Hoval CompactGas 700 Assembly Instructions Manual
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Hoval CompactGas 700 Assembly Instructions Manual

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Technical information
Assembly instructions
Hoval CompactGas (700-2800)
for natural gas and liquid gas
Hoval products must be installed and commissioned
only by appropriately qualified experts. These instruc-
tions are intended exclusively for the specialist. Electri-
cal installations may only be carried out by a qualified
electrician.
Subject to modifi cations
|
4 205 753 / 06 - 06/14
These instructions apply to the following ty-
pes:
Nominal output at 80/60 °C and natural gas
1-CompactGas (700)
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
The gas boiler series Compact is suitable and appro-
ved for use as heat generator for water heating plants
with permitted flow temperatures up to 110 °C
are designed for closed-circuit plants according to
EN 12828.
see section Technical data
1)
700 kW
. They
1)
EN

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Summary of Contents for Hoval CompactGas 700

  • Page 1 1-CompactGas (1800) 1800 kW 1-CompactGas (2200) 2200 kW 1-CompactGas (2800) 2800 kW Hoval products must be installed and commissioned The gas boiler series Compact is suitable and appro- only by appropriately qualified experts. These instruc- ved for use as heat generator for water heating plants tions are intended exclusively for the specialist.

  • Page 2: Table Of Contents

    TABLE OF CONTENTS Safety notices Key to symbols ..................................4 Important notices Measures on receipt of the appliance ..........................5 Warranty ....................................5 Instructions ..................................5 Regulations, official approvals ............................5 2.4.1 Germany ...................................5 2.4.2 Austria ....................................6 2.4.3 Switzerland ..................................6 Assembly Installation, levelling ................................7 Mounting the condensate drain ............................9 Mounting the thermal insulation ............................9 Mounting the cladding and the boiler control ........................
  • Page 3 TABLE OF CONTENTS Commissioning Safety notices ..................................24 Charging with water ................................24 Water quality ..................................25 6.3.1 Heating Water .................................25 6.3.2 Filling and replacement water ............................25 Venting the gas pipes ................................26 Handing over the plant to the operator ..........................26 Record - Activation of screed function ..........................27 Maintenance Information for combustion controller/chimney sweep regarding emission monitor key ..........29 Safety notices ..................................30...

  • Page 4: Safety Notices

    IMPORTANT INFORMATION Safety notices The plant must only be commissioned when all relevant standards and safety re- gulations have been fulfilled. 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 filled with water...

  • Page 5: Important Notices

    – procedure for heat and technical gas- for the operation of your plant can be flow calculations. found together in the Hoval plant hand- • OENORM 12828 Heating systems in book. Please keep all instructions in a buildings: planning of hot water heating safe and accessible place! systems.

  • Page 6: Switzerland

    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- flow calculations. - SN EN 12828 Heating systems in buil- dings: planning of hot water heating systems.

  • Page 7: Assembly

    Assembly Boiler door hinges may only be changed Installation, levelling over by Hoval Service! No special foundation plate is required for installing the boiler (sufficient supporting capacity for the boiler must The boiler door must be closed when changing over the be guaranteed);...

  • Page 8: Mounting The Condensate Drain

    ASSEMBLY 7. For types 1800,2200,2800: boiler body. The insulating mat (1a, Fig. 06) has to be Remount support for door positioning (5, Fig. 01) on applied in such a way that the large recess (1b, Fig. the other side, readjust if necessary resp. level boiler 06) is located at the back.
  • Page 9 ASSEMBLY Fig. 06 4 205 753 / 06...

  • Page 10: Mounting The Cladding And The Boiler Control

    ASSEMBLY 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 first).
  • Page 11 ASSEMBLY 4 205 753 / 06...

  • Page 12: Mounting The Side Shutters

    ASSEMBLY Mounting the side shutters 3.5.2 Mounting the fixed side shutter (detail D) The cladding shutter system serves for covering the gap between the boiler door and the side wall. The shutter at 4. Open boiler door, mount hinges (40, Fig. 11) on the boiler door hinge side must be flexible.

  • Page 13: Technical Details

    Technical details 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.

  • Page 14: Technical Data

    TECHNICAL INFORMATION Technical data Type (700) (1000) (1400) (1800) (2200) (2800) • Nominal output at 80/60 °C 1000 1400 1800 2200 2800 • Range of output at 80/60 °C 250-700 300-1000 420-1400 540-1800 660-2200 840-2800 • Burner input maximum 1037 1458 1865 2280...

  • Page 15: Dimensions / Space Required

    TECHNICAL INFORMATION Dimensions / Space required 4.3.1 Dimensions (all dimensions in mm) Fig. 13 Type k (inside) (700) 1100 1150 1175 6xM12 15˚ (1000) 1280 1330 1384 6xM12 15˚ (1400) 1480 1530 1584 6xM16 15˚ (1800) 1580 1630 1684 6xM16 15˚...

  • Page 16: Base Size

    TECHNICAL INFORMATION 4.3.2 Base size Dimensions without insulation and casing Boiler incl. boiler door, outlet without flue gas collector (dimensions in mm) Fig. 14 Type k (inside) (700) 1100 1436 1153 6xM12 15˚ (1000) 1280 1646 1363 6xM12 15˚ (1400) 1480 1886 1563...

  • Page 17: Flue Gas And Output Diagrams

    TECHNICAL INFORMATION Flue gas and output diagrams 4.4.1 Flue gas - output diagram 1400 1800 1000 2200 2800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 2400 2500 2600 2700 2800 Nominal output (kW) kW = Boiler output •...

  • Page 18: Installation

    INSTALLATION Flue gas connection, flue gas pipe, dimen- Installation sions of flue gas pipe Safety notices To guarantee economic and fault-free operation, boiler and chimney must be mutually adapted to create a func- Caution! tional unit. Danger of injury through sharp edges. Handle the cladding panels with care and avoid contact with sharp edges.
  • Page 19 INSTALLATION The function of the chimney, i.e. the production of the ne- If the integration of a transition element from the boiler cessary delivery pressure is basically dependent on: flue gas outlet to the chimney inlet is necessary, it should be executed as a slender cone.

  • Page 20: Installing The Burner

    INSTALLATION Hydraulic connection Installing the burner • Burner installation dimensions may be obtained from point 4.3.2. In accordance with EN 12828:2003 the following safety • The burner is mounted on the boiler door by means of devices are integrated in the boiler: the seal and screws.

  • Page 21: Hydraulic Schematic

    INSTALLATION 5.5.3 Hydraulic schematic Notice! The minimum boiler temperature of 75 °C as well as the minimum return tempera- Important notices: ture of 35 °C must never fall below the sta- - The examples stated below are principle schema- ted value in any of the operating status tics which do not contain all the details for instal- given (see technical data).

  • Page 22: Electrical Connection

    INSTALLATION Electrical connection The electrical connection has to be car- ried out by a qualified and authorised electrician. The connection diagram is to be found in the boiler control box. The wiring diagram is supplied separate- Cables to be connected may be lead laterally along the boiler into a cable channel forward towards the control box.

  • Page 23: Commissioning

    The first commissioning of the plant, times before being refilled. maintenance and servicing work may only be carried out by qualified personnel or by Hoval customer service personnel. Caution The plant may be damaged through the use of unsuitable liquids.

  • Page 24: Water Quality

    In particular, attention must be paid to the following stipu- lations: Filling and replacement water • Hoval boilers and calorifi ers are designed for heating • For a plant using Hoval boilers untreated drinking water plants without signifi cant oxygen intake (plant type I ac- cording to EN 14868).

  • Page 25: Venting The Gas Pipes

    COMMISSIONING Venting the gas pipes § Observe the relevant regulations while venting the gas pipes • Open the gas stop valve. • Vent the gas pipe up to the gas arma- ture.. Handing over the plant to the operator The plant installer is responsible for pro- viding instruction covering the entire plant.

  • Page 26: Record - Activation Of Screed Function

    COMMISSIONING Record - Activation of screed function Cross where applicable; cut out record and fasten to the control during the active screed function. Minimum requirements for the activation of the screed function: Minimum age cement screed 21 days Minimum age calcium sulphate screed 7 days Flow temperature monitor installed and connected For newly laid screed - see „Recommendation of the Federal Association of Radiant Panel Heating“.
  • Page 27 COMMISSIONING Parameter 16 „Screed function“ (Parameter HC, MC1 or MC2) Example: Maximum fl ow temperature 40°C 1 Function heating Starting day + 7 days [°C] VLSol 55°C maximum set level! maximal 55°C einstellbar! 1=Funktionsheizen 1 = Function heating Funktionsheizen START DAYS START 1 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 TAGE]...

  • Page 28: Maintenance

    MAINTENANCE Maintenance Information for combustion controller/chimney sweep regarding emission monitor key All other control elements of the control unit are described in the operating instructions. The emission monitor key can also be used to change over to manual operating mode. Emission monitor key / Manual operation To protect under fl oor heating systems against invalid overheating during emis-...

  • Page 29: Safety Notices

    MAINTENANCE Safety notices Caution Danger of injury through sharp edges. Handle the cladding panels with care and avoid contact with sharp edges. Caution Danger of injury for unqualified person- nel. Servicing and Cleaning may only be car- ried out by qualified personnel or by Ho- val customer service personnel.

  • Page 30: Cleaning

    MAINTENANCE Cleaning Inadequate cleaning results not only in increased fuel consumption, but also shortens the service life of the boi- ler. The boiler must be cleaned by the chimney sweeper once a year. Switch off the main switch • Remove burner plug and and cut off the fuel supply. •...

  • Page 31: Overview Of Settings Table Of Parameters

    OVERVIEW OF SETTINGS Overview of settings Table of parameters Regulator Setting range / Designation Factory Setting values Type of device: DHW: Address: Surface operation Key : Heating curve HC OFF, 0,20 ..3,5 Heating curve MC1 OFF, 0,20 ..3,5 Heating curve MC2 OFF, 0,20 ..
  • Page 32 OVERVIEW OF SETTINGS Table for Time programs DHW circuit Time program P1 Time program P2 Time program P3 Cycle 1 Cycle 2 Cycle 3 Cycle 1 Cycle 2 Cycle 3 Cycle 1 Cycle 2 Cycle 3 from from from from from from from...
  • Page 33 OVERVIEW OF SETTINGS HYDRAULIC Par. Designation Factory Lev. Function allocation of the output DHW charging pump Function allocation of the output Mixer circuit 1 Function allocation of the output Mixer circuit 2 Function allocation of the output Direct circuit Pump Function allocation of the variable output 1 Function allocation of the variable output 2 OFF/ 4/ 43...
  • Page 34 OVERVIEW OF SETTINGS Par. Designation Factory Lev. DHW-NIGHT DHW - economy temperature 40/ 45 °C DHW-legionella protection-day 2:00 DHW-egionella protection-time 50/ 55/ 65/ DHW-legionella protection-temperature 70 °C DHW-temperature recording 50/ 55/ 65/ DHW-maximum temperature limit 70 °C DHW-mode of operation ON/ OFF DHW-tank discharge protection DHW-charging temperature excess...
  • Page 35 OVERVIEW OF SETTINGS MIX. VALVE-1 Par. Designation Factory Lev. Type of reduced operation ECO/ ABS MK= 1,10 Heating system (exponent) Room override (in connection with room sensor) Room factor 100 % Adaptation heating curve Switch-on optimisation Heating limit Room frost protection limit 10 °C Room thermostat function Outside temperature allocation...
  • Page 36 OVERVIEW OF SETTINGS MIX. VALVE-2 Par. Designation Factory Lev. Type of reduced operation ECO/ ABS MK= 1,10 Heating system (exponent) Room override (in connection with room sensor) Room factor 100 % Adaptation heating curve Switch-on optimisation Heating limit Room frost protection limit 10 °C Room thermostat function Outside temperature allocation...
  • Page 37 OVERVIEW OF SETTINGS HEAT GENER. Par. Designation Factory Lev. H-GEN model 1/ 2/ 5 OFF/ 3 Start-up protection H-GEN 5/ 48/ 65/ 75 Minimum temperature limit H-GEN °C 75/ 85 °C Maximum temperature limit H-GEN Mode of action minimum temperature limit H-GEN Sensor mode operation for H-GEN Minimum burner running time 2 min...
  • Page 38 OVERVIEW OF SETTINGS RETURN CONTR Par. Designation Factory Lev. Minimum limit return temperature / reference value return 38 °C temperature Switch-off difference Pump follow-on time 1 min SOLAR Par. Designation Factory Lev. 10 K Switch-on difference Switch-off difference Minimum running time SOP 3 min Solar collector maximum temperature 100 °C...
  • Page 39 OVERVIEW OF SETTINGS BUFFER Par. Designation Factory Lev. Minimum temperature 5/ 20 °C 95 °C Maximum temperature 8/ 10/ 12K Temperature elevation, H-GEN Switching difference 2/ 5/ 10K Forced discharge Skimming function switch-on difference 10 K Skimming function switch-off difference Start-up protection Discharge protection Buffer mode of operation...
  • Page 40 OVERVIEW OF SETTINGS SERVICE Par. Designation Factory Lev. Service 1 (Cleaning ST1 ) Suspend message «CLEANING ST-1» for X days Cleaning according to fi xed date Cleaning according to fi xed interval Cleaning according to cleaning counter Reset cleaning display 1 Service 2 (Cleaning ST2) Suspend message «CLEANING ST-2»...

  • Page 41: Fault Reporting Overview Toptronic ® T

    OVERVIEW OF SETTINGS FAULT REPORTING OVERVIEW TopTronic ® Status Designation Fault type Code Remark System External sensor Interruption 10-0 System External sensor Short-circuit 10-1 System Boiler sensor Interruption 11-0 System Boiler sensor Short-circuit 11-1 System Flow sensor 1 Interruption 12-0 MC1=off, YK1=no current System Flow sensor 1...
  • Page 42 Regulator with address 10 is System Activity 70-8 missing System Activity Data bus error 70-9 No Hoval regulator System HP return sensor Return min. temp. below setpoint 85-4 System HP return sensor Return max. temp. exceeded 85-5 Heat source min. temp. below...
  • Page 43 4 205 753 / 06...
  • Page 44 COPY FOR PLANT USER Confirmation The user (owner) of the system herewith confi rms that • he has received adequate instruction in the operating and maintenance of the installation, • received and taken note of the operating and maintenance instructions and, where applicable other documents con- cerning the heat generator and any further components.

This manual is also suitable for:

Compactgas 1000Compactgas 1400Compactgas 1800Compactgas 2200Compactgas 2800

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