Technical information

Installation instructions
Hoval CompactGas (700-2800)
for natural gas and liquid gas

These instructions apply to the following types:

Nominal output at 80/60 C and natural gas
41-CompactGas
(700) 700 kW
41-CompactGas
(1000) 1000 kW
41-CompactGas
(1400) 1400 kW
41-CompactGas
(1800) 1800 kW
41-CompactGas
(2200) 2200 kW
41-CompactGas
(2800) 2800 kW

Hoval products must be installed and commissioned

only by appropriately qualified experts. These instructions are intended exclusively for the specialist. Electrical installations may only be carried out by a qualified
electrician.

Subject to modifications

4 213 633 / 00 - 04/15

The gas boiler series Compact is suitable and approved 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

EN

TABLE OF CONTENTS
1.

Safety notices

1.1
General safety instructions..................................................................................................................................................4
1.2
Explanation of the symbols.................................................................................................................................................4
1.2.1 Warnings...........................................................................................................................................................................4
1.2.2 Symbols.............................................................................................................................................................................4
1.3
On delivery............................................................................................................................................................................5
1.4 Guarantee.............................................................................................................................................................................5
1.5 Instructions...........................................................................................................................................................................5
1.6
Regulations, official approvals............................................................................................................................................6
1.6.1 Germany..........................................................................................................................................................................6
1.6.2 Austria...............................................................................................................................................................................6
1.6.3
Switzerland .....................................................................................................................................................................6

2. Assembly

2.1
2.2
2.3
2.4
2.4.1
2.4.2
2.5
2.5.1
2.5.2

3.

Installation, levelling............................................................................................................................................................7
Mounting the condensate drain...........................................................................................................................................8
Mounting the thermal insulation..........................................................................................................................................8
Mounting the cladding and the boiler control...................................................................................................................10
Boiler controller TopTronic E...........................................................................................................................................10
Boiler controller T0.2 / T2.2..............................................................................................................................................10
Mounting the side shutters................................................................................................................................................12
Mounting the flexible side shutter (detail A,B,C)...............................................................................................................12
Mounting the fixed side shutter (detail D).........................................................................................................................12

Technical details

3.1
Description of the boiler....................................................................................................................................................13
3.2
Technical data.....................................................................................................................................................................14
3.3
Dimensions / Space required.............................................................................................................................................15
3.3.1 Dimensions......................................................................................................................................................................15
3.3.2
Base size.........................................................................................................................................................................16
3.4
Flue gas and output diagrams...........................................................................................................................................17
3.4.1
Flue gas - output diagram................................................................................................................................................17
3.4.2
Flue gas resistance..........................................................................................................................................................17

4. Installation
4.1
4.2
4.3
4.4
4.5
4.5.1
4.5.2
4.5.3
4.6
4.7
4.7.1
4.7.2

Safety notices.....................................................................................................................................................................18
Requirements for boiler room............................................................................................................................................18
Flue gas connection, flue gas pipe, dimensions of flue gas pipe....................................................................................18
Installing the burner...........................................................................................................................................................20
Hydraulic connection.........................................................................................................................................................20
Pressure maintenance.....................................................................................................................................................20
Hydraulic connection........................................................................................................................................................20
Hydraulic schematic.........................................................................................................................................................21
Gas connection...................................................................................................................................................................21
Electrical connection..........................................................................................................................................................22
Recommended cable cross sections................................................................................................................................22
Safety measures relating to EMC assembly.....................................................................................................................22

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TABLE OF CONTENTS
5. Commissioning
5.1
5.2
5.3
5.3.1
5.3.2
5.4
5.5
5.6

Safety notices.....................................................................................................................................................................23
Charging with water...........................................................................................................................................................23
Water quality.......................................................................................................................................................................24
Heating Water..................................................................................................................................................................24
Filling and replacement water..........................................................................................................................................24
Venting the gas pipes.........................................................................................................................................................25
Handing over the plant to the operator.............................................................................................................................25
Record - Activation of screed function..............................................................................................................................26

6. Maintenance

6.1
Information for combustion controller/chimney sweep regarding emission monitor key..............................................28
6.2
Safety notices.....................................................................................................................................................................29
6.3 Venting................................................................................................................................................................................29
6.4
Replenishing water.............................................................................................................................................................29
6.5 Cleaning..............................................................................................................................................................................30

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IMPORTANT INFORMATION

1.

1.1

Safety notices

General safety instructions

The system may only be placed in operation
if all the relevant standards and safety regulations 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.

1.2 Explanation of the symbols

1.2.1 Warnings
DANGER

WARNING

!
!

... 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

WARNING
All electric power supply circuits must be
switched off before accessing the terminals.

... indicates a situation of possible danger

which can lead to serious or fatal injuries if
not avoided.
CAUTION

WARNING
The heat generator can only be de-energised
by disconnection from the mains (e.g. all-pole switch).

... indicates a situation of immediate danger

which will lead to serious or fatal injuries if
not avoided.

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:

Incorrect handling of potentially explosive

substances can lead to serious damage, potentially fatal injuries and incalculable costs.
Information:
Provides important information.

Follow the instructions for use.

Requirements to comply with the instructions

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IMPORTANT INFORMATION

Tool:
Which tools and other equipment are required.

Provides important information. Refers to

standards and directives.

1.3

On delivery

Carrreceiving the boiler.y out a visual inspection immediately 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

Guarantee

The 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, combustion air)
Corrosion by halogen compounds (e.g. paints, adhesives, solvents)
Unsuitable chemical additives to the heating water
Damage caused by the application of force
Corrosion by halogen compounds (e.g. paints, adhesives, solvents)
Corrosion caused by not observing the required water
quality

1.5

Instructions

All instructions relevant to your system can be found in

the Hoval system manual! In exceptional cases, the instructions can be found with the components!
Further sources of information:
Hoval catalogue
Standards, regulations

4 213 633 / 00

IMPORTANT INFORMATION
1.6

Regulations, official approvals

The standards and directives stated under points 1.7.1 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 procedure 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 excess
pressures / safety valves / for group II steam boilers.
-- 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 attachment N-430 020.

1.6.3 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 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 airconditioning plant.
-- SWKI 80-2 Technical safety regulations for heating installations.
-- KRW Corrosion caused by halides.
-- KRW/VSO/FKR Electrical connections on heating boilers and burners ready to plug in.
-- FCOS - Guidelines for liquid gaz, part 2
and further regulations and standards issued by CEN,
CEN ELEC, DIN, VDE, DVGW, TRD and government
authorities. The regulations issued by local buildings authorities, insurers and chimney sweeps must also be observed. Where gas is used as a fuel the regulations of the
local gas supplier must be observed. An official licence
may be needed.

1.6.2 Austria
-- OENORM 12831 Heating installations in buildings
procedure for calculating the standard heating load
-- OENORM 13384 Exhaust gas systems procedure for
heat and technical gasflow calculations.
-- OENORM 12828 Heating systems in buildings: planning of hot water heating systems.
-- Norm B 8130 Open hot water, systems, safety installations.
-- Norm B 8131 Closed-circuit hot water systems, safety, construction and testing regulations.
-- Norm B 8133 Water heating systems, technical safety
requirements.
-- Norm B 8136 Heating systems, space requirements
and other building requirements.
-- Norm M 7515 Calculation of chimney dimensions; definition of expressions, calculation procedures.
-- Norm H 5171 Heating systems technical building
requirements.
-- VGW TR gas

4 213 633 / 00

ASSEMBLY

2.

2.1

Assembly

Installation, levelling

No special foundation plate is required for installing the

boiler (sufficient supporting capacity for the boiler must
be guaranteed); see section Technical data for operational weight.
In the case of boiler installation in the domestic domain,
vibration absorbers are to be mounted under the boiler
plinth rails.
Space required
for mounting the thermal insulation and sheet metal cladding:
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.
Levelling
The upper edge of the boiler water jacket (boiler longitudinal axis) must be levelled by means of a spirit level until
it is aligned exactly horizontally.

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 only:
Dismantle support for door positioning (fig. 02).
2. Tighten the top and bottom lock nuts (1, fig. 01) towards the swing-out flange (manually).
3. Mount flange nuts (2, fig. 01) with the hole diagonally 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).
Figure shows situation after transformation
(boiler door opens to the left)

Mount the door liner (door cladding) before installing the burner (for heating trials, with the
boiler not yet thermally insulated).

Delivery from factory-boiler door opens to the right

However the boiler door hinges can be changed over to
enable the door to be opened to the left. This can be useful when space is limited.

3
5

fig. 01

fig. 02

Position mechanical jack

Figure shows situation as delivered

(boiler door opens to the right)

4 213 633 / 00

ASSEMBLY
7. For types 1800,2200,2800:
Remount support for door positioning (5, fig. 01) on
the other side, readjust if necessary resp. level boiler
door 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. 10cm.
9. Raise boiler door (20-30mm) by means of a mechanical jack (or jack) by slightly loosening flange nuts (8,
fig. 02).
NOTICE
Do 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.

2.2

Mounting the condensate drain

2.3

Mounting the thermal insulation

1. Wrap the insulating mats (1,1a, fig. 06) around the

boiler body. The insulating mat (1a, fig. 06) has to be
applied in such a way that the large recess (1b, fig.
06) is located at the back.
2. Fix the insulating mats (1/1a, fig. 06) with plastic
straps and strap fasteners (2a, fig. 06):
-- Tension springs (2, fig. 05) serve for additional fixing (2b, fig. 06)
-- Do not overtighten the straps (reduced insulation
effect)
3. Place insulating mats (3, fig. 06) on the boiler rear panel and attach them to the insulating mat of the boiler
body using tension springs.
4. Wrap the insulating mat (4, fig. 06) around the flue
gas collector ring and fix it below with retaining discs
(fig. 04).
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).

The consensate drain is to be mounted according to (fig.

03).

fig. 05
Notice
The mounting of the insulating mats (6,7, fig.
06) may be facilitated by cutting them through
at the narrowest section.

7. Attach the Compact Gas (1800-2800) insulating mats

fig. 03

(8a, fig. 06) to the boiler door without the use of retaining discs.

The remaining insulating mats (20a,24, fig. 10) are fixed

with the mounting of the cladding (see fig. 06).

fig. 04
8

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8a

fig. 06

4 213 633 / 00

2b

1b

Insulating mat may be partitioned

2a

1a

2a

ASSEMBLY

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 hexagonal
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 (cable routing according to Image fig. 10). Insert right and
left side panels (22, fig. 10) into retaining bracket (32,
fig. 10), attach 1 C-Clip each (29, fig. 10) to the front
of the side panels.
3. Insert rear panels (23, fig. 10) into folded edges (22,
fig. 10) (Compact Gas (2800): 6 pieces) of side wall.
4. Insert 2 insulating mats (24, fig. 10) left and right in
longitudinal direction (to prevent vertical air circulation).

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

14
12
13a

12b
12d

2.4.1 Boiler controller TopTronic E

5. 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 3.5
x 6.5 and serrated washers (12b).

14

12c

12b

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 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.
NOTICE

13a

The capillaries must not be folded or kinked!

12. Attach cover plate to the boiler controller (12d, fig.
08) with self-tapping screws 3.5 x 6.5 and serrated
lock washers.

12
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.

10

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 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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4 213 633 / 00

fig. 10

CompactGas
(1800-2800)
cutaway view

20

31

29

20b

34

22

20a

24

31

25

30

21

26

22

27

33

28

12

32
23

22

23

14

15

15c

15a

fig. 09

ASSEMBLY

11

ASSEMBLY
2.5

Mounting the side shutters

The cladding shutter system serves for covering the gap

between the boiler door and the side wall. The shutter at
the boiler door hinge side must be flexible.

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).

2.5.1 Mounting the flexible side shutter (detail A,B,C)

2.5.2 Mounting the fixed side shutter (detail D)

1. Mount hinges (40, fig. 11) on top and bottom of front

side wall using self-tapping screws 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!

4. Open boiler door, mount hinges (40, fig. 11) on top

and bottom of front side wall using self-tapping screws 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).

45 incline
boiler side

B
42

44
40
41a

C
46

47

48

41

49

42

42

43

44

44
41

45

12

44

40

40

fig. 11

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TECHNICAL INFORMATION

3.

3.1

Technical details

Description of the boiler

The Hoval CompactGas is a low-pollution, energy saving

gas boiler. The Hoval CompactGas has a horizontal combustion chamber as primary heating area and a secondary heating area consisting of aluFer composite tubing.
The CompactGas is designed for operation using natural
gas and liquid gas. The construction principles are displayed in the following diagram.

fig. 12

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13

TECHNICAL INFORMATION
3.2

Technical data

Type

(700)

(1000)

(1400)

(1800)

(2200)

(2800)

Nominal output at 80/60 C

Range of output at 80/60 C
Burner input maximum

kW
kW
kW

700
250-700
725

1000
300-1000
1037

1400
420-1400
1458

1800
540-1800
1865

2200
660-2200
2280

2800
840-2800
2901

C
C
C
C

105
75
35

105
75
35

105
75
35

105
75
35

105
75
35

105
75
35

120

120

120

120

120

120

Maximum working temperature 1

Minimum working temperature
Minimum boiler return temperature
Safety temperature limiter setting
(water side) 2

Working/test pressure
Boiler efficiency at full load at 80/60 C
(net calorific value/gross calorific value)
Efficiency at partial load 30% (EN 303)
(net calorific value/gross calorific value)
Standard efficiency 75/60 C (according to DIN 4702 part 8)
(net calorific value/gross calorific value)
Stand-by loss at 70 C

bar

6/9

6/9

6/9

6/9

6/9

10/16

96.5/87.0

96.4/86.9

96.0/86.5

96.5/87.0

96.5/87.0

96.5/87.0

97.4/87.7

97.4/87.7

97.3/87.7

97.4/87.7

97.5/87.8

97.5/87.8

97.4/87.7

97.4/87.8

97.1/87.5

97.5/87.9

97.5/87.9

97.5/87.9

Flue gas temperature at nominal output at 80/60 C

Watt

850

1000

1200

1350

1550

1800

94

101

102

99

93

92

Flue gas resistance at nominal output

10.5% CO2 natural gas
500 m over sea level (Tolerance 20%)
Flue gas mass flow at nominal output
10.5% CO2 natural gas

mbar

4.9

4.8

4.7

5.7

6.5

7.2

kg/h

1133

1623

2271

2923

3571

4546

Flow resistance boiler 3

Water flow resistance
Water flow volume

z-value
mbar
m/h

0.012
10.8
30.0

0.012
22.0
42.9

0.003
10.8
60.0

0.003
17.9
77.1

0.003
26.7
94.3

0.002
28.8
120.0

litres
mm
kg
kg
m

670
80
1390
1250
36.52

1130
80
2100
1960
44.23

1580
80
2794
2654
68.49

2020
80
3500
3200
89.51

2534
80
4455
4105
117.26

2844
80
5567
5167
142.34

mm
m

584/1835
0.492

684/1985
0.729

830/2180
1.179

830/2301
1.244

830/3076
1.663

922/3272
2.222

Boiler water content

Insulation thickness boiler body
Weight (incl. casing) 6 bar
Weight (without casing) 6 bar
Heating surface

Combustion chamber dimension

inside x length
Combustion chamber volume

at 20 K
at 20 K

Dimensions
1
2
3

see Dimensions

Limited by the boiler control T2.2 to 90 C resp. U3.2 and T0.2 to 105 C.
Maximum safety temperature for boiler control T2.2: 110 C resp. U3.2 and T0.2: 120 C.
Flow resistance boiler in mbar = volume flow (m3/h)2 x z

14

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TECHNICAL INFORMATION
3.3 Dimensions / Space required
3.3.1 Dimensions
(all dimensions in mm)

Type
(700)
(1000)
(1400)
(1800)
(2200)
(2800)
Type
(700)
(1000)
(1400)
(1800)
(2200)
(2800)

k (inside)

1100
1280
1480
1580
1580
1680

1150
1330
1530
1630
1630
1730

1175
1384
1584
1684
1684
1784

591
710
810
860
860
910

250
310
330
360
360
360

290
350
400
400
400
400

330
400
450
450
450
450

4xM12
6xM12
6xM16
6xM16
6xM16
6xM16

15/45
15
15
15
15
15

303
353
403
453
453
503

l*

1436
1646
1886
2038
2038
2188

2229
2430
2600
2790
3529
3745

240
240
240
257
257
257

1930
2130
2300
2438
3213
3430

389
438
438
438
438
638

1110
1210
1350
1350
2125
2100

170
170
170
187
187
187

1271
1487
1708
1808
1808
1908

96
103
124
124
124
124

1406
1564
1780
1884
2659
2799

420
500
550
600
600
600

31
31
31
48
48
48

Tilting out of the boiler door

* 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 6

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, PN6

boiler door opens to the right or left

(dimensions in mm))
3 Flue gas outlet
4 Draining R 1
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 with immersion pocket
for boiler temperature sensor
CompactGas
Type
(700)
(1000)
(1400)
(1800)
(2200)
(2800)

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875
1052
1252
1337
1337
1435

120
120
120
120
120
120

15

TECHNICAL INFORMATION
3.3.2 Base size

Dimensions without insulation and casing

Boiler incl. boiler door, outlet without flue gas collector
(dimensions in mm)

fig. 13
Type

b*

k (inside)

(700)
(1000)
(1400)
(1800)

1100
1280
1480
1580

1436
1646
1886
2038

1153
1363
1563
1663

590
710
810
860

250
310
330
330

290
350
400
400

330
400
450
450

6xM12
6xM12
6xM16
6xM16

15
15
15
15

303
353
403
453

(2200)

1580

2038

1663

860

330

400

450

6xM16

15

453

(2800)

1680

2188

1763

910

330

400

450

6xM16

15

503

DN

80
80
80
80
80
80

2212
2423
2593
2731
3506
3723

209
209
209
209
209
209

1930
2130
2300
2438
3213
3430

389
438
438
438
438
638

1110
1210
1350
1350
2125
2100

84,5
96
112
112
112
112

1271
1487
1708
1808
1808
1908

180
180
200
200
200
200

125
125
150
150
150
200

Type
(700)
(1000)
(1400)
(1800)
(2200)
(2800)

Combustion chamber dimensions

Type
(700)
(1000)
(1400)
(1800)
(2200)
(2800)

219
219
219
219
219
219

1644
1748
1896
1998
2773
2968

1835
1985
2180
2301
3076
3288

584
684
830
830
830
922

189
189
189
189
189
189

fig. 14

16

4 213 633 / 00

TECHNICAL INFORMATION
3.4 Flue gas and output diagrams
3.4.1 Flue gas - output diagram
105

1400

1800

1000

100

2200
2800

Flue gas temperature (C)

95

700

90

85

80

75

70

200

300

400

500

600

700

800

900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 2400 2500 2600 2700 2800

Nominal output (kW)

kW =
C =

Boiler output
Flue gas temperature on clean surface,
boiler flow temperature
80C, return temperature 60C
(in accordance with DIN 4702).

Operated with natural gas H, = 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 of 0,09 causes a modification of the flue
gas temperature of 8 K.

3.4.2 Flue gas resistance

8.0

2800
7.0

2200
1800

Flue gas resistance (mbar)

6.0

700

5.0

1000

1400

4.0

3.0

2.0

1.0

0.0

200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700 1800 1900 2000 2100 2200 2300 2400 2500 2600 2700 2800

Boiler output (kW)

4 213 633 / 00

17

INSTALLATION

4.

Installation

4.1

Safety notices
CAUTION
Danger of injury through sharp edges.
Handle the cladding panels with care and
avoid contact with sharp edges.

4.2

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 functional unit.
NOTICE
Moisture-resistant and acid-proof chimneys
must be used for the CompactGas.

Requirements for boiler room

Observe the local and national building regulations regarding boiler rooms.
Observe the local and national regulations
regarding ventilation and deaeration of boiler rooms.
Gas boilers may not be installed in rooms
which may contain halogen compounds
which may combine with the combustion
air (e.g. laundry rooms, drying rooms, workshops, hairdressing salon).
Halogen compounds may occur in, amongst
others, cleaning, de-greasing and solvent substances, adhesives and bleaching
agents.

Always make sure that there is an adequate supply of

fresh air to the boiler room, to ensure that the combustion
air supply necessary for all the firing systems operated
can flow in without hindrance and that no oxygen deficiency occurs for the operating personnel.

Renovation, respectively chimney cross section adjustment may be necessary with existing chimney installations, 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 insulation, 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.

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 500cm2 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
appropriate supplement is to be made with grilles to ensure that the free cross section reaches the above values.
In Austria the Norm H 5171 additionally stipulates a flue
air aperture. This must have a minimum cross section 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.

18

4 213 633 / 00

INSTALLATION
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)
NOTICE
The condensate accumulating in the flue gas
pipe must not flow back to the boiler.A condensate trap (Fig. 16) must therefore be installed at the flue gas outlet (not included in
the scope of delivery).

ref. c)
Dimensioning of chimney cross section. The cross sections are to be calculated for boilers without delivery pressure 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
Norm M7515.
The values for calculation can be obtained
from the table
in section Technical data.

condensate trap
condensate trap

fig. 15
NOTICE
Normally only one heat generator may be
connected to the chimney!
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.
vom
from the
boiler
Kessel

zum
to
the chimney
Schornstein

fig. 16

4 213 633 / 00

19

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.
NOTICE
With gas burners, the burner housing weight
is to be directly supported by a strut to the
floor.

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 maintenance

A pressure expansion tank sized appropriately for the heating plant, water volume and head has to be installed
on site.

4.5.2 Hydraulic connection

The minimum return temperature has to be ensured by

constant return flow control. A minimum water circulation
is not necessary.

NOTICE
Boiler 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.

P
Dies
ist
ein
unerlaubter Weg!
Gehen Sie einen
Schritt zurck oder
lschen Sie dieses
Shape!
Sie
haben
die
Mglichkeit
ein
Ceuoem
tG
n
s pSahc
ap
e as
zu
nehmen!!!
hovhovalhovalhova
lhovalhovalhovalho
valhovalhovalhoval
hovalhovalhovalho
valhovalhova
valhoval
hovalhova
RLF

ZUP
YKR

fig. 18

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.

20

4 213 633 / 00

INSTALLATION
4.5.3 Hydraulic schematic
The examples stated below are principle
schematics which do not contain all the details for installation. The installation must be
done according to the local conditions, dimensioning and regulations.
For underfloor heating, a flow temperature
monitor must be built in.
Shut-off devices to the safety valve (pressure 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
NOTICE
The minimum boiler temperature of 75C as
well as the minimum return temperature of
35 C must never fall below the stated value
in any of the operating status given (see
technical data).

4.6

Gas connection
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.

fig. 19

TTE-WEZ
VF1
B1.1
MK1
YK1
YKR
AF
SF
RLF
DKP
SLP
KKP

TopTronic E basic module heat generator (installed)

Flow temperature sensor 1
Flow temperature limit thermostat (if required)
Pump mixer circuit 1
Actuator mixer 1
Actuator, return mixer
Outdoor sensor
Calorifier sensor
Return sensor
Pump for heating circuit without mixer
Calorifier loading pump
Boiler circuit pump

4 213 633 / 00

Optional
RBM
TTE-GW

TopTronic E room control module

TopTronic E Gateway

TTE-FE HK
VF2
B1.2
MK2
YK2

TopTronicE module expansion heating circuit

Flow temperature sensor 2
Flow temperature limit thermostat (if required)
Pump mixer circuit 2
Actuator mixer 2

21

INSTALLATION
4.7

Electrical connection

4.7.1 Recommended cable cross sections

A qualified technician must install the electrical supply to the equipment.

The connection diagram is located in the electrical box of the heat generator; the circuit diagram is supplied separately. Refer to this for
the conductor cross-section required for the
mains supply.

Line type

Cables carrying mains

supply voltages from
actuators

min 1.0mm2

unlimited m

WARNING

Cables carrying low

voltage (sensors)

min 0.5mm2

max. 50m

Data bus lines (shielded)

2x2x0.6mm2

max. 100m

The heat generator can only be de-energised

by disconnection from the mains (e.g. all-pole switch).
WARNING
All 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
control box. The cables may be lead through the cover
opening into the control box.
For Austria and Germany:
A connection diagram is supplied with the boiler control.
An all-pole main switch must be installed in the power
supply lead with at least 3 mm contact gap.
For Switzerland:
The plant specific electrical plan must be followed when
making the electrical connection!

Cross-section

Length

Electrical power supply of min 2.5mm

the heat generator (230V) 16A fuse

with

Electrical power supply of min 1.0mm2

the heat generator (400V) 10A fuse

with

unlimited m
unlimited m

4.7.2 Safety measures relating to EMC assembly

1. In the case of control units with their own mains supply, it is imperative that cables carrying mains voltage
are routed separately from sensor or data bus cables.
If cable ducts are used, these must be provided with
separator strips.
2. The mains connection for the heating system (boiler control panel regulator unit) must be designed as
an independent electrical circuit. Neither fluorescent
lamps nor any other equipment which might cause interference may be connected, nor may it be possible
to connect such equipment.
Fuse
Boiler room emergency
switch

Boiler room lighting and power

sockets must be in a separate
circuit

EMC safety measures

Lay mains and sensor resp. bus lines separately for control devices with separate mains power supply.
NOTICE
Use cable channels with separators.
The mains supply for the heating plant (boiler - switching
block - controller) must be wired as an independent electrical circuit.

Heat generator

fig. 20
3. The outdoor sensor must not be fitted in the vicinity
of transmitters and receivers (on garage walls near
receivers for garage door openers, amateur radio antennae, radio alarm installations or in the immediate
vicinity of transmitters etc.)

No other power consuming items (lights, sockets, ...) may

be included in the same circuit.
The outside sensor may not be installed in the vicinity of
transmission and receiving devices (garage door opener,
amateur radio antennae, alarm systems...).

22

4 213 633 / 00

COMMISSIONING

5.

Commissioning
NOTICE
After filling the plant, thoroughly vent the system and check the water side for leaks.
NOTICE
During the first commissioning of the plant
the correct functioning of all safety and control 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 contain large quantities of dust (e.g. building site)
the combustion air must be filtered.
NOTICE
It is very important that gas flow pressure is
controlled and the CO2 value is correctly set.

5.1

Safety notices
CAUTION
Schnittverletzungen durch scharfe Kanten.
Teile der Verkleidung vorsichtig handhaben
und Kontakt mit scharfen Kanten vermeiden.

5.2

Charging with water

Only 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 supplier.
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 concentration must be checked at least once per year.
When replenishing antifreeze or anti-corrosion agents the same product should be used.
When changing over to operation without
antifreeze or anti-corrosion agents the plant
must be thoroughly flushed several times before being refilled.

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
customer service.
Damage to the system by filling unauthorised
liquids.
The filled water must be of drinking water quality (See point 5.3).

4 213 633 / 00

23

COMMISSIONING
5.3

Water quality

Parts of the boiler which have contact with water are

made of ferrous materials.

Heating Water

The European Standard EN 14868 and the directive VDI 2035 must be observed.

In particular, attention must be paid to the following stipulations:

Hoval boilers and calorifiers are designed for heating
plants without significant oxygen intake (plant type I according 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 refilling is necessary)
must be equipped with separate circuits.
Treated filling and replacement water must be tested at
least 1x yearly. According to the inhibitor manufacturers
instructions, more frequent testing may be necessary.
A refilling 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 replacement water.

On account of the danger of stress cracking corrosion

the chloride, nitrate and sulfate contents 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 filling and replacement water. However, as not all drinking 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 suited 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 efficiency 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 content of the plant).
The total amount of filling 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.

New and if applicable existing installations need to be

adequately cleaned and flushed befor being filled. The
boiler may only be filled after the heating system has
been flushed!

Maximum filling capacity based on VDI 2035

Total hardness of the filling water up to ...
[mol/m ]
fH
dH
eH
~mg/l
Conductance 2
Boiler size of the
individual boiler
50 to 200 kW
200 to 600 kW
over 600 kW
3 1

1
2

<0,1
<1
<0,56
<0,71
<10
<20

0,5
5
2,8
3,6
50,0
100,0

1
10
5,6
7,1
100,0
200,0

1,5
15
8,4
10,7
150,0
300,0

2
20
11,2
14,2
200,0
400,0

2,5
25
14,0
17,8
250,0
500,0

3
30
16,8
21,3
300,0
600,0

>3,0
>30
>16,8
>21,3
>300
>600

maximum filling quantity without desalination

NO REQUI50 l/kW 20 l/kW 20 l/kW
RE50 l/kW 50 l/kW 20 l/kW
MENT

always desalinate

Sum of alkaline earths

If the conductance in S/cm exceeds the tabular value an analysis of the water is necessary.

24

4 213 633 / 00

COMMISSIONING
5.4

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 armature.

5.5

Handing over the plant to the operator

The 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.

4 213 633 / 00

25

COMMISSIONING
5.6

Record - Activation of screed function

Description of function
The control module of the TopTronic E contains a functional sequence used for drying out screed floors. To start the
screed drying, it is necessary for the individual functions to be set accordingly.
Flow temperature

Heating-up phase
(

Inertia phase

04-061)

Cool down phase

(04-064)

04-062)

40 C

Stabilisation temperature

35 C

(04-063)

30 C
-5 K

5K

25 C

20 C

Current heat generator temperature = start temperature

1d

10

1d

11

12

13

14

Start

Function

15

Days

16

End

Parameters Value

Description

Heating-up phase

04-061

5 K/d

Kelvin per day (rising)

Stabilisation temperature

04-063

40.0 C

Set maximum temperature

Inertia phase

04-064

10

Number of days in stabilisation temperature

Cooling off phase

04-062

-5 K/d

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-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 flow 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.

26

4 213 633 / 00

COMMISSIONING
Function display
1

2
No.

Icon

Function

Screed drying active

Various settings can be made as
well. Prioritisation of the screed function means the settings are only active at the end of the function.

Information remaining run time

Request 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.
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 ow temperature discussed with:

Screed function activated on:

Screed function ends on:

..........................................................................................
Date and signature

4 213 633 / 00

27

MAINTENANCE

6.

Maintenance

6.1

Information for combustion controller/chimney sweep regarding emission monitor key

This chapter is exclusively intended to describe the function of emissions and manual operation settings for the firing
monitoring technician / chimney sweep. All operating elements are described in the operating instructions.

CAUTION
Danger of scalding with hot water, since the hot water temperature can exceed the target setpoint
temperature.
NOTICE
In order to protect underfloor 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 specification 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 calorifiers 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!

28

4 213 633 / 00

MAINTENANCE
6.2

Safety notices
CAUTION
Danger of injury through sharp edges.
Handle the cladding panels with care and
avoid contact with sharp edges.
CAUTION

!
6.3

Danger of injury for unqualified personnel.

Servicing and Cleaning may only be carried
out by qualified personnel or by Hoval customer service personnel.

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 pressure:

Connect hose to water tap.

Evacuate the air from the hose.
Connect hose to filling and drainage valve.
Replenish replacement water.

4 213 633 / 00

29

MAINTENANCE
6.5

Cleaning

Inadequate cleaning results not only in increased fuel

consumption, but also shortens the service life of the
boiler.

49

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.

fig. 21

Unscrew the hexagonal sealing nuts with hole (49; fig.

20) using the steel mandrel supplied.
NOTICE
The 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 contamination (51; fig. 21).
The pipes (51, fig. 21) must be cleaned even if minor
contamination resp. incrustation has been detected.
Thoroughly clean combustion chamber (50, fig. 21)
using a brush or spray.
The second compartment (51, fig. 21) must be cleaned
by means of a high-pressure cleaner (e.g. Krcher, fig.
22) with a special nozzle (point jet nozzle, fig. 23) and
hot water.

51

50
fig. 22

Close boiler door and tighten screws firmly.

Reconnect burner plug and start up the boiler to maximum operating temperature in order to dry the heating
surfaces.

fig. 23

fig. 24

30

4 213 633 / 00

4 213 633 / 00

31

COPY FOR PLANT USER

Confirmation
The user (owner) of the system herewith conrms 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 concerning the heat generator and any further components.
and is consequently sufciently familiar with the installation.

Installation address:

Type:
Serial number:
Year of manufacture:

Place, Date:
System installer:

System user:

COPY OF SYSTEM INSTALLER

Confirmation
The user (owner) of the system herewith conrms 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 concerning the heat generator and any further components.
and is consequently sufciently familiar with the installation.

Installation address:

Type:
Serial number:
Year of manufacture:

Place, Date:
System installer:

System user: