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
i
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.
i
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
i
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
i
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
i
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
i
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)
3
1
2
23
Fig. 04 Fig. 05
5
Position mechani-
cal jack
Figure shows situation after transformation
(boiler door opens to the left)
8

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
i
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
3
2a
1
2
2a
2b
5
7
8
6
4
Fig. 06
1a
8a
Insulating mat may be partitioned
1b

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
14
Fig. 07
15
12c
180°
12d
12c
12b
12
12a
Fig. 08
Fig. 09
16
17
18

114 205 753 / 06
ASSEMBLY
21
30
26
27
28
25
22
23
23
24
20a
20b 22
22
31
33
29 32
12
20 31
14
34
Compact Gas (1800-2800) cutaway view
Fig. 10

12 4 205 753 / 06
ASSEMBLY
3.5 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.
3.5.1 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).
3.5.2 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)
45
49
48
47
46
C
42 43
40
41
D
44
44
45° incline
boiler side
42
44
A
4 0
B
40
41
42
44
41a
Fig. 11

134 205 753 / 06
TECHNICAL INFORMATION
4. Technical details
4.1 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

14 4 205 753 / 06
TECHNICAL INFORMATION
4.2 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
• 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

154 205 753 / 06
TECHNICAL INFORMATION
4.3 Dimensions / Space required
4.3.1 Dimensions
(all dimensions in mm)
Type a b c d e f g h i k (inside)
(700) 1100 1150 1175 590 250 290 330 6xM12 15˚ 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 860 330 400 450 6xM16 15˚ 453
(2200) 1580 1630 1684 860 330 400 450 6xM16 15˚ 453
(2800) 1680 1730 1784 910 330 400 450 6xM16 15˚ 503
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
Flow
(700) DN 125, PN6
(1000) DN 125, PN 6
(1400) DN 150, PN 6
(1800) DN 150, PN 6
(2200) DN 150, PN 6
(2800) DN 200, PN 10
1 Flue gas outlet
2Draining R 1″
3 Condensate drain D 31/25 mm (on both sides)
4 Electrical connection (on both sides)
5 Control panel
6Sleeve Rp ¾″ with immersion pocket
for boiler temperature sensor
Return
(700) DN 125, PN6
(1000) DN 125, PN 6
(1400) DN 150, PN 6
(1800) DN 150, PN 6
(2200) DN 150, PN 6
(2800) DN 200, PN 10
Fig. 13

16 4 205 753 / 06
TECHNICAL INFORMATION
4.3.2 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
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
* with condensate trap: + 155 mm
A condensate trap must imperatively be mounted!
Combustion chamber dimensions
Type 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 2968 3288 922 189
(2800) 219 2941 3272 930 189
Fig. 14
Fig. 15

174 205 753 / 06
TECHNICAL INFORMATION
4.4 Flue gas and output diagrams
4.4.1 Flue gas - output diagram
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 reduc-
tion 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.
4.4.2 Flue gas resistance
Flue gas resistance (mbar)
0.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 2400 2500 2600 2700 2800
1000 1400
1800
2200 2800
700
Flue gas temperature (°C)
Nominal output (kW)
70
75
80
85
90
95
100
105
200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 2400 2500 2600 2700 2800
1000
1400 1800
2800
2200
700
Boiler output (kW)

18 4 205 753 / 06
INSTALLATION
5. Installation
5.1 Safety notices
Caution!
Danger of injury through sharp edges.
Handle the cladding panels with care and
avoid contact with sharp edges.
5.2 Requirements for boiler room
§
• Observe the local and national building
regulations regarding boiler rooms.
• Observe the local and national regulati-
ons regarding ventilation and deaerati-
on of boiler rooms.
• Gas boilers may not be installed in
rooms which may contain halogen com-
pounds which may combine with the
combustion air (e.g. laundry rooms,
drying rooms, workshops, hairdressing
salon).
•
Halogen compounds may occur in,
amongst others, cleaning, de-greasing
and solvent substances, 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ci-
ency 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 section of
180 cm2up to a nominal heat output of 100 kW. The cross
section is to be increased by 1 cm2for each additionnal
kW.
5.3 Flue gas connection, flue gas pipe, dimen-
sions of flue gas pipe
To guarantee economic and fault-free operation, boiler
and chimney must be mutually adapted to create a func-
tional unit.
Renovation, respectively chimney cross section adjust-
ment may be necessary with existing chimney installati-
ons, according to the instructions of a chimney specialist.

194 205 753 / 06
INSTALLATION
The function of the chimney, i.e. the production of the ne-
cessary delivery pressure is basically dependent on:
a) he type (nature) of the chimney (thermal in-
sulation, interior
surface roughness, sealing etc),
b) the connection of the boiler to the chimney
according to specication,
c) the correct chimney cross section dimensio-
ning.
§
The national regulations must be obser-
ved.
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)
The condensate accumulating in the ue
gas pipe must not ow back to the boiler.A
condensate trap (Fig. 16) must therefore
be installed at the ue gas outlet (not in-
cluded in the scope of delivery).
condensate trap
condensate trap
Fig. 16
Normally only one heat generator may be
connected to the chimney!
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
Fig. 17
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 slo-
pe, 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.
i
The values for calculation can be obtai-
ned from the table
in section Technical data.
from boiler to chimney

20 4 205 753 / 06
INSTALLATION
5.4 Installing the burner
• Burner installation dimensions may be obtained from
point 4.3.2.
• The burner is mounted on the boiler door by means of
the seal and screws. On installing, comply with the gui-
delines and instructions for mounting the burner on the
heat generator.
•
Use only burners tested according to EN 676 resp.
EN 267
• The space between the burner pipe and the boiler door
is to be insulated with the insulating wool supplied.
With gas burners, the burner housing
weight is to be directly supported by a
strut to the oor.
Boiler sight glass cooling:
A cooling line must be routed from the
burner to the sight glass (Fig. 18), in order
to cool the boiler sight glass and keep it
clean. Either a hose or a copper pipe can
be used.
Fig. 18
Noise damping
• Gas pipelines are to be installed so that no vibrations
can be transferred to the building.
• The burner can be covered with a noise-damping hood.
• It is recommended to incorporate a noise damper
downstream of the boiler in the ue gas pipe.
5.5 Hydraulic connection
In accordance with EN 12828:2003 the following safety
devices are integrated in the boiler:
- temperature regulator
- temperature measuring device TBmax + 20%
- safety temperature limiter
A complete failure of the water circuit must be taken into
account plant-specically according to DIN EN 12828.
In Germany, a low water protection must be provided.
5.5.1 Pressure maintenance
A pressure expansion tank sized appropriately for the
heating plant, water volume and head has to be installed
on site.
5.5.2 Hydraulic connection
The minimum return temperature has to be ensured by
constant return ow control. A minimum water circulation
is not necessary.
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Fig. 19