. 11) and hexagonal
screw M4 x 10 (49, Fig. 11) (detail C).
2.5.2 Mounting the fixed side shutter (detail D)
4. Open boiler door, mount hinges (40, Fig. 11) on
top and bottom of front side wall using self-tapping
screws Ø 3,5 x 9,5.
5. Mount side shutter (41, Fig. 11) according to gure on
top and bottom using 4 pieces of cross-head screws
(42,43, Fig. 11) and distance spacers (44, Fig. 11).
Fig. 11
45
49
48
47
46
C
42
43
40
41
D
44
44
45° incline
boiler side
42
44
A
40
B
40
41
42
44
41a
12 4 214 864 / 01
ASSEMBLY

3. Technical details
3.1 Description of the boiler
The Hoval CompactGas is a low-pollution, energy saving
gas boiler. The Hoval CompactGas has a horizontal com-
bustion chamber as primary heating area and a second-
ary heating area consisting of aluFer®composite tubing.
The CompactGas is designed for operation using natural
gas and liquid gas. The construction principles are dis-
played in the following diagram.
Fig. 12
13
4 214 864 / 01
TECHNICAL INFORMATION

3.2 Technical data
Type (700) (1000) (1400) (1800) (2200) (2800)
• Nominal output at 80/60 °C kW 700 1000 1400 1800 2200 2800
• Range of output at 80/60 °C kW 250-700 300-1000 420-1400 540-1800 660-2200 840-2800
• Burner input maximum kW 725 1037 1458 1865 2280 2901
• Maximum working temperature 1°C 105 105 105 105 105 105
• Minimum working temperature °C 75 75 75 75 75 75
• Minimum boiler return temperature °C 35 35 35 35 35 35
• Safety temperature limiter setting (water side) 2°C 120 120 120 120 120 120
• Working/test pressure bar 6/9 6/9 6/9 6/9 6/9 10/16
•Boiler efciency at full load at 80/60 °C
(net caloric value/gross caloric value) % 96.5/87.0 96.4/86.9 96.0/86.5 96.5/87.0 96.5/87.0 96.5/87.0
•Efciency at partial load 30 % (EN 303)
(net caloric value/gross caloric value) % 97.4/87.7 97.4/87.7 97.3/87.7 97.4/87.7 97.5/87.8 97.5/87.8
•Standard efciency 75/60 °C (according to DIN 4702 part 8)
(net caloric value/gross caloric value) % 97.4/87.7 97.4/87.8 97.1/87.5 97.5/87.9 97.5/87.9 97.5/87.9
• Stand-by loss at 70 °C Watt 850 1000 1200 1350 1550 1800
• Flue gas temperature at nominal output at 80/60 °C °C 94 101 102 99 93 92
• Maximum chimney draught Pa 20 20 20 20 20 20
• Flue gas resistance at nominal output
10.5 % CO2natural gas
500 m over sea level (Tolerance ± 20 %) mbar 4.9 4.8 4.7 5.7 6.5 7.2
•Flue gas mass ow at nominal output
10.5 % CO2natural gas kg/h 1133 1623 2271 2923 3571 4546
• Flow resistance boiler 3z-value 0.012 0.012 0.003 0.003 0.003 0.002
•Water ow resistance at 20 K mbar 10.8 22.0 10.8 17.9 26.7 28.8
•Water ow volume at 20 K m³/h 30.0 42.9 60.0 77.1 94.3 120.0
• Boiler water content litres 670 1130 1580 2020 2534 2844
• Insulation thickness boiler body mm 80 80 80 80 80 80
• Weight (incl. casing) 6 bar kg 1390 2100 2794 3500 4455 5567
• Weight (without casing) 6 bar kg 1250 1960 2654 3200 4105 5167
• Heating surface m² 36.52 44.23 68.49 89.51 117.26 142.34
• Combustion chamber dimension
Ø inside x length mm 584/1835 684/1985 830/2180 830/2301 830/3076 922/3272
• Combustion chamber volume m³ 0.492 0.729 1.179 1.244 1.663 2.222
• Dimensions see Dimensions
1Limited by the boiler control T2.2 to 90 °C resp. U3.2 and T0.2 to 105 °C.
2Maximum safety temperature for boiler control T2.2: 110 °C resp. U3.2 and T0.2: 120 °C.
3 Flow resistance boiler in mbar = volume ow (m3/h)2 x z
14 4 214 864 / 01
TECHNICAL INFORMATION

Type (3500) (4200)
• Nominal output at 80/60 °C kW 3500 4200
• Range of output at 80/60 °C kW 1050-3500 1260-4200
• Burner input maximum kW 3626 4 4351 4
• Maximum working temperature 1°C 105 105
• Minimum working temperature °C 75 75
• Minimum boiler return temperature °C 35 35
• Safety temperature limiter setting (water side) 2°C 120 120
• Working/test pressure bar 10/16 10/16
•Boiler efciency at full load at 80/60 °C
(net caloric value/gross caloric value) % 96/86,5 4 96/86,5 4
•Efciency at partial load 30 % (EN 303)
(net caloric value/gross caloric value) % 97/87,3 4 97/87,3 4
•Standard efciency 75/60 °C (according to DIN 4702 part 8)
(net caloric value/gross caloric value) % 97/87,4 4 97/87,4 4
• Stand-by loss at 70 °C Watt 2180 4 2290 4
• Flue gas temperature at nominal output at 80/60 °C °C 93 4 94 4
• Maximum chimney draught Pa 20 20
• Flue gas resistance at nominal output
10.5 % CO2natural gas
500 m over sea level (Tolerance ± 20 %) mbar 7,9 4 8,5 4
•Flue gas mass ow at nominal output
10.5 % CO2natural gas kg/h 5665 4 6798 4
• Flow resistance boiler 3z-value 0,002 4 0,002 4
•Water ow resistance at 20 K mbar 32 4 33,8 4
•Water ow volume at 20 K m³/h 150 4 180,6 4
• Boiler water content litres 3553 4 3628 4
• Insulation thickness boiler body mm 80 80
• Weight (incl. casing) 6 bar kg 7980 4 8200 4
• Weight (without casing) 6 bar kg 7580 4 7800 4
• Heating surface m² 178,33 217,21
• Combustion chamber dimension
Ø inside x length mm 1050/2998 1050/3308
• Combustion chamber volume m³ 2,596 2,88
• Dimensions see Dimensions
1Limited by the boiler control T2.2 to 90 °C resp. U3.2 and T0.2 to 105 °C.
2Maximum safety temperature for boiler control T2.2: 110 °C resp. U3.2 and T0.2: 120 °C.
3 Flow resistance boiler in mbar = volume ow (m3/h)2 x z
4The values have been calculated resp. interpolated. They must be veried by means of tests.
154 214 864 / 01
TECHNICAL INFORMATION

3.3 Dimensions / Space required
3.3.1 Dimensions
(all dimensions in mm)
Type a b c d e f g h i k (inside)
(700) 1100 1150 1175 591 250 290 330 4xM12 15˚/45˚ 303
(1000) 1280 1330 1384 710 310 350 400 6xM12 15˚ 353
(1400) 1480 1530 1584 810 330 400 450 6xM16 15˚ 403
(1800) 1580 1630 1684 860 360 400 450 6xM16 15˚ 453
(2200) 1580 1630 1684 860 360 400 450 6xM16 15˚ 453
(2800) 1680 1730 1784 910 360 400 450 6xM16 15˚ 503
(3500) 1850 1928 1995 1018 360 400 450 6xM16 15˚ 553
(4200) 1850 1928 1995 1018 360 400 450 6xM16 15˚ 603
Type l * m n o p q r s t u v w
(700) 1436 2229 240 1930 389 1110 170 1271 96 1406 420 31
(1000) 1646 2430 240 2130 438 1210 170 1487 103 1564 500 31
(1400) 1886 2600 240 2300 438 1350 170 1708 124 1780 550 31
(1800) 2038 2790 257 2438 438 1350 187 1808 124 1884 600 48
(2200) 2038 3529 257 3213 438 2125 187 1808 124 2659 600 48
(2800) 2188 3745 257 3430 638 2100 187 1908 124 2799 600 48
(3500) 2398 3905 337 3510 668 2123 236 2121 126 3141 600x600 65
(4200) 2398 4205 337 3810 668 2423 236 2121 126 3441 600x600 65
* with Condensate trap: + 155 mm
A condesate trap must imperatively be mounted!
1 Flow
(700) DN 125, PN6
(1000) DN 125, PN6
(1400) DN 150, PN6
(1800) DN 150, PN6
(2200) DN 150, PN6
(2800) DN 200, PN 10
(3500) DN 200, PN 10
(4200) DN 200, PN 10
2 Return
(700) DN 125, PN6
(1000) DN 125, PN6
(1400) DN 150, PN6
(1800) DN 150, PN6
(2200) DN 150, PN6
(2800) DN 200, PN10
(3500) DN 200, PN10
(4200) DN 200, PN10
3 Flue gas outlet
4 Draining R 1½″
5 Condensate drain D31/25 mm
(on both sides)
6 Electrical connection (on both sides)
7 Control panel
(optionally on the left or right hand side)
8 Sleeve Rp ¾″ with immersion pocket
for boiler temperature sensor
Tilting out of the boiler door
boiler door opens to the right or left
(dimensions in mm)
CompactGas
Type a b
(700) 875 120
(1000) 1052 120
(1400) 1252 120
(1800) 1337 120
(2200) 1337 120
(2800) 1435 120
(3500) 1700 160
(4200) 1700 160
16 4 214 864 / 01
TECHNICAL INFORMATION

3.3.2 Base size
Dimensions without insulation and casing Boiler
incl. boiler door, outlet without ue gas collector
(dimensions in mm)
Type a b * c d e f g h i k (inside)
(700) 1100 1436 1153 590 250 290 330 6xM12 15˚ 303
(1000) 1280 1646 1363 710 310 350 400 6xM12 15˚ 353
(1400) 1480 1886 1563 810 330 400 450 6xM16 15˚ 403
(1800) 1580 2038 1663 860 330 400 450 6xM16 15˚ 453
(2200) 1580 2038 1663 860 330 400 450 6xM16 15˚ 453
(2800) 1680 2188 1763 910 330 400 450 6xM16 15˚ 503
(3500) 1850 2398 1995 1018 360 400 450 6xM16 15˚ 553
(4200) 1850 2398 1995 1018 360 400 450 6xM16 15˚ 603
Type l m n o p q r s t DN
(700) 80 2212 209 1930 389 1110 84,5 1271 180 125
(1000) 80 2423 209 2130 438 1210 96 1487 180 125
(1400) 80 2593 209 2300 438 1350 112 1708 200 150
(1800) 80 2731 209 2438 438 1350 112 1808 200 150
(2200) 80 3506 209 3213 438 2125 112 1808 200 150
(2800) 80 3723 209 3430 638 2100 112 1908 200 200
(3500) 80 3820 315 3450 668 2123 135 2121 200 200
(4200) 80 4111 315 3760 668 2423 135 2121 200 200
Combustion chamber dimensions
Typ A B C D E
[phone] 1835 584 189
(1000) 219 1748 1985 684 189
(1400) 219 1896 2180 830 189
(1800) 219 1998 2301 830 189
(2200) 219 2773 3076 830 189
(2800) 219 2968 3288 922 189
(3500) 280 3000 3337 1050 256
(4200) 280 3300 3637 1050 256
Fig. 13
Fig. 14
17
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TECHNICAL INFORMATION

3.4 Flue gas and output diagrams
3.4.1 Flue gas - output diagram
3.4.2 Flue gas resistance
kW = Boiler output
°C = Flue gas temperature on clean surface,
boiler ow temperature
80°C, return temperature 60°C
(in accordance with DIN 4702).
• Operated with natural gas H, λ = 1,15 with max. bruner output
• (CO2natural gas H = 10,5 %)
• A reduction of the boiler water temperature of -10 K
causes a reduction of the ue gas temperature of approx. 6-8 K.
• A modication of lambda λ of ± 0,09
causes a modication of the ue gas temperature of ± 8 K.
Flue gas temperature (°C)
Nominal output (kW)
70
75
80
85
90
95
100
105
200 400 600 800 1'000 1'200 1'400 1'600 1'800 2'000 2'200 2'400 2'600 2'800 3'000 3'200 3'400 3'600 3'800 4'000 4'200
700
1000
1400 1800 2200
2800
3500
4200
Values calculated without liability!
Boiler output (kW)
Flue gas resistance (mbar)
0.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000 3200 3400 3600 3800 4000 4200
700 1000 1400
1800
2200
2800
3500
4200
Values calculated without liability!
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TECHNICAL INFORMATION

4. Installation
4.1 Safety notices
CAUTION
Danger of injury through sharp edges.
Handle the cladding panels with care and
avoid contact with sharp edges.
4.2 Requirements for boiler room
§
• Observe the local and national building reg
-
ulations regarding boiler rooms.
•
Observe the local and national regulations
regarding ventilation and deaeration of boil
-
er rooms.
• Do not set up in very dusty rooms. If neces
-
sary, use an external combustion air supply
and/or lter for the supply air.
•
Gas boilers may not be installed in rooms
which may contain halogen compounds
which may combine with the combus
-
tion air (e.g. laundry rooms, drying rooms,
workshops, hairdressing salon). Halogen
compounds may occur in, amongst oth
-
ers, cleaning, de-greasing and solvent sub
-
stances, adhesives and bleaching agents.
Always make sure that there is an adequate supply of
fresh air to the boiler room, to ensure that the combustion
air supply necessary for all the ring systems operated
can ow in without hindrance and that no oxygen de-
ciency occurs for the operating personnel.
The binding values for the size of intake air apertures
are not usually stated in the relevant regulations, it is laid
down only that the partial vacuum in the boiler room must
not exceed 3 N/m2. To comply with this requirement, an
air supply cross section of 500 cm2is to be provided up
to a nominal heat output of 1000 kW. With rectangular
apertures the side ratio is not to exceed 1.5 : 1 and an ap-
propriate supplement is to be made with grilles to ensure
that the free cross section reaches the above values.
In Austria the ÖNORM H 5171 additionally stipulates a
ue air aperture. This must have a minimum cross sec-
tion of 180 cm2up to a nominal heat output of 100 kW.
The cross section is to be increased by 1 cm2for each
additionnal kW.
4.3 Flue gas connection, flue gas pipe,
dimensions of flue gas pipe
To guarantee economic and fault-free operation, boiler
and chimney must be mutually adapted to create a func-
tional unit.
NOTICE
Moisture-resistant and acid-proof chimneys
must be used for the CompactGas.
Renovation, respectively chimney cross section adjust-
ment may be necessary with existing chimney installa-
tions, according to the instructions of a chimney specialist.
The function of the chimney, i.e. the production of the
necessary delivery pressure is basically dependent on:
a) he type (nature) of the chimney (thermal insu-
lation, interior surface roughness, sealing etc),
b) the connection of the boiler to the chimney
according to specication,
c) the correct chimney cross section
dimensioning.
§
The national regulations must be observed.
19
4 214 864 / 01
INSTALLATION

If the integration of a transition element from the boiler
ue gas outlet to the chimney inlet is necessary, it should
be executed as a slender cone.
vom
Kessel
zum
Schornstein
to the
chimney
from the
boiler
Fig. 16
ref. c)
Dimensioning of chimney cross section. The cross sec-
tions are to be calculated for boilers without delivery pres-
sure demand according to EN 13384. Take into account
the local, special situation (position of the house on a
slope, chimney position, roof pitch, shape of the chimney
mouth etc.)!
In Switzerland, take note of SIA recommendation 384/4!
In Austria the calculation is carried out according to
ÖNORM M 7515.
The values for calculation can be obtained
from the table in section Technical data.
ref. a)
Chimneys according to EN 13384, part 1/2, execution
types I and II are appropriate for modern ring systems
(advice from the chimney specialist is necessary). Pay
attention to the ue gas temperature at nominal output,
see section Technical data.
ref. b)
NOTICE
The condensate accumulating in the ue gas
pipe must not ow back to the boiler. A con-
densate trap (Fig. 15) must therefore be in-
stal led at the ue gas outlet (not included in
the scope of delivery).
condensate trap
condensate trap
Fig. 15
NOTICE
Normally only one heat generator may be
connected to the chimney!
20 4 214 864 / 01
INSTALLATION