Hoval CompactGas 1000 Technical Information Download | Manualshive

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4 214 864 / 01

ASSEMBLY

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Summary of Contents for CompactGas 1000

Page 1: ...types Nominal output at 80 60 C and natural gas 42 CompactGas 700 700 kW 42 CompactGas 1000 1000 kW 42 CompactGas 1400 1400 kW 42 CompactGas 1800 1800 kW 42 CompactGas 2200 2200 kW 42 CompactGas 2800 2800 kW 42 CompactGas 3500 3500 kW 42 CompactGas 4200 4200 kW Hoval CompactGas 700 4200 for natural gas and liquid gas The gas boiler series Compact is suitable and ap proved for use as heat generator...

Page 2: ...ail A B C 12 2 5 2 Mounting the fixed side shutter detail D 12 3 Technical details 3 1 Description of the boiler 13 3 2 Technical data 14 3 3 Dimensions Space required 16 3 3 1 Dimensions 16 3 3 2 Base size 17 3 4 Flue gas and output diagrams 18 3 4 1 Flue gas output diagram 18 3 4 2 Flue gas resistance 18 4 Installation 4 1 Safety notices 19 4 2 Requirements for boiler room 19 4 3 Flue gas connec...

Page 3: ...ater 26 5 4 Venting the gas pipes 27 5 5 Handing over the plant to the operator 27 5 6 Record Activation of screed function 28 6 Maintenance 6 1 Information for combustion controller chimney sweep regarding emission monitor key 30 6 2 Safety notices 31 6 3 Venting 31 6 4 Replenishing water 31 6 5 Cleaning 32 3 4 214 864 01 TABLE OF CONTENTS ...

Page 4: ...al 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 dan...

Page 5: ...384 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 T...

Page 6: ...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 ...

Page 7: ... boiler door hinges can be changed over to enable the door to be opened to the left This can be use ful when space is limited NOTICE Boiler door hinges may only be changed over by Hoval Service The boiler door must be closed when changing over the hinges procedure 1 For types 1800 2200 2800 3500 4200 only Dismantle support for door positioning 5 Fig 02 2 Tighten the top and bottom lock nuts 1 Fig ...

Page 8: ...at 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 W...

Page 9: ...3 2a 1 1b 2 2a 2b 5 7 8 6 4 Fig 06 1a 8a Insulating mat may be partitioned 9 4 214 864 01 ASSEMBLY ...

Page 10: ...rough 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 NOTICE The 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 12b 12d 14 13a Fig 08 9 Mount ...

Page 11: ...4214864_B02 15 10 2015 SJU A 21 30 26 27 28 25 22 23 23 24 20a 20b 22 22 31 33 29 32 12 20 31 14 34 15c 15 15a 35 CompactGas 1800 2800 cutaway view Fig 09 Fig 10 11 4 214 864 01 ASSEMBLY ...

Page 12: ...om 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 ...

Page 13: ...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 13 4 214 864 01 TECHNICAL INFORMATION ...

Page 14: ...erature 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 gas 500 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 output 10 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 r...

Page 15: ... 20 Flue gas resistance at nominal output 10 5 CO2 natural gas 500 m over sea level Tolerance 20 mbar 7 9 4 8 5 4 Flue gas mass flow at nominal output 10 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 m h 150 4 180 6 4 Boiler water content litres 3553 4 3628 4 Insulation thickness boiler...

Page 16: ...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 ...

Page 17: ...0 450 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 315 376...

Page 18: ...ion of lambda λ of 0 09 causes a modification of the flue gas temperature of 8 K Flue gas temperature 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 1000 1400 1800 2200 2800 3500 4200 Values calculated without liability Boiler output kW Flue gas resistance mbar 0 0 1 0 2 0 3 0 4...

Page 19: ...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...

Page 20: ...4 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 d...

Page 21: ...e flue gas pipe 4 5 Hydraulic connection In accordance with EN 12828 2003 the following safety devices are integrated in the boiler temperature regulator temperature measuring device TBmax 20 safety temperature limiter A complete failure of the water circuit must be taken into account plant specifically according to DIN EN 12828 In Germany a low water protection must be provided 4 5 1 Pressure mai...

Page 22: ...nnection DANGER Danger 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 1 B1 1 Flow temperature limit ther...

Page 23: ...r 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 p...

Page 24: ...onnect 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 t...

Page 25: ... CO2 value is correctly set 5 1 Safety notices CAUTION Risk 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 water Only authorised perso...

Page 26: ... 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 fill ing and replacement water However as not all drink ing water is suitable for use as filling and replacement water the water quality must fulfil the standard set in VDI 2035 Should the mains water available not be suit ed for use then it mu...

Page 27: ...e 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...

Page 28: ...Kelvin per day falling Activate screed function 04 060 1 ON Start and stop screed drying NOTICE The graphic table shows the factory settings The time profile and the maximum flow 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...

Page 29: ...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 NOTICE The time profile and the maximum flow temperature must be discussed with the screed layer otherwise there could be damage to the screen and in particular cracks Screed function activated by Proﬁle and ﬂow temperature discuss...

Page 30: ...ctivated 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 specification of return to the main menu Setpoint temperature Maximum temperature limit Forced ...

Page 31: ...n 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 ai...

Page 32: ... 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 fir...

Page 33: ...33 4 214 864 01 ...

Page 34: ...Type Serial number Year of manufacture Place Date System installer System user Confirmation The user owner of the system herewith conﬁrms 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 an...

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