Hoval PowerBloc EG Specification sheet

Subject to modification
Operating and installation manual
Hoval PowerBloc EG (12,15,20)
Hoval PowerBloc FG (12,15,20)
4 218 891 / 00 –09/20

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Table of contents
1. General information.........................................................................................................5
1.1. The principle of cogeneration .................................................................................5
2. Basic information ............................................................................................................6
2.1. Copyright and reservation of rights.........................................................................6
2.2. Warranty.................................................................................................................6
2.3. Liability...................................................................................................................7
2.4. Responsibilities of the owner..................................................................................7
2.5. Standards and directives........................................................................................8
2.6. Notes on the representation of symbols and signal words....................................10
2.7. Service addresses................................................................................................11
3. Safety..............................................................................................................................12
3.1. Basic safety instructions.......................................................................................12
3.1.1. Observance of the operating instructions................................................12
3.1.2. Qualification of the personnel, duty of care of the owner.........................12
3.2. Safety markings on the product............................................................................12
3.3. Safety markings in this manual.............................................................................13
3.3.1. DANGER marking...................................................................................13
3.3.2. WARNING marking.................................................................................13
3.3.3. CAUTION marking..................................................................................15
3.3.4. IMPORTANT marking.............................................................................15
3.4. Waste disposal.....................................................................................................16
3.5. Intended use of the plant......................................................................................16
3.5.1. General...................................................................................................16
3.5.2. Possible misuse......................................................................................17
3.5.3. Fire hazard / fire fighting.........................................................................17
3.5.4. Mechanical hazards................................................................................17
3.5.5. Electrical hazards ...................................................................................18
3.6. General safety instructions...................................................................................18
3.7. Special safety instructions....................................................................................21
3.7.1. Fuel variants...........................................................................................21
3.7.2. Generator protection...............................................................................21
3.7.3. Coolant tank with safety closure .............................................................21
3.7.4. Temperature monitoring..........................................................................21
3.7.5. Integrated network and plant protection..................................................22
3.7.6. CO sensor (optional)...............................................................................22
3.7.7. Base group with frame............................................................................22
3.7.8. Driveline..................................................................................................22
3.7.9. Gas engine.............................................................................................22
3.7.10. Generator ............................................................................................23
3.7.11. Lubricating oil supply ..............................................................................23
3.7.12. Gas line ..................................................................................................23
3.7.13. Heat exchanger system..........................................................................24
3.7.14. Power factor correction...........................................................................25
4. Technical documentation..............................................................................................26

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4.1. Technical documentation..........................................................................................26
4.2. Transport and installation..........................................................................................28
4.2.1. Safety.....................................................................................................28
4.2.2. Transport................................................................................................29
4.2.3. Storage conditions..................................................................................29
4.2.4. Installation ..............................................................................................30
4.3. Assembly and installation.....................................................................................31
4.4. Installation and connection conditions..................................................................37
4.4.1. Installation conditions of the cogeneration plant......................................40
4.4.2. Combustion air .......................................................................................40
4.4.3. Extract air ...............................................................................................40
4.4.4. Condensate............................................................................................41
4.4.5. Gas connection.......................................................................................42
4.4.6. Electrical integration ...............................................................................42
4.4.8. Hydraulic integration into the heating system..........................................42
4.4.9. Dimensions and weight...........................................................................46
4.4.10. Floor and base........................................................................................46
4.4.11. Water quality……………………………………………………………………46
4.4.12. Installation diagram.................................................................................47
4.4.13. Connection conditions ............................................................................48
4.4.14. Connection diagram................................................................................49
4.4.15. Power supply..........................................................................................51
5. Commissioning and decommissioning........................................................................52
5.1. Commissioning.....................................................................................................53
5.1.1. Safety.....................................................................................................53
5.1.2. Assembly and installation .......................................................................54
5.1.3. Preparatory work for installation of the CHP plant...................................54
5.1.4. Installing the CHP plant ..........................................................................54
5.1.5. Connecting the CHP plant ......................................................................54
5.1.6. Connection work.....................................................................................54
5.1.7. Start-up...................................................................................................55
5.1.8. Preparing for initial commissioning .........................................................55
5.1.9. Carrying out initial commissioning...........................................................55
5.2. Decommissioning, corrosion protection and disposal ...........................................56
5.2.1. Special notes for decommissioning.........................................................56
5.2.2. Final decommissioning and disposal.......................................................56
5.2.3. Corrosion protection ...............................................................................57
5.2.4. Waste disposal.......................................................................................57
6. ATROMATIC operating instructions.............................................................................58
6.1. Introduction ..........................................................................................................58
6.2. Menu structure.....................................................................................................58
6.3. Main screen..........................................................................................................60
6.3.1. Chimney sweep function.........................................................................62
6.4. Details –Menu structure 1....................................................................................63
6.4.1. History –Menu structure 1.1...................................................................63
6.4.2. Power, Output, network, motor (menu structure 1.2.)..............................71

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6.4.3. Temperatures (menu structure 1.3.)........................................................72
6.4.4. Oil change / service interval (menu structure 1.4.)..................................73
6.4.5. System information / language (menu structure 1.5.)..............................74
6.5. Code / setup (menu structure 2.)..........................................................................75
6.6. User level 1..........................................................................................................75
6.6.1. Power curve (menu structure 2.1.)..........................................................76
6.6.2. Schedule (menu structure 2.2.)...............................................................77
6.6.3. Time / date (menu structure 2.3.)............................................................79
6.6.4. LAN (menu structure 2.4)........................................................................80
6.6.5. E-mail (menu structure 2.5).....................................................................82
6.6.6. Additional functions (menu structure 2.6.)...............................................83
6.7. User level 2..........................................................................................................98
6.7.1. Oil change (menu structure 2.6.9)...........................................................99
6.7.2. Service interval (menu structure 2.6.10)................................................100
6.7.3. Allowed power (menu structure 2.6.11).................................................101
6.7.4. Fresh oil pump (menu structure 2.6.12)................................................102
6.7.5. System operator (menu structure 2.6.13)..............................................103
6.7.6. Serial number (menu structure 2.6.14)..................................................104
6.7.7. Temperature configuration (menu structure 2.6.15) ..............................105
6.7.8. Manual control (menu structure 2.6.16) ................................................106
6.7.9. Other parameters (menu structure 2.6.17)............................................107
6.8. Stop mode / error (menu structure 2.6.19)..........................................................112
6.8.1. Error window.........................................................................................112
6.8.2. Error list (menu structure 2.6.20) ..........................................................115
6.9. Warning (menu structure 2.6.21)........................................................................118
6.10. Standards...........................................................................................................120
7. Service and maintenance............................................................................................121
7.1. Safety.................................................................................................................121
7.2. Cleaning and lubrication.....................................................................................122
7.2.1. Cleaning ...............................................................................................122
7.2.2. Lubrication............................................................................................122
7.3. Maintenance intervals and servicing work ..........................................................122
7.3.1. Maintenance intervals...........................................................................122
7.3.2. Repair work ..........................................................................................123
7.4. Connection work.................................................................................................124
7.5. Electrical installation...........................................................................................124
7.6. Connecting to the electrical grid .........................................................................124
8. Remote maintenance and installation........................................................................125
8.1. Installing the remote maintenance module: ........................................................125
8.2. CHP plant software configuration .......................................................................127
8.3. Cascade connection:..........................................................................................128
8.4. Changing the Micro SD card...............................................................................129
8.5. Connection diagram for the remote maintenance module:..................................130
131

Basic information
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1. General information
1.1. The principle of cogeneration
Cogeneration plants use an internal combustion engine to drive a generator that
generates electrical power. The resulting waste heat is used as heating energy (as shown
in Figure 1: Principle of cogeneration). Such cogeneration plants are also referred to as
combined heat and power (CHP) plants.
Figure 1: Principle of cogeneration
Cogeneration enables decentralised generation of heat and electricity. Although it has
been in use for decades, the technology based on it has only been used to a limited
extent.
The decisive step forward is the innovative control system. CHP plants with static control
only adapt moderately to the change in demand parameters. Thanks to dynamic control
modules, the CHP plant adapts to different load specifications. The CHP plant converts
the energy contained in the gas fuel with an efficiency of almost 100 %. This enormously
increases energy efficiency in the combined heat and power supply of medium-sized
properties.
It can be used in buildings with an annual electricity consumption of approx. 60,000 kWh
or more and an annual fuel consumption of approx. 150,000 kWh or more. These include,
for example, residential complexes from approx. 18 residential units, accommodation
facilities, nursing homes and senior citizens' homes, commercial properties with heating
and cooling requirements, communal facilities, churches, etc.

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2. Basic information
2.1. Copyright and reservation of rights
These operating instructions are protected by copyright. The passing on and
reproduction of this document, exploitation and communication of its contents
are FORBIDDEN, unless expressly permitted in writing by Hoval. Violations will
result in damages. All rights in the event of patent, utility model or design
registration are reserved.
Hoval reserves all rights to this document and to the object depicted therein. Without the
prior written consent of Hoval, this document may not be reproduced in whole or in part,
copied or in any form made accessible to third parties in whole or in part and used outside
the purpose for which it was handed over to the recipient.
These operating instructions essentially contain information on the structure, function,
assembly, commissioning, operation and maintenance of your cogeneration plant.
All appendices are integral parts of the operating instructions.
Your cogeneration plant has been built in accordance with recognised safety regulations.
However, improper use may endanger persons or cause damage to property.
2.2. Warranty
Non-compliance with the operating instructions shall invalidate the warranty, as shall any
modification or repair to the plant without the prior written consent of Hoval. Furthermore,
Hoval shall not be liable for damage or accidents caused by improper handling, excessive
strain or force majeure.
In principle, the "Standard terms and conditions of delivery" of Hoval apply. Hoval grants a
warranty / guarantee of 12 months on its combined heat and power plants starting from
the respective commissioning date or at the latest 3 months after the delivery date.
The following conditions must be met in order for the warranty to be approved:
All major customer services during the warranty period are carried out exclusively
by Hoval or a specialist company approved or authorised by Hoval.
If the plant is not put into operation within 3 months of delivery and/or notification
of readiness for dispatch, a subsequent application of corrosion protection shall be
necessary and must be paid for.
The plant is not allowed to be operated beyond the maximum rated power, which
is indicated for the respective type on the technical data sheet.
The plant must not be operated with defective or improperly installed safety and
monitoring devices.
A gas engine oil approved by Hoval must be used as engine oil. For further
information, see the "Operating materials" chapter.
The owner is not allowed to make any technical changes to the plant.
Only genuine spare and wear parts are allowed to be used for repairs.

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2.3. Liability
Hoval is only liable for direct personal injury and damage to property on the basis of the
applicable product liability law if the plant is used for the purpose prescribed in the
operating instructions or for the contractually agreed use.
Hoval shall not be liable for compensation for damage that has not occurred to the plant
itself (loss of use, loss of production and profit as well as other direct or indirect losses).
2.4. Responsibilities of the owner
The CHP plant was designed and built taking into account a risk assessment and after
careful selection of the harmonised standards to be complied with and other technical
specifications. It thus corresponds to the state of the art and guarantees a maximum
of safety.
However, this safety can only be achieved in operational practice if all necessary
measures are taken. It is the duty of care of the owner of the plant to plan these measures
and to check they are carried out.
In particular, the owner must ensure that
the plant is only used for its intended purpose
the plant is only operated in perfect, functional condition and the safety devices in
particular are regularly checked for their functionality
the necessary personal protective equipment is available to the operating,
maintenance and repair personnel, and is used
the operating instructions are always available in a legible condition and complete
at the place of use of the plant
only sufficiently qualified and authorised personnel operate, maintain and repair
the plant
this personnel is regularly instructed in all applicable questions of occupational
safety and environmental protection and is familiar with the operating instructions
and in particular with the safety instructions contained therein
no safety and warning notices attached to the plant are removed and all of them
remain in a legible condition
a risk assessment (within the meaning of Article 5 of the Occupational Health and
Safety Act) is carried out to determine the other hazards arising from the special
working conditions at the location where the plant is to be used
all further instructions and safety instructions resulting from the risk assessment of
the workplaces at the plant are summarised in one operational instruction (in the
sense of Article 6 of the Work Equipment Usage Ordinance).

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2.5. Standards and directives
The plant has been designed and built in accordance with the currently valid technical
rules and recognised safety regulations. The basic safety requirements, standards and
guidelines were applied in the design of the plant.
The safety of the plant is documented by the declaration of conformity.
All safety data refers to the currently valid regulations of the European Union. In other
countries, the applicable laws and regulations must be observed. In addition to the safety
instructions in these operating instructions, the accident prevention regulations for power-
operated working machines as well as the generally applicable regulations for
environmental protection must be observed and adhered to.
Instructions, ordinances and laws
2006/42/EC
EC Machinery Directive
2006/95/EC
Low-Voltage Directive
2004/108/EC
Directive on Electromagnetic Compatibility
BImSchv
German Federal Immission Control Ordinance
MFeuVo
Model firing ordinance of the federal states FeuVo
Fundamental standards
DIN EN ISO 60204-1
Safety of machinery; Electrical equipment of machines
DIN EN ISO 12100
Safety of machinery; Basic concepts, general principles
for design
DIN EN ISO 13857
Safety of machinery; Safety distances to prevent hazard
zones being reached by upper and lower limbs
DIN EN ISO 13850
Safety of machinery; Emergency stop function - Principles
for design
DIN EN ISO 13732
Ergonomics of the thermal environment; Methods for the
assessment of human responses to contact with surfaces
DIN EN 547
Safety of machinery; Human body measurements
DIN EN 574
Safety of machinery; Two-hand control devices
DIN EN 614
Safety of machinery; Ergonomic design principles
DIN EN 626
Safety of machinery; Reduction of risk to health from
hazardous substances emitted by machinery
DIN EN 894
Safety of machinery; Ergonomics requirements for the
design of displays and control actuators
DIN EN 953
Safety of machinery; Guards - General requirements for
the design and construction of fixed and movable guards
DIN EN 981
Safety of machinery; System of auditory and visual danger
and information signals

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DIN EN 1037
Safety of machinery; Prevention of unexpected start-up
DIN EN 1127-1
Explosive atmospheres; Explosion prevention and
protection, Part 1: Basic concepts and methodology
DIN EN 12828
Heating systems in buildings - Design of hot water systems
(replacement for DIN 4751)
DIN EN 12831
Heating systems in buildings
DIN EN 13849
Safety of machinery; Safety-related parts of control systems
DIN EN 14336/2005
Heating systems in buildings
DIN EN 14868/2003
Protection of metallic materials against corrosion
DIN EN 60529
Degrees of protection provided by enclosures (IP Code)
DIN EN 61310-2
Safety of machinery; Indication, marking and actuation,
Part 2: Requirements for marking
Product-dependent standards
ISO 8999
Reciprocating internal combustion engines, graphical
symbols
DIN EN ISO 13407
Human-centred design processes for interactive systems
DIN EN ISO 6826
Reciprocating internal combustion engines, fire protection
DIN ISO 8528 ff.
Reciprocating internal combustion engine driven alternating
current generating sets
DIN EN 1679-1
Reciprocating internal combustion engines; safety,
Part 1: Diesel engines
DIN EN 12601
Reciprocating internal combustion engine driven alternating
current generating sets; safety
DIN 1988
Codes of practice for drinking water installations (TRWI)
DIN 3380
Gas pressure regulators for supply pressures up to 100 bar
DIN 3386
Gasfilters having a maximum working pressure of less or
equal to 5 bar - Requirements and testing
DIN 3398-3
Pressure cut-off switches for gaseous substances;
requirements and testing
DIN 4751
Safety requirements for heating installations with flow
temperatures up to 110 °C replaced by DIN EN 12828
DIN 6280-14
Generating sets; Reciprocating internal combustion
engines driven generating sets, Part 14: Combined heat
and power system (CHPS) with reciprocating internal
combustion engines; basics, requirements, components,
application and maintenance

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Other basic regulations
BGV A8
Safety and health marking at the workplace
TRF 1996
Technical rules for liquid gas
ATV –Worksheet A251
Introduction of condensation water from gas and oil-
operated firing plants in public sewage and small-scale
water treatment plants, edition Nov. 1998, GFA Verlag für
Abwasser, Abfall und Gewässerschutz
VDI 2035
Water treatment for heating systems
2.6. Notes on the representation of symbols and signal words
DANGER
Warning of personal injuries that are already acute at the moment of the warning.
Warning of dangerous situations which, if not avoided, will result in serious injury or death.
WARNING
Warning of personal injuries that depend on behaviour.
Warning of dangerous situations which, if not avoided, can result in serious injury or
death.
CAUTION
Warning of damage to property which cannot result in personal injury.
Warning of dangerous situations which, if not avoided, could result in minor to
moderate injury.
IMPORTANT
Provides information on how to avoid damage to property or misuse.
Draws attention to possible damage to property and other important information.
NOTICE
Information about the handling of the machine and activities to be carried out on or with it.

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2.7. Service addresses
Switzerland
Hoval AG
General Wille-Strasse 201
8706 Feldmeilen ZH
[phone]
[email protected]
Austria
Hoval Gesellschaft m.b.H.
Hovalstrasse 11
4614 Marchtrenk
[phone]
[email protected]
Germany
Hoval GmbH
Humboldtstrasse 30
85609 Aschheim-Dornach
[phone]
[e-mail]
Italy
Hoval s.r.l.
Via XXV Aprile 1945 snc
24050 Zanica (BG)
[phone]
[email protected]
UK
Hoval Ltd.
Northgate
Newark Notts. NG24 1JN
[phone]
[e-mail]
France
Hoval SAS
Parc d'Activité de la Porte Sud
Bâtiment C - Rue du Pont au Péage
67118 Geispolsheim
[phone]
[e-mail]

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3. Safety
3.1. Basic safety instructions
3.1.1. Observance of the operating instructions
The operating instructions must be read and understood by the personnel and must be
observed during all work. For this reason, always keep the operating instructions handy in
the immediate vicinity of the plant.
The owner of the plant is responsible for the training and safety of the operating
personnel. It is therefore very important that these operating instructions are actually
handed over to the persons concerned.
The owner and the operating personnel of the plant are obliged to observe and comply
with the instructions given in these operating instructions. Operating personnel who work
with the transport, installation, operation, maintenance or repair of the plant, must have
read and understood these operating instructions.
The owner must specially instruct operating personnel who cannot read and draw
attention to the dangers involved in handling the plant. The plant is only allowed to be
operated by persons who have been instructed and informed about the dangers. It is
recommended that service personnel be consulted for instruction.
3.1.2. Qualification of the personnel, duty of care of the owner
Only instructed personnel are allowed to operate and maintain the plant. It is the responsibility
of the plant owner to ensure the minimum qualification of personnel to operate the plant.
IMPORTANT
All work that goes beyond the operation of the plant is only allowed to be carried
out by authorised specialist personnel.
Specialist personnel is defined as persons who, due to their technical training, knowledge
and experience as well as knowledge of the relevant standards, are able to assess the
work assigned to them and recognise possible hazards (based on the definition in EN
60204-1).
3.2. Safety markings on the product
DANGER
To avoid danger and damage, observe the general safety instructions and the information
in the associated operating instructions.
WARNING
Warning of dangerous voltage present at the equipment.
WARNING
Warning of hot surfaces with a temperature above 60 °C.
WARNING
Substances with this marking must be disposed of in an environmentally friendly manner.

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3.3. Safety markings in this manual
3.3.1. DANGER marking
DANGER
COMPLY WITH THE GENERAL SAFETY INSTRUCTIONS!
To avoid hazards and damage, observe:
the safety instructions in chapter 2
the information in the relevant chapters
the information in the associated operating instructions
The danger warning must be observed. The danger must be counteracted with the
necessary care (e.g. protective clothing) or caution. Work on or with the plant should be
carried out with the utmost caution.
3.3.2. WARNING marking
WARNING
Warning of hand injuries!
Attention, keep your hands away from areas bearing this warning sign! There is a risk that
hands may be crushed, pulled in or otherwise injured.
WARNING
Warning of slipping hazard!
Care must be taken when walking, running or climbing because of the danger of slipping
on traffic routes (in exceptional situations, e.g. after cleaning work or in the event of
hazards caused by icy or slippery roads in entrance areas of buildings).
WARNING
Warning of tripping hazard!
In the case of undetectable tripping points in traffic routes (height differences of more than
six millimetres, e.g. between workplaces due to steps or temporary tripping points, such
as cables or other lines), look at the floor in order to detect the danger point and overcome
it without difficulty.
WARNING
Warning of hot surface!
Hot surfaces, at a temperature of 45 °C or more (coagulation of protein), which can cause
burns in humans, should not be touched without protective gloves.
WARNING
Warning of environmental hazards!
Substances with this marking must be disposed of in an environmentally friendly manner.

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W arn un g v or
herabfalle n d e n
G e ge ns tä nden
WARNING
Warning of flammable substances!
In work rooms (e.g. storage rooms) or in the vicinity of storage cabinets with hazardous
contents, do not carry out any work that causes the substances to ignite.
WARNING
During transport with lifting equipment, injuries may result from falling objects.
WARNING
During transport, there is a risk of injury from falling or slipping objects. Never step under
suspended loads!
WARNING
Warning: Danger of electric shocks!
Electrical hazards to persons due to direct contact with live parts. Elements likely to
present an electrical hazard must be positioned or protected in such a way that they
cannot be touched by personnel.
Electrostatic discharge when touching the plant. The plant and machine parts must be
earthed so that potential differences can be compensated.
When handling products such as machines, tools, etc., contact with live parts can lead to
dangerous body currents. If the rules of conduct are not observed, this can result in
serious physical damage, including loss of limbs or damage to property. Persons who
carry out work on or with the product should do so with great care.
Warning:
Falling objects
Warning:
Suspended load

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3.3.3. CAUTION marking
Caution
Caution: Use hand protection!
Due to the risk of injury, hand protection must be worn. Read the operating instructions
before using the hand protection! The operating instructions describe the right type of
protective glove and where it should be used.
Caution
Caution: Use foot protection!
Safety shoes must be worn to protect the feet from foot injuries. Foot injuries can be
caused by tools or workpieces falling over or down, incorrectly attached loads, jamming of
the foot as well as the penetration of nails or metal chips into the sole.
3.3.4. IMPORTANT marking
IMPORTANT: Use hand protection!
If there is a risk of injury to arms and hands, protective gloves should be worn.
IMPORTANT: Use hearing protection!
If high sound levels (noise) occur in an area, hearing protection must be worn in this area.

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3.4. Waste disposal
WARNING
All work on and with the plant must comply with the regulations on waste avoidance and
the proper recycling and disposal of waste. In particular during assembly, installation,
maintenance and repair work as well as during decommissioning, it must be ensured that
substances hazardous to groundwater such as greases, oils, antifreeze agents, cleaning
fluids containing solvents, etc. cannot enter the ground or the sewerage system. These
substances must be collected, stored, transported and disposed of in suitable containers.
The product data sheets are available from Hoval Service (for service address, see
chapter 1.7). They must be observed during disposal.
3.5. Intended use of the plant
3.5.1. General
The plant is only allowed to be used for its intended purpose.
The plant is only allowed to be operated in a faultless, safe working condition.
The plant is only allowed to be operated by persons expressly authorised to do so.
The safety and monitoring devices must be easily accessible and regularly
checked for completeness and function.
When operating the plant, the general accident prevention regulations for power-
driven machines apply.
Warning and instruction signs must not be removed and must always be in a
legible condition.
Protective devices must not be modified or dismantled. They must be checked
regularly for function.
The CHP plant is a compact, ready-to-connect plant for the utilisation of natural gas, liquid
gas and sewage / biogas. The energy contained in the fuel gas is converted into electrical
and thermal energy by combustion. The electrical power is transferred to the low-voltage
system at the installation site. The resulting heat is dissipated into the heating system of
the building. The CHP plant serves exclusively this purpose.
The CHP plant is only allowed to be operated with the prescribed fuel gas. More detailed
information can be found in chapter 3.7.1 Fuel variants.
The plant is only allowed to be used in a technically faultless condition and in accordance
with its intended use, paying attention to safety aspects and potential hazards. Any other
or more extensive use shall be deemed improper. The manufacturer can accept no liability
for damage resulting from improper use. Expansions and conversions by third parties are
only allowed to be carried out in consultation with Hoval.
The intended use also includes reading all operating instructions of the plant and
observing all instructions contained therein - in particular the safety instructions. This also
includes carrying out all inspection and maintenance work in the prescribed time intervals.

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3.5.2. Possible misuse
Any use other than the intended use is not permitted.
Possible improper applications include non-compliance with safety equipment, safety
regulations and current accident prevention regulations. Hoval is not liable for damage
resulting from improper use.
The possible consequences are shown below.
3.5.3. Fire hazard / fire fighting
DANGER
Keep materials at risk of fire and explosion away from hot surfaces.
Ensure that there are no naked flames in the work area. Only use suitable extinguishing
agents for extinguishing fires. There is a risk of fire and explosion when cleaning with
cleaning agents which can lead to fire and explosion.
3.5.4. Mechanical hazards
WARNING
Warning of hand injuries!
Attention, keep your hands away from areas bearing this warning sign! There is a risk that
hands may be crushed, pulled in or otherwise injured.
WARNING
During transport with lifting equipment, injuries may result from falling objects.
WARNING
During transport, there is a risk of injury from falling or slipping objects. Never step under
suspended loads!
W arn un g v or
herabfalle n d e n
G e ge ns tä nden
Warning:
Falling objects
Warning:
Suspended load

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3.5.5. Electrical hazards
WARNING
Risk of electric shock!
Electrical hazards due to people coming into direct contact with live parts. Parts
likely to present an electrical hazard must be positioned or protected in such a way
that they cannot be touched by personnel.
There is a risk of fatal electric shock from live parts! Even when the main switch is
switched off, electrical voltage is present at the power supply terminals in the control
cabinet of the CHP plant. Before working on the plant, the power supply must be switched
off and secured against being switched on again.
The electrical installation is only allowed to be carried out by a specialist electrician trained
by Hoval.
WARNING
Risk of electric shock!
Electrostatic discharge when touching the machine: The plant and machine parts must be
earthed so that potential differences can be compensated.
3.6. General safety instructions
Specialist personnel
Installation, commissioning, maintenance and repairs to the CHP plant are only allowed to
be carried out by qualified installers.
Maintenance
The CHP plant must be serviced and inspected at the prescribed intervals. Documentation
(maintenance book) must be kept for this purpose. If the documentation is not kept,
any warranty claims will lapse.
Covers
Behind the covers which can only be removed with auxiliary means (keys, tools), there are
components which if touched can lead to injuries (hot and/or live parts). These covers are
only allowed to be removed by specialist personnel.
Seals
It is forbidden to destroy seals. If the seals are destroyed or opened, the manufacturer's
warranty will be invalidated.
Frost protection
The heating system must be protected from frost. This is only guaranteed if the CHP plant
always remains in operation. If the plant is switched off, the manufacturer does not
assume any warranty for frost damage.
Operating parameters
The operating instructions must be read carefully before any parameters on the CHP plant
are modified. Unauthorised modification of the type-related nominal output is prohibited.

Safety
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Condensate drain
If the CHP plant has been out of operation for a relatively long period of time, it must be
ensured that the siphon of the condensate drain is filled with water.
Behaviour if you smell gas
Turn off the gas valve (due to sparking, neither the light nor other electrical
switches are allowed to be switched on and the all-pole disconnection point must
not be switched off).
Ventilate and notify service centre, gas supply company or recognised specialist
workshop
Do not use a telephone in the danger zone
Do not use a naked flame (e.g. lighter, match). Do not smoke.
Behaviour in the event of fire or water damage
Close gas valve
Switch off all-pole disconnection point
Notify service centre.
Operation with propane gas
Only propane gas with a motor octane number (MON) of at least 92 is allowed to be used!
In the event of non-observance, the manufacturer does not assume any warranty for
damage which does or may result from this.
Contamination during the building phase
If the CHP plant is installed during the building phase, the electronics and the air filter
must be checked and cleaned after completion of the construction.
Installation and adjustment
For your own safety, please note that installation, adjustment and maintenance of the unit
are only allowed to be carried out by Hoval or authorised service partners. This also
applies to the inspection and repair of the unit as well as changes to the set gas quantity.
Modifications
You must not make any changes
to the unit,
to the supply lines for gas, supply air, water and electricity,
to the exhaust gas line,
to the discharge pipes and to the safety valves for the heating water.
The prohibition on modifications also applies to structural conditions in the vicinity of the
unit, insofar as these may have an influence on operational safety.
Ventilation
Ventilation slots must always be kept free. Do not cover ventilation openings with clothing
or similar items.
Units with extract air ducting
Do not install any additional units with extract air ducting (e.g. fans, tumble dryers or
cooker hoods) in the vicinity of the unit. Consult with the manufacturer before doing so.

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Tight-sealing windows
When installing tight-sealing windows, you must ensure, in consultation with the
manufacturer, that there is still a sufficient supply of combustion air to the unit.
Explosive or highly inflammable substances
Do not use or store explosive or highly inflammable substances (petrol, paint, paper) in
the installation room of the unit.
Inspection
The CHP plant must be serviced and inspected at the prescribed intervals, otherwise all
claims under warranty are invalidated. The unit must be inspected annually. Maintenance
must be carried out in accordance with the regulations after a maximum of 6,000
operating hours or at the latest after one year.
Improper use
Any use that goes beyond that described above shall be deemed to be improper use.
No liability is assumed for damage caused by the non-observance of these operating
instructions.
Corrosion protection
Do not use sprays, solvents, chlorine-based cleansing agents, paints, adhesives etc. in
the proximity of the unit. Under unfavourable circumstances, these substances can lead to
corrosion - including in the exhaust gas system.
Filling the heating system
For filling and refilling the heating system, tap water / drinking water is usually sufficient.
In exceptional cases, however, the water quality can deviate greatly (strongly corrosive or
very hard water). The water must be treated accordingly under these circumstances.
Checking the water level
Check the water level of the heating system regularly.
Emergency generator
The unit was connected to the mains supply during installation. If you wish to keep the unit
ready for operation with an emergency generator in the event of a power failure, its
technical values (voltage, frequency, earthing) must correspond to those of the mains
supply and at least match the power consumption of your unit.