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