Post on 06-Jun-2020
Subject to modifi cations | EN
Technical informationAssembly instructions
4 214 864 / 01 - 05/17
Hoval products must be installed and commissioned only by appropriately qualified experts. These instruc-tions are intended exclusively for the specialist. Elec-trical installations may only be carried out by a qualified electrician.
These instructions apply to the following types:Nominal output at 80/60 °C and natural gas42-CompactGas (700) 700 kW42-CompactGas (1000) 1000 kW42-CompactGas (1400) 1400 kW42-CompactGas (1800) 1800 kW42-CompactGas (2200) 2200 kW42-CompactGas (2800) 2800 kW42-CompactGas (3500) 3500 kW42-CompactGas (4200) 4200 kW
Hoval CompactGas (700-4200)for natural gas and liquid gas
The gas boiler series Compact is suitable and ap-proved for use as heat generator for water heating plants with permitted flow temperatures up to 110 °C1). They are designed for closed-circuit plants according to EN 12828.1) see section Technical data
1. Safety notices1.1 General safety instructions .................................................................................................................................................41.2 Explanation of the symbols ................................................................................................................................................41.2.1 Warnings ..........................................................................................................................................................................41.2.2 Symbols ............................................................................................................................................................................41.3 On delivery ...........................................................................................................................................................................51.4 Guarantee ............................................................................................................................................................................51.5 Instructions ..........................................................................................................................................................................51.6 Regulations, official approvals ...........................................................................................................................................51.6.1 Germany § ........................................................................................................................................................................51.6.2 Austria § ...........................................................................................................................................................................51.6.3 Switzerland § ....................................................................................................................................................................6
2. Assembly2.1 Installation, levelling ...........................................................................................................................................................72.2 Mounting the condensate drain ..........................................................................................................................................82.3 Mounting the thermal insulation .........................................................................................................................................82.4 Mounting the cladding and the boiler control ..................................................................................................................102.4.1 Boiler controller TopTronic® E ..........................................................................................................................................102.4.2 Boiler controller T0.2 / T2.2 .............................................................................................................................................102.5 Mounting the side shutters ...............................................................................................................................................122.5.1 Mounting the flexible side shutter (detail A,B,C) ..............................................................................................................122.5.2 Mounting the fixed side shutter (detail D) ........................................................................................................................12
3. Technical details3.1 Description of the boiler ...................................................................................................................................................133.2 Technical data ....................................................................................................................................................................143.3 Dimensions / Space required ............................................................................................................................................163.3.1 Dimensions .....................................................................................................................................................................163.3.2 Base size ........................................................................................................................................................................173.4 Flue gas and output diagrams ..........................................................................................................................................183.4.1 Flue gas - output diagram ...............................................................................................................................................183.4.2 Flue gas resistance .........................................................................................................................................................18
4. Installation4.1 Safety notices ....................................................................................................................................................................194.2 Requirements for boiler room ...........................................................................................................................................194.3 Flue gas connection, flue gas pipe, dimensions of flue gas pipe ...................................................................................194.4 Installing the burner ..........................................................................................................................................................214.5 Hydraulic connection ........................................................................................................................................................214.5.1 Pressure maintenance ....................................................................................................................................................214.5.2 Hydraulic connection .......................................................................................................................................................214.5.3 Hydraulic schematic ........................................................................................................................................................224.6 Gas connection ..................................................................................................................................................................224.7 Electrical connection .........................................................................................................................................................234.7.1 Safety measures relating to EMC-compliant assembly ....................................................................................................244.7.2 Recommended cable cross sections ...............................................................................................................................25
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TABLE OF CONTENTS
5. Commissioning5.1 Safety notices ....................................................................................................................................................................255.2 Charging with water ..........................................................................................................................................................255.3 Water quality ......................................................................................................................................................................265.3.1 Heating Water .................................................................................................................................................................265.3.2 Filling and replacement water .........................................................................................................................................265.4 Venting the gas pipes ........................................................................................................................................................275.5 Handing over the plant to the operator ............................................................................................................................275.6 Record - Activation of screed function .............................................................................................................................28
6. Maintenance6.1 Information for combustion controller/chimney sweep regarding emission monitor key .............................................306.2 Safety notices ....................................................................................................................................................................316.3 Venting ...............................................................................................................................................................................316.4 Replenishing water ............................................................................................................................................................316.5 Cleaning .............................................................................................................................................................................32
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TABLE OF CONTENTS
1. Safety notices1.1 General safety instructions
The system may only be placed in operation if all the relevant standards and safety regula-tions have been complied with.
At least the following conditions must be satisfied for a trial operation: - Safety valve installed (system sealed) - Control in operation (connected to the mains current supply system)
- Sensor for safety temperature limiter connected (= boiler temperature sensor)
- System filled with water - Expansion vessel connected - Flue gas connectors connected to the flue gas pipeline at the chimney or flue.
- Burner preset.
WARNINGThe heat generator can only be de-energised by disconnection from the mains (e.g. all-pole switch).
WARNINGAll electric power supply circuits must be switched off before accessing the terminals.
1.2 Explanation of the symbols1.2.1 Warnings
!
DANGER... indicates a situation of immediate danger which will lead to serious or fatal injuries if not avoided.
!WARNING... indicates a situation of possible danger which can lead to serious or fatal injuries if not avoided.
!CAUTION... indicates a situation of possible danger which can lead to minor or slight injuries if not avoided.
NOTICE... indicates a situation of possible danger which can lead to damage to property if not avoided.
1.2.2 Symbols
!General warning of a danger zone.
«Warning: dangerous electrical voltage» as a warning for accident prevention.Ensures that people do not come into contact with electrical voltage. The danger sign with the black lighting symbol warns against the danger of electrical voltage.
Warning of cutting injuries:Avoid cutting injuries. Clearly indicate the dan-ger of cutting on sharp-edged parts to avoid serious and costly injuries.
Incorrect handling of potentially explosive substances can lead to serious damage, po-tentially fatal injuries and incalculable costs.
Description of an activity instruction.
Information:Provides important information.
§Provides important information. Refers to stand ards and directives.
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IMPORTANT INFORMATION
1.3 On deliveryCarrreceiving the boiler.y out a visual inspection imme-diately on. If any damage is found, take the necessary steps as defined in the delivery contract. The respective risk carrier bears the cost of repairs.
1.4 GuaranteeThe warranty does not cover defects attributable to:• Failure to comply with these instructions• Failure to comply with the operating instructions• Incorrect installation• Impermissible modifications• Incorrect handling• Contaminated operating materials (gas, water, com-
bustion air)• Corrosion by halogen compounds (e.g. paints, adhe-
sives, solvents)• Unsuitable chemical additives to the heating water• Damage caused by the application of force• Corrosion by halogen compounds (e.g. paints, adhe-
sives, solvents)• Corrosion caused by not observing the required water
quality
1.5 InstructionsAll instructions relevant to your system can be found in the Hoval system manual! In exceptional cases, the in-structions can be found with the components!
Further sources of information:• Hoval catalogue• Standards, regulations
1.6 Regulations, official approvalsThe standards and directives stated under points 1.6.1 to 1.6.3 must be taken into account during installation and operation of the system.
1.6.1 Germany § - DIN EN 12831 Heating systems in buildings – proce-dure for calculating the standard heating load.
- DIN EN 13384 Exhaust gas systems – thermal and fluid dynamic calculation methods.
- DIN EN 12828 Heating systems in buildings - planning of hot water systems.
- DIN 4756 Gas-fired systems: design, construction and technical safety requirements, planning and execution (for operation with gas burners).
- DIN 18160 House chimneys, requirements, planning and execution.
- TRD 702 Steam boiler plants with calorifiers of the group II.
- TRD 721 Safety equipment to safeguard against ex-cess pressures / safety valves / for group II steam boil-ers.
- VDI 2035 Prevention of damage by corrosion and the formation of scale in hot water systems.
- DIN 57 116 / VDI 0116 Electrical equipment for firing systems.
- (VDE regulation). - For further standards applying to Germany see attach-ment N-430 020.
1.6.2 Austria § - ÖNORM 12831 Heating installations in buildings – pro-cedure for calculating the standard heating load
- ÖNORM 13384 Exhaust gas systems – procedure for heat and technical gasflow calculations.
- ÖNORM 12828 Heating systems in buildings: planning of hot water heating systems.
- ÖNORM B 8130 Open hot water, systems, safety in-stallations.
- ÖNORM B 8131 Closed-circuit hot water systems, safety, construction and testing regulations.
- ÖNORM B 8133 Water heating systems, technical safety requirements.
- ÖNORM B 8136 Heating systems, space requirements and other building requirements.
- ÖNORM M 7515 Calculation of chimney dimen-sions; definition of expressions, calculation proce-dures.
- ÖNORM H 5171 Heating systems – technical building requirements.
- ÖVGW TR gas
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IMPORTANT INFORMATION
1.6.3 Switzerland § - SN EN 12831 Heating installations in buildings – proce-dure for calculating the standard heating load.
- SN EN 13384 Exhaust gas systems – procedure for heat and technical gasflow calculations.
- SN EN 12828 Heating systems in buildings: planning of hot water heating systems.
- VKF-Association of Cantonal Fire Insurers. - Regulations of the fire police. - SVGW Schweiz. Swiss Gas and Water Federation. - SNV 27 10 20 Aeration and ventilation of the boiler room.
- SWKI 88-4 Water treatment for heating, steam and air-conditioning plant.
- SWKI 80-2 Technical safety regulations for heating in-stallations.
- KRW Corrosion caused by halides. - KRW/VSO/FKR Electrical connections on heating boil-ers and burners ready to plug in.
- FCOS - Guidelines for liquid gaz, part 2
and further regulations and standards issued by CEN, CEN ELEC, DIN, VDE, DVGW, TRD and government authorities. The regulations issued by local buildings au-thorities, insurers and chimney sweeps must also be ob-served. Where gas is used as a fuel the regulations of the local gas supplier must be observed. An official licence may be needed.
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IMPORTANT INFORMATION
2. Assembly2.1 Installation, levellingNo special foundation plate is required for installing the boiler (sufficient supporting capacity for the boiler must be guaranteed); see section Technical data for opera-tional weight.
In the case of boiler installation in the domestic domain, vibration absorbers are to be mounted under the boiler plinth rails.
Space requiredfor 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 first be completely thermally insulated and cased before being placed into the installation position designated.
LevellingThe upper edge of the boiler water jacket (boiler longitu-dinal axis) must be levelled by means of a spirit level until it is aligned exactly horizontally.
Mount the door liner (door cladding) before in-stalling the burner (for heating trials, with the boiler not yet thermally insulated).
Delivery from factory-boiler door opens to the rightHowever 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.
NOTICEBoiler door hinges may only be changed over by Hoval Service!
The boiler door must be closed when changing over the hinges - procedure:1. For types 1800, 2200, 2800, 3500, 4200 only:
Dismantle support for door positioning (5, Fig. 02).2. Tighten the top and bottom lock nuts (1, Fig. 01) to-
wards the swing-out flange (manually).3. Mount flange nuts (2, Fig. 01) with the hole diago-
nally on the new opening side, i.e., - change over the bottom left and top right flange nut and - change over the top left and bottom right flange nut.
4. Open boiler door after removing flange nuts (2, Fig. 02) and turn back locknuts (3, Fig. 02) approx. 1-2cm. As a result, the boiler door is pressed against the sealing gasket without hindrance.
5. Mount the burner plug connector on the other side. The cable must not contact any hot parts.
6. Mount door rabbet (4, Fig. 02) on the other side and adjust it (angle of door opening 90°).
312
Fig. 01
Figure shows situation after transformation(boiler door opens to the left)
23
Fig. 02
4
5
Position mechanical jack
8
Figure shows situation as delivered(boiler door opens to the right)
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ASSEMBLY
2.2 Mounting the condensate drainThe consensate drain is to be mounted according to (Fig. 03, Fig. 04).
!CAUTIONTo achieve a siphon effect, the condensate drain hose must be routed as shown in the drawing - fill the hose with water before com-missioning!
Fig. 03
Fig. 04
7. For types 1800, 2200, 2800, 3500, 4200:Remount support for door positioning (5, Fig. 01) on the other side, readjust if necessary resp. level boiler door first!
After changing over the hinges it might be necessary to align (level) the boiler door! (Hanging boiler door)Procedure:8. Open boiler door approx. 10 cm. 9. Raise boiler door (20-30 mm) by means of a mechan-
ical jack (or jack) by slightly loosening flange nuts (8, Fig. 02).
NOTICEDo not loosen flange nuts entirely nor remove them as the boiler door might fall down.
10. After leveling the boiler door, retighten flange nuts (8, Fig. 02) securely.
2.3 Mounting the thermal insulation1. Wrap the insulating mats (1,1a, Fig. 06) around the
boiler body. The insulating mat (1a, Fig. 06) has to be applied in such a way that the large recess (1b, Fig. 06) is located at the back.
2. Fix the insulating mats (1/1a, Fig. 06) with plastic straps (2, Fig. 06) and strap fasteners (2a, Fig. 06): - Tension springs (2b, Fig. 06) serve for additional fixing - 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 flue gas collector ring and fix it below with retaining discs (Fig. 05).
5. Wrap the insulating mat (5, Fig. 06) around the flue gas collector and fix it using retaining discs (Fig. 05).
6. Place insulating mats (6,7,8, Fig. 06) on the boiler front and fix them with retaining discs (Fig. 05).
Fig. 05
NoticeThe 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 fixed with the mounting of the cladding (see Fig. 06).
CAUTIONDanger of injury through sharp edges.Handle the cladding panels with care and avoid contact with sharp edges.
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ASSEMBLY
3
2a1
1b
2
2a2b
5
7
86
4
Fig. 06
1a
8a
Insu
latin
g m
at m
ay b
e pa
rtitio
ned
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ASSEMBLY
2.4 Mounting the cladding and the boiler control
1. Fix bolts (20, Fig. 10) (Compact Gas (1800-2800): incl. distance spacers) at the boiler door using hex-agonal nuts and U-washers, then insert insulating mat (20a, Fig. 10) into boiler door cladding (20b, Fig. 10) and mount onto boiler door (Compact Gas (1800-2800): 2 parts boiler door claddings - mount inferior first).
2. Integrate burner plug (21, Fig. 10) into the left (resp. right) side panel and lead burner cable upwards (ca-ble routing according to Image Fig. 10). Insert right and left side panels (22, Fig. 10) into retaining bracket (32, Fig. 10), attach 1 C-Clip each (29, Fig. 10) to the front of the side panels. Route the condensate drain hose through the side wall. (35, Fig. 10).
3. Insert rear panels (23, Fig. 10) into folded edges (22, Fig. 10) (Compact Gas (2800): 6 pieces) of side wall.
4. Insert 2 insulating mats (24, Fig. 10) left and right in longitudinal direction (to prevent vertical air circulation).
2.4.1 Boiler controller TopTronic® E5. Mount the special screws with nuts (14, Fig. 07) on the
side panel. Then hook the boiler controller (12, Fig. 07) into the side wall with the recesses for the special screws and secure it with 4 self-tapping screws ø 3.5 x 6.5 and serrated washers (12b).
12a
12b
12
13a
12c
12c
Fig. 07
6. Pull the capillaries with the immersion sensors (15, Fig. 09) through the opening (13a, Fig. 07) in the side panel, insert them into the immersion sleeve (15a, Fig. 09) as far as the stop and fix in position with retaining spring (15c, Fig. 09).
7. Plug in the burner plug.
NOTICEThe capillaries must not be folded or kinked!
8. Close the boiler controller and screw on (12c, Fig. 07),
continue with fitting the casing.
2.4.2 Boiler controller T0.2 / T2.2
12
12b12d
14
13a
Fig. 08
9. Mount the special screws with nuts (14, Fig. 08) on the side panel. Then hook the boiler control (12, Fig. 08) onto the special screws and secure using self-tapping screws ø 3.5 x 6.5 and serrated lock washers (12b, Fig. 08).
10. Pull the capillaries with the immersion sensors (15, Fig. 09) through the opening (13a, Fig. 08) in the side panel, insert them into the immersion sleeve (15a, Fig. 09) as far as the stop and fix in position with retaining spring (15c, Fig. 09).
11. Plug in the burner plug.
NOTICEThe capillaries must not be folded or kinked!
12. Attach cover plate to the boiler controller (12d, Fig. 08) with self-tapping screws ø 3.5 x 6.5 and serrated lock washers.
continue with fitting the casing.
13. Bring burner connector plug to the control box and plug in (21, Fig. 10).
14. Place walkable cover in proper sequence 26, 27, 28 on the bracket (32, Fig. 10), fix front cover (30, Fig. 10) using 2 self-tapping screws (31, Fig. 10 Ø 4,8 x 50 and level with height-adjustable elbow (34, Fig. 10).
15. Affix rating plate and retainer for handbook (33, Fig. 10) to the side.
16. Mounting the side shutter see Fig. 11.
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ASSEMBLY
4214
864_
B02
15.1
0.20
15 /
SJU
L
A
21
30
26
27
28
25
22
23
23
24 20a
20b
22
22
31
33
2932
12
2031
14
34
15c 15
15a
35
Com
pact
Gas
(180
0-28
00)
cuta
way
vie
w
Fig.
09
Fig.
10
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ASSEMBLY
2.5 Mounting the side shuttersThe 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 flexible.
2.5.1 Mounting the flexible side shutter (detail A,B,C)
1. Mount hinges (40, Fig. 11) on top and bottom of front side wall using self-tapping screws Ø 3,5 x 9,5.
2. Mount side shutter (41, Fig. 11) on right half of hinge using 2 pieces of cross-head screws (42, Fig. 11) and distance spacers (44, Fig. 11), use 1 piece each for top and bottom (detail A,B). Secure against extraction using two hexagonal locknuts (41a, Fig. 11). - ! Do no clamp the hinge!
3. Mount magnets (46, Fig. 11) on top and bottom hole of side ends (41, Fig. 11) using hexagonal nut M10 (47, Fig. 11), U-washer (48, Fig. 11) and hexagonal screw M4 x 10 (49, Fig. 11) (detail C).
2.5.2 Mounting the fixed side shutter (detail D)4. Open boiler door, mount hinges (40, Fig. 11) on
top and bottom of front side wall using self-tapping screws Ø 3,5 x 9,5.
5. Mount side shutter (41, Fig. 11) according to figure on top and bottom using 4 pieces of cross-head screws (42,43, Fig. 11) and distance spacers (44, Fig. 11).
Fig. 11 45
49484746
C
4243
4041
D
44
44
45° inclineboiler side
42
44
A
40
B
40
41
42
44
41a
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ASSEMBLY
3. Technical details3.1 Description of the boilerThe 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
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TECHNICAL INFORMATION
3.2 Technical dataType (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 efficiency at full load at 80/60 °C
(net calorific value/gross calorific 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
• Efficiency at partial load 30 % (EN 303)(net calorific value/gross calorific 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 efficiency 75/60 °C (according to DIN 4702 part 8)(net calorific value/gross calorific value) % 97.4/87.7 97.4/87.8 97.1/87.5 97.5/87.9 97.5/87.9 97.5/87.9
• Stand-by loss at 70 °C Watt 850 1000 1200 1350 1550 1800• Flue gas temperature at nominal output at 80/60 °C °C 94 101 102 99 93 92• Maximum chimney draught Pa 20 20 20 20 20 20• Flue gas resistance at nominal output
10.5 % CO2 natural gas500 m over sea level (Tolerance ± 20 %) mbar 4.9 4.8 4.7 5.7 6.5 7.2
• Flue gas mass flow at nominal output10.5 % CO2 natural gas kg/h 1133 1623 2271 2923 3571 4546
• Flow resistance boiler 3 z-value 0.012 0.012 0.003 0.003 0.003 0.002• Water flow resistance at 20 K mbar 10.8 22.0 10.8 17.9 26.7 28.8• Water flow 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
1 Limited by the boiler control T2.2 to 90 °C resp. U3.2 and T0.2 to 105 °C.2 Maximum safety temperature for boiler control T2.2: 110 °C resp. U3.2 and T0.2: 120 °C.3 Flow resistance boiler in mbar = volume flow (m3/h)2 x z
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TECHNICAL INFORMATION
Type (3500) (4200)• Nominal output at 80/60 °C kW 3500 4200• Range of output at 80/60 °C kW 1050-3500 1260-4200• Burner input maximum kW 3626 4 4351 4
• Maximum working temperature 1 °C 105 105• Minimum working temperature °C 75 75• Minimum boiler return temperature °C 35 35• Safety temperature limiter setting (water side) 2 °C 120 120• Working/test pressure bar 10/16 10/16• Boiler efficiency at full load at 80/60 °C
(net calorific value/gross calorific value) % 96/86,5 4 96/86,5 4
• Efficiency at partial load 30 % (EN 303)(net calorific value/gross calorific value) % 97/87,3 4 97/87,3 4
• Standard efficiency 75/60 °C (according to DIN 4702 part 8)(net calorific value/gross calorific value) % 97/87,4 4 97/87,4 4
• Stand-by loss at 70 °C Watt 2180 4 2290 4
• Flue gas temperature at nominal output at 80/60 °C °C 93 4 94 4
• Maximum chimney draught Pa 20 20• Flue gas resistance at nominal output
10.5 % CO2 natural gas500 m over sea level (Tolerance ± 20 %) mbar 7,9 4 8,5 4
• Flue gas mass flow at nominal output10.5 % CO2 natural gas kg/h 5665 4 6798 4
• Flow resistance boiler 3 z-value 0,002 4 0,002 4
• Water flow resistance at 20 K mbar 32 4 33,8 4
• Water flow volume at 20 K m³/h 150 4 180,6 4
• Boiler water content litres 3553 4 3628 4
• Insulation thickness boiler body mm 80 80• Weight (incl. casing) 6 bar kg 7980 4 8200 4
• Weight (without casing) 6 bar kg 7580 4 7800 4
• Heating surface m² 178,33 217,21• Combustion chamber dimension
Ø inside x length mm 1050/2998 1050/3308• Combustion chamber volume m³ 2,596 2,88• Dimensions see Dimensions
1 Limited by the boiler control T2.2 to 90 °C resp. U3.2 and T0.2 to 105 °C.2 Maximum safety temperature for boiler control T2.2: 110 °C resp. U3.2 and T0.2: 120 °C.3 Flow resistance boiler in mbar = volume flow (m3/h)2 x z4 The values have been calculated resp. interpolated. They must be verified by means of tests.
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TECHNICAL INFORMATION
3.3 Dimensions / Space required3.3.1 Dimensions(all dimensions in mm)
Type a b c d e f g h i k (inside)(700) 1100 1150 1175 591 250 290 330 4xM12 15˚/45˚ 303(1000) 1280 1330 1384 710 310 350 400 6xM12 15˚ 353(1400) 1480 1530 1584 810 330 400 450 6xM16 15˚ 403(1800) 1580 1630 1684 860 360 400 450 6xM16 15˚ 453(2200) 1580 1630 1684 860 360 400 450 6xM16 15˚ 453(2800) 1680 1730 1784 910 360 400 450 6xM16 15˚ 503(3500) 1850 1928 1995 1018 360 400 450 6xM16 15˚ 553(4200) 1850 1928 1995 1018 360 400 450 6xM16 15˚ 603
Type l * m n o p q r s t u v w(700) 1436 2229 240 1930 389 1110 170 1271 96 1406 420 31(1000) 1646 2430 240 2130 438 1210 170 1487 103 1564 500 31(1400) 1886 2600 240 2300 438 1350 170 1708 124 1780 550 31(1800) 2038 2790 257 2438 438 1350 187 1808 124 1884 600 48(2200) 2038 3529 257 3213 438 2125 187 1808 124 2659 600 48(2800) 2188 3745 257 3430 638 2100 187 1908 124 2799 600 48(3500) 2398 3905 337 3510 668 2123 236 2121 126 3141 600x600 65(4200) 2398 4205 337 3810 668 2423 236 2121 126 3441 600x600 65
* with Condensate trap: + 155 mm A condesate trap must imperatively be mounted!
1 Flow(700) DN 125, PN6(1000) DN 125, PN6 (1400) DN 150, PN6 (1800) DN 150, PN6 (2200) DN 150, PN6 (2800) DN 200, PN 10(3500) DN 200, PN 10(4200) DN 200, PN 10
2 Return(700) DN 125, PN6(1000) DN 125, PN6 (1400) DN 150, PN6 (1800) DN 150, PN6 (2200) DN 150, PN6 (2800) DN 200, PN10(3500) DN 200, PN10(4200) DN 200, PN10
3 Flue gas outlet4 Draining R 1½″5 Condensate drain D31/25 mm
(on both sides)6 Electrical connection (on both sides)7 Control panel
(optionally on the left or right hand side)8 Sleeve Rp ¾″ with immersion pocket for boiler temperature sensor
Tilting out of the boiler doorboiler door opens to the right or left(dimensions in mm)
CompactGasType a b(700) 875 120(1000) 1052 120(1400) 1252 120(1800) 1337 120(2200) 1337 120(2800) 1435 120(3500) 1700 160(4200) 1700 160
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TECHNICAL INFORMATION
3.3.2 Base sizeDimensions without insulation and casing Boiler incl. boiler door, outlet without flue gas collector(dimensions in mm)
Type a b * c d e f g h i k (inside)
(700) 1100 1436 1153 590 250 290 330 6xM12 15˚ 303(1000) 1280 1646 1363 710 310 350 400 6xM12 15˚ 353(1400) 1480 1886 1563 810 330 400 450 6xM16 15˚ 403(1800) 1580 2038 1663 860 330 400 450 6xM16 15˚ 453(2200) 1580 2038 1663 860 330 400 450 6xM16 15˚ 453(2800) 1680 2188 1763 910 330 400 450 6xM16 15˚ 503(3500) 1850 2398 1995 1018 360 400 450 6xM16 15˚ 553(4200) 1850 2398 1995 1018 360 400 450 6xM16 15˚ 603
Type l m n o p q r s t DN
(700) 80 2212 209 1930 389 1110 84,5 1271 180 125(1000) 80 2423 209 2130 438 1210 96 1487 180 125(1400) 80 2593 209 2300 438 1350 112 1708 200 150(1800) 80 2731 209 2438 438 1350 112 1808 200 150(2200) 80 3506 209 3213 438 2125 112 1808 200 150(2800) 80 3723 209 3430 638 2100 112 1908 200 200(3500) 80 3820 315 3450 668 2123 135 2121 200 200(4200) 80 4111 315 3760 668 2423 135 2121 200 200
Combustion chamber dimensions
Typ A B C D E
(700) 219 1644 1835 584 189(1000) 219 1748 1985 684 189(1400) 219 1896 2180 830 189(1800) 219 1998 2301 830 189(2200) 219 2773 3076 830 189(2800) 219 2968 3288 922 189(3500) 280 3000 3337 1050 256(4200) 280 3300 3637 1050 256
Fig. 13
Fig. 14
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TECHNICAL INFORMATION
3.4 Flue gas and output diagrams3.4.1 Flue gas - output diagram
3.4.2 Flue gas resistance
kW = Boiler output°C = Flue gas temperature on clean surface, boiler flow temperature 80°C, return temperature 60°C (in accordance with DIN 4702).
• Operated with natural gas H, λ = 1,15 with max. bruner output• (CO2 natural gas H = 10,5 %)• A reduction of the boiler water temperature of -10 K
causes a reduction of the flue gas temperature of approx. 6-8 K.• A modification of lambda λ of ± 0,09
causes a modification of the flue gas temperature of ± 8 K.
Flue
gas
tem
pera
ture
(°C
)
Nominal output (kW)
70
75
80
85
90
95
100
105
200 400 600 800 1'000 1'200 1'400 1'600 1'800 2'000 2'200 2'400 2'600 2'800 3'000 3'200 3'400 3'600 3'800 4'000 4'200
700
10001400
1800 2200
2800
35004200
Values calculated without liability!
Boiler output (kW)
Flue
gas
resi
stan
ce (m
bar)
0.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 2600 2800 3000 3200 3400 3600 3800 4000 4200
700 1000 1400
1800
22002800
3500
4200
Values calculated without liability!
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TECHNICAL INFORMATION
4. Installation4.1 Safety notices
CAUTIONDanger of injury through sharp edges. Handle the cladding panels with care and avoid contact with sharp edges.
4.2 Requirements for boiler room
§• Observe the local and national building reg-
ulations regarding boiler rooms.• Observe the local and national regulations
regarding ventilation and deaeration of boil-er rooms.
• Do not set up in very dusty rooms. If neces-sary, use an external combustion air supply and/or filter for the supply air.
• Gas boilers may not be installed in rooms which may contain halogen compounds which may combine with the combus-tion air (e.g. laundry rooms, drying rooms, workshops, hairdressing salon). Halogen compounds may occur in, amongst oth-ers, cleaning, de-greasing and solvent sub-stances, adhesives and bleaching agents.
Always make sure that there is an adequate supply of fresh air to the boiler room, to ensure that the combustion air supply necessary for all the firing systems operated can flow in without hindrance and that no oxygen defi-ciency occurs for the operating personnel.
The binding values for the size of intake air apertures are not usually stated in the relevant regulations, it is laid down only that the partial vacuum in the boiler room must not exceed 3 N/m2. To comply with this requirement, an air supply cross section of 500 cm2 is 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 flue air aperture. This must have a minimum cross sec-tion of 180 cm2 up to a nominal heat output of 100 kW. The cross section is to be increased by 1 cm2 for each additionnal kW.
4.3 Flue gas connection, flue gas pipe, dimensions of flue gas pipe
To guarantee economic and fault-free operation, boiler and chimney must be mutually adapted to create a func-tional unit.
NOTICEMoisture-resistant and acid-proof chimneys must be used for the CompactGas.
Renovation, respectively chimney cross section adjust-ment may be necessary with existing chimney installa-tions, according to the instructions of a chimney specialist.
The function of the chimney, i.e. the production of the necessary delivery pressure is basically dependent on:
a) he type (nature) of the chimney (thermal insu-lation, interior surface roughness, sealing etc),
b) the connection of the boiler to the chimney according to specification,
c) the correct chimney cross section dimensioning.
§The national regulations must be observed.
194 214 864 / 01
INSTALLATION
If the integration of a transition element from the boiler flue gas outlet to the chimney inlet is necessary, it should be executed as a slender cone.
vomKessel
zumSchornsteinto the chimney
from theboiler
Fig. 16
ref. c)Dimensioning of chimney cross section. The cross sec-tions are to be calculated for boilers without delivery pres-sure demand according to EN 13384. Take into account the local, special situation (position of the house on a slope, chimney position, roof pitch, shape of the chimney mouth etc.)!In Switzerland, take note of SIA recommendation 384/4!In Austria the calculation is carried out according to ÖNORM M 7515.
The values for calculation can be obtained from the table in section Technical data.
ref. a)Chimneys according to EN 13384, part 1/2, execution types I and II are appropriate for modern firing systems (advice from the chimney specialist is necessary). Pay attention to the flue gas temperature at nominal output, see section Technical data.
ref. b)
NOTICEThe condensate accumulating in the flue gas pipe must not flow back to the boiler. A con-den sate trap (Fig. 15) must therefore be in-stal led at the flue gas outlet (not included in the scope of delivery).
condensate trap
condensate trap
Fig. 15
NOTICENormally only one heat generator may be connected to the chimney!
20 4 214 864 / 01
INSTALLATION
4.4 Installing the burner• Burner installation dimensions may be obtained from
point 3.3.2.• The burner is mounted on the boiler door by means
of the seal and screws. On installing, comply with the guidelines 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.
NOTICEWith gas burners, the burner housing weight is to be directly supported by a strut to the floor.
NOTICEBoiler sight glass cooling:A cooling line must be routed from the burner to the sight glass (Fig. 17), in order to cool the boiler sight glass and keep it clean. Either a hose or a copper pipe can be used.
Fig. 17
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 flue gas pipe.
4.5 Hydraulic connectionIn 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-specifically according to DIN EN 12828.In Germany, a low water protection must be provided.
4.5.1 Pressure maintenanceA pressure expansion tank sized appropriately for the heating plant, water volume and head has to be installed on site.
4.5.2 Hydraulic connectionThe minimum return temperature has to be ensured by constant return flow control. A minimum water circulation is not necessary.
i seiD s e t innu alre etbu r W e !g
eheG S n i enie e ncS rh üruz tti redo kc
csöl neh eiS seid sehS epa !
Sie ah be id n egöM khcil e tie in
uen hS se uz epahen m ne !!!
oh vohv ohla ohlav avohl ohlav hlav o hlav ohlav o hlav o av avohl l
oh ohlav ohlav hlav ohlav o hlav o avhlav o lav
oh ohlav av
moC p Gtca as
FLR
P
KY R
UZ P
Fig. 18
214 214 864 / 01
INSTALLATION
4.5.3 Hydraulic schematic
• The examples stated below are principle schematics which do not contain all the de-tails for installation. The installation must be done according to the local conditions, di-mensioning and regulations.
• For underfloor heating, a flow temperature monitor must be built in.
• Shut-off devices to the safety valve (pres-sure expansion tank, safety valve, etc.) are to safe against unintended closing!
Example CompactGas (700-2800)Gas boiler with
- Free-standing calorifier - Wall distributor with 3 heating circuits
NOTICEThe minimum boiler temperature of 75 °C as well as the minimum return temperature of 35 °C must never fall below the stated val-ue in any of the operating status given (see technical data).
4.6 Gas connection
DANGERDanger of explosion if there are leaks in the gas fittings.After installing the boiler, check all gas pipes and fittings for leaks.
• For gas connection see diagrams in section 3.3.1.• Lead the gas connection straight towards the rear!• After installation check for leaks.
TTE-WEZ TopTronic® E basic module heat generator (installed)VF1 Flow temperature sensor 1B1.1 Flow temperature limit thermostat (if required)MK1 Pump mixer circuit 1YK1 Actuator mixer 1YKR Actuator, return mixerAF Outdoor sensorSF Calorifier sensorRLF Return sensorDKP Pump for heating circuit without mixerSLP Calorifier loading pumpKKP Boiler circuit pump
OptionalRBM TopTronic® E room control moduleTTE-GW TopTronic® E Gateway
TTE-FE HK TopTronic® E module expansion heating circuitVF2 Flow temperature sensor 2B1.2 Flow temperature limit thermostat (if required)MK2 Pump mixer circuit 2YK2 Actuator mixer 2
22 4 214 864 / 01
INSTALLATION
4.7 Electrical connectionA qualified technician must install the electri-cal supply to the equipment.The connection diagram is located in the elec-trical box of the heat generator; the circuit dia-gram is supplied separately.
WARNINGThe heat generator can only be de-energised by disconnection from the mains (e.g. all-pole switch).
WARNINGAll electric power supply circuits must be switched off before accessing the terminals.
Cables to be connected may be lead laterally along the boiler into a cable channel forward towards the control box. A removable, narrow covering is located on the con-trol box. The cables may be lead through the cover open-ing into the control box.
Important!A main switch must be installed on-site in the supply line which performs an all-poles cut-out and has a clearance of at least 3 mm between the open contacts.
For Switzerland:The plant specific electrical plan must be followed when making the electrical connection, if one is available!
Open electrical box fully:Remove wing nut and loosen holding cord
Cable feed-in is at the bottom
Folding out the electrical box (Opening angle 55°):Remove the screws (left and right)
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INSTALLATION
4.7.1 Safety measures relating to EMC-compliant assembly
24 4 214 864 / 01
INSTALLATION
• Cables carrying mains voltage must be routed sepa-rately from sensor or data bus cables. A minimum di-stance of 2 cm between the cables must be observed. Cable crossovers are permitted.
15 cm
Netz 230 V
2 cm
Datenbusleitung 12 V
Mains 230V
Data bus line 12 V
• In the case of controller modules with their own mains supply, it is imperative that cables carrying mains vol-tage are routed separately from sensor or data bus cables. If cable ducts are used, these must be provided with separator strips.
• When mounting controller modules or room control mo-dules, maintain a minimum clearance of 40 cm from other electrical devices with electromagnetic emissi-ons, such as power contactors, motors, transformers, dimmers, microwave ovens and TV sets, loudspeakers, computers, mobile phones, etc.
40 cm
• Avoid unnecessary cable lengths, including in spare cables• Coils of relays, contactors and other inductors in the pa-
nel, and possibly in the vicinity, must be connected. The connection can be made with RC elements, for example.
• Measures must be taken in the building and on electri-cal equipment to protect the units against overvoltage caused by lightning strikes.
• The mains connection for the heating system must be designed as an independent electrical circuit. Neither fl uorescent lamps nor any other equipment which might cause interference may be connected, nor may it be possible to connect such equipment.
Wärmeerzeuger
Heizraumbeleuchtung und Steckdosen auf getrenntem Stromkreis anschliessen
Sicherung
Heizraum-Notschalter
Fuse
Boiler room emergency switch
Boiler room lighting and power sockets must be in a separate circuit
• Equipotential bonding must be established between the individual control components, control panels and the heating system.
• Shielded cables must be used for the data lines.Recommended versions: J-Y(ST)Y 2 x 2 x 0.6 mm
• Shields of data lines, analogue signal cables and power cables must be connected to earth over a large area with a highly conductive connection. The cable shields must be connected to a shield bar directly after the ent-ry of the cable into the panel.
• Multiple earthing of a cable is not permitted (ripple pickup).
Hier nicht erden!
Basis-/ReglerModul mit BedienModul
Do not earth here!
Basic/controller module with control module
In the case of star-shaped data bus networks, double earthing is not permitted. The earthing must be carried out on one side at the star point.
PE
L
H
+
Abschirmung
4-Draht-Bus
PEShielding
4-wire bus
• The outdoor sensor must not be mounted in the vicini-ty of transmitters and receivers (on garage walls near receivers for garage door openers, amateur radio an-tennae, radio alarm installations or in the immediate vicinity of large transmitters, etc.).
To ensure correct electrical installation, unit connec-tion and equipotential bonding (energy supply com-pany and building installation), all applicable laws, regulations and standards must be complied with; in particular, the regulations of the responsible energy supply company. This work must be performed by qualifi ed electricians.
4.7.2 Recommended cable cross sections
Line type Cross-section LengthElectrical power supply of the heat generator (230 V)
min. 2.5 mm2 with 16A fuse
unlimited m
Electrical power supply of the heat generator (400 V)
min. 1.0 mm2 with 10A fuse
unlimited m
Cables carrying mains supply voltages from actuators
min. 1.0 mm2 unlimited m
Cables carrying lowvoltage (sensors)
min. 0.5 mm2 max. 50 m
Data bus lines (shielded) 2x2x0.6 mm2 max. 100 m
5. Commissioning
NOTICEAfter filling the plant, thoroughly vent the sys-tem and check the water side for leaks.
NOTICEDuring the first commissioning of the plant the correct functioning of all safety and con-trol devices must be verified.The operator must be thoroughly instructed on the operation and servicing of the plant. Where the supply may be expected to con-tain large quantities of dust (e.g. building site) the combustion air must be filtered.
!CAUTIONBefore the boiler is commissioned, the con-densate drain hose must be filled with water!
NOTICEIt is very important that gas flow pressure is controlled and the CO2 value is correctly set.
5.1 Safety notices
!
CAUTIONRisk of injury for non-expert personnel.Initial start-up, maintenance and cleaning work are only allowed to be performed by trained specialist personnel or by Hoval cus-tomer service.
Damage to the system by filling unauthorised liquids.The filled water must be of drinking water quality (See point 5.3).
5.2 Charging with waterOnly authorised persons may charge the plant with water for operation.
§The European Standard EN 14868 and the Directive VDI 2035 must be observed (see point 6.3).
• Open stop valves in flow and return flow circuits.
• Connect hose to filling valve.• Slowly fill the plant with water.• Monitor the water level via the manometer.
Use only chemical additives which have been confirmed to be suitable by the chemical sup-plier.Antifreeze may only be added to a maximum of 25 % and at least to the extent specified by the manufacturer. The antifreeze and anti-corrosion concentra-tion must be checked at least once per year.When replenishing antifreeze or anti-corro-sion agents the same product should be used.When changing over to operation without anti-freeze or anti-corrosion agents the plant must be thoroughly flushed several times before being refilled.
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COMMISSIONING
5.3 Water quality
26 4 214 864 / 01
COMMISSIONING
Heating Water
§The European Standard EN 14868 and the di-rective VDI 2035 must be observed.
In particular, attention must be paid to the following stipu-lations:• Hoval boilers and calorifi ers are designed for heating
plants without signifi cant oxygen intake (plant type I ac-cording to EN 14868).
• Plants with - continuous oxygen intake (e.g. underfloor heating systems without diffusion proof plastic piping) or
- intermittent oxygen intake (e.g. where frequent refill-ing is necessary)
must be equipped with separate circuits.
• Treated fi lling and replacement water must be tested at least 1x yearly. According to the inhibitor manufacturer‘s instructions, more frequent testing may be necessary.
• A refi lling is not necessary if the quality of the heating water in existing installations (e.g. exchange of boiler) conforms to VDI 2035.The Directive VDI 2035 applies equally to the replace-ment water.
• New and if applicable existing installations need to be adequately cleaned and fl ushed befor being fi lled. The boiler may only be fi lled after the heating system has been fl ushed!
• Parts of the boiler which have con tact with water are made of ferrous materials.
• On account of the danger of stress cracking corrosion the chloride, nitrate and sulfate con tents of the heating water must not exceed 200 mg/l in total.
• The pH value of the heating water should lie between 8.3 and 9.5 after 6-12 weeks of heating operation.
Filling and replacement water• For a plant using Hoval boilers untreated drinking water
is generally best suited as heating medium, i.e. as fi ll-ing and replacement water. However, as not all drink-ing water is suitable for use as fi lling and replacement water the water quality must fulfi l the standard set in VDI 2035. Should the mains water available not be suit-ed for use then it must be desalinated and/or be treated with inhibitors. The stipulations of EN 14868 must be observed.
• In order to maintain a high level of boiler effi ciency and to avoid overheating of the heating surfaces the values given in the table should not be exceeded (dependent on boiler performance ratings - for multi-boiler plants rating of smallest boiler applies - and on the water con-tent of the plant).
• The total amount of fi lling and replacement water which is used throughout the total service life of the boiler must not exceed three times the water capacity of the plant.
Maximum filling capacity based on VDI 2035Total hardness of the fi lling water up to ...
[mol/m3] 1 <0,1 0,5 1 1,5 2 2,5 3 >3,0f°H <1 5 10 15 20 25 30 >30d°H <0,56 2,8 5,6 8,4 11,2 14,0 16,8 >16,8e°H <0,71 3,6 7,1 10,7 14,2 17,8 21,3 >21,3~mg/l <10 50,0 100,0 150,0 200,0 250,0 300,0 >300Conductance 2 <20 100,0 200,0 300,0 400,0 500,0 600,0 >600Boiler size of the individual boiler maximum fi lling quantity without desalination
50 to 200 kW NO REQUI- 50 l/kW 20 l/kW 20 l/kWalways desalinate200 to 600 kW RE- 50 l/kW 50 l/kW 20 l/kW
over 600 kW MENT
1 Sum of alkaline earths2 If the conductance in µS/cm exceeds the tabular value an analysis of the water is necessary.
5.4 Venting the gas pipes
§Observe the relevant regulations while vent-ing the gas pipes
• Open the gas stop valve.• Vent the gas pipe up to the gas armature.
5.5 Handing over the plant to the operatorThe plant installer is responsible for providing instruction covering the entire plant.
The following steps must be carried out when handing over the plant:• Instruction in the operation and upkeep of the plant.• Handing over of all instructions and documents.• Providing notice to the operator that these instructions
must always be kept available near the plant.• Written confirmation of the instruction.• Completion certificate see last page.
274 214 864 / 01
COMMISSIONING
5.6 Record - Activation of screed function
28 4 214 864 / 01
COMMISSIONING
Description of function
The control module of the TopTronic® E contains a functional sequence used for drying out screed fl oors. To start the screed drying, it is necessary for the individual functions to be set accordingly.
Heating-up phase( 04-061)
Start End
Current heat generator temperature = start temperature
Inertia phase(04-064)
Stabilisation temperature(04-063)
Cool down phase( 04-062)
Flow temperature
Days10
20 °C
25 °C
30 °C
35 °C
40 °C
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
1 d 1 d
5 K -5 K
Function Parameters Value DescriptionHeating-up phase 04-061 5 K/d Kelvin per day (rising)Stabilisation temperature 04-063 40.0 °C Set maximum temperatureInertia phase 04-064 10 Number of days in stabilisation temperatureCooling off phase 04-062 -5 K/d Kelvin per day (falling)Activate screed function 04-060 1 (ON) Start and stop screed drying
NOTICEThe graphic/table shows the factory settings. The time profi le and the maximum fl ow temperature must be discussed with the screed layer, otherwise there could be damage to the screen – and in particular, cracks.
REACTION screed function• Start/stop: Switch parameter 04-060 ON (1) or OFF (0) • Power failure in heating-up phase: program restart• Failure in the steady-state phase: Retain maximum temperature and add the failure time to the steady-state phase• Power failure in the cooling off phase: Measurement of actual fl ow value and continue cooling until start value
reached• Program end: Previous basic program active again
Settings in the TopTronic® E control module
Can only be set in the corresponding user level.
Settings under Start screen > Main menu > Service > H-GEN > Heating circuit > Heating circuit 1, 2, 3* > Screen > 04-060 to 04-064.
* If there are several heating circuits, a separate screed function must be assigned to each heating circuit.
294 214 864 / 01
COMMISSIONING
Function display
1 2
No. Icon Function1 Screed drying active
Various settings can be made as well. Prioritisation of the screed func-tion means the settings are only ac-tive at the end of the function.
2 Information remaining run timeRequest of the active function phase, the ACT temperature as well as the remaining run time.
Logging
Please cut out the log and attach it to the controller during active screed function.
NOTICEThe time profi le and the maximum fl ow temperature must be discussed with the screed layer, otherwise there could be damage to the screen – and in particular, cracks.
Screed function activated by: Profi le and fl ow temperature discussed with:
Screed function activated on: Screed function ends on:
..........................................................................................Date and signature
6. Maintenance6.1 Information for combustion controller/chimney sweep regarding emission monitor key
30 4 214 864 / 01
MAINTENANCE
This chapter is exclusively intended to describe the function of emissions and manual operation settings for the fi ring monitoring technician / chimney sweep. All operating elements are described in the operating instructions.
!CAUTIONDanger of scalding with hot water, since the hot water temperature can exceed the target setpoint temperature.
NOTICEIn order to protect underfl oor heating systems against impermissible superheating during emissions measurement / manual operation, it is necessary to implement appropriate safety measures (e.g. pump switch-off with maximum thermostat). The output and duration of the emission measurement can be set in the "Emission" main menu, and reactivated if required.
Emission metering
Setting at: Home screen > Main menu (page 1) > Emission.
For detailed information see operating instructions, "Emission" chapter.
Power limitation with 2-stage burner:0 to 50% = 1st stage 51 to 100% = 2nd stage
REACTION to emission metering• Go back after expiry of the time unit/time specifi cation of return to the main menu• Setpoint temperature = Maximum temperature limit• Forced energy is used in an attempt to keep the corresponding heat generator temperature to 60 °C• Regulate heating circuits and the calorifi ers to their maximum temperature (in the direct heating circuit only if the hot
water basic program is set to parallel operation)
Manual mode
Settings under: Home screen > Main menu (page 2) > Manual operation.
For detailed information see operating instructions, "Emission" chapter.
REACTION for manual operation• Setting the required setpoint temperature using the selected heating or hot water circuit• All heating pumps ON• Note the maximum permissible temperature of surface heating!
6.2 Safety notices
CAUTIONDanger of injury through sharp edges.Handle the cladding panels with care and avoid contact with sharp edges.
!CAUTIONDanger of injury for unqualified personnel.Servicing and Cleaning may only be carried out by qualified personnel or by Hoval cus-tomer service personnel.
6.3 Venting• Open all radiator valves• Heat up plant for at least 12 hours
with a high flow temperature.• Switch off boiler and wait for 5 minutes.• Thoroughly vent the plant.
6.4 Replenishing water
§The European Standard EN 14868 and the Directive VDI 2035 must be observed (see point 5.3).
Replacement water has to be refilled if the pressure falls below the minimum plant pres-sure:
• Connect hose to water tap.• Evacuate the air from the hose.• Connect hose to filling and drainage valve.• Replenish replacement water.
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MAINTENANCE
6.5 Cleaning• Inadequate cleaning results not only in increased fuel
consumption, but also shortens the service life of the boiler.
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.
• Unscrew the hexagonal sealing nuts with hole (49, Fig. 19) using the steel mandrel supplied.
NOTICEThe sealing nuts without a hole must on no account be unscrewed.
• Open the boiler door and swing out burner.
• Visual check and detection of degree of pipe contami-nation (51, Fig. 20).
• The pipes (51, Fig. 20) must be cleaned even if minor contamination resp. incrustation has been detected.
• Thoroughly clean combustion chamber (50, Fig. 20) us-ing a brush or spray.
• The second compartment (51, Fig. 20) must be cleaned by means of a high-pressure cleaner (e.g. Kärcher, Fig. 21) with a special nozzle (point jet nozzle, Fig. 22) and hot water.
• Close boiler door and tighten screws firmly.
• Reconnect burner plug and start up the boiler to maxi-mum operating temperature in order to dry the heating surfaces.
• Clean/flush condensate drain hose (Fig. 23).
!CAUTIONFlue gas can emerge if the condensate drain hose is not filled with water.
49
Fig. 19
5051Fig. 20
Fig. 21
Fig. 22
Fig. 23
32 4 214 864 / 01
MAINTENANCE
334 214 864 / 01
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.• and is consequently suffi ciently familiar with the installation.
Installation address: Type:
Serial number:
Year of manufacture:
Place, Date:
System installer: System 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.• and is consequently suffi ciently familiar with the installation.
Installation address: Type:
Serial number:
Year of manufacture:
Place, Date:
System installer: System user:
COPY FOR PLANT USER
COPY OF SYSTEM INSTALLER