Atag Q 25S, Q 51S, Q 38S, Q 60S, Q 38C Installation & Servicing Instructions Manual
...
8G.51.40.00/03.06 Changes reserved.
Installation & Servicing
Instructions
These instructions to be retained by user.
Boiler G.C No
Q 25S 41-310-08
Q 38S 41-310-09
Q 51S 41-310-10
Q 60S 41-310-11
Q 25C 47-310-10
Q 38C 47-310-11
Q 51C 47-310-12
CE PIN 0063BQ3021
Installation & Servicing Instructions ATAG
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Central heating on / off
Domestic hot water (DHW) on / off
Pump programme on / off
Reset key Unlocking the boiler
in case of error
Step key Selecting chapters
display
Explanations of symbols and signs on the Control Tower display.
1
2
No heat requirement
Ventilation phase
Ignition phase
Burner active on central heating
Burner active on hot water
Fan check
Burner off when room thermostat is demanding
Pump overrun phase for central heating
Pump overrun phase for hot water
Burner off because of to high flow water temperature
Automatic venting programme
3
4
5
6
7
8
9
A
Water pressure is to low (<1,0 bar),
flashing FILL will alternate with indication
of water pressure, boiler power of 50% is
possible. The installation needs to be
topped up.
Operation indication
(in the first display position by technical read out)
Mode key Selecting chapters
Water pressure is to high (>2,8 bar), if
HIGH indication remains continuously
visible, the boiler is taken out of operation.
The installation pressure needs to be
decreased by draining water.
Water pressure is to low (<0,7 bar), FILL
indication remains continuously visible,
the boiler is taken out of operation. The
installation needs to be topped up.
0
From Good-read out to Technical read out (and vice versa):
- Press 5 sec. on the STEP key.
Installation & Servicing Instructions ATAG
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Content
1 Introduction ................................................................................................................................... 4
2 Regulations................................................................................................................................... 4
3 Scope of the supply ...................................................................................................................... 6
4 Description of the boiler................................................................................................................. 6
5 Mounting the boiler ....................................................................................................................... 6
5.1 Dimensions........................................................................................................................ 7
6 Connecting the boiler .................................................................................................................... 9
6.1 Central heating system ...................................................................................................... 9
6.2 Expansion vessel.............................................................................................................11
6.2.1 Expansion vessel module ................................................................................................ 12
6.3 Underfloor heating system (plastic pipes)......................................................................... 13
6.4 Gas connection ...............................................................................................................13
6.5 Hot water supply.............................................................................................................. 13
6.6 Condensation drain pipe................................................................................................... 14
6.7 Flue gas exhaust system and air supply system ............................................................. 15
6.7.1 Dimensions of the flue gas and air intake duct ................................................................. 18
7 External hot water cylinders........................................................................................................ 19
8 Electrical connection................................................................................................................... 20
9 Boiler controls............................................................................................................................. 22
9.1 Explanation of the function keys ...................................................................................... 23
10 Filling and venting the boiler and installation................................................................................ 24
10.1 Hot water supply.............................................................................................................. 24
11 Commissioning the boiler............................................................................................................ 25
11.1 Central heating system .................................................................................................... 25
11.2 Hot water supply.............................................................................................................. 25
11.3 Adjustments .................................................................................................................... 26
11.4 Activating factory settings (green key function) ................................................................ 28
12 Isolating the boiler...................................................................................................................... 29
13 Commissioning ........................................................................................................................... 29
13.1 Checking for contamination.............................................................................................. 29
13.2 Checking of the zero pressure control .............................................................................. 30
13.3 Checking the CO2............................................................................................................ 31
14 Maintenance ............................................................................................................................... 32
14.1 Frequency of maintenance............................................................................................... 32
14.2 Maintenance activities...................................................................................................... 33
14.3 Warranty.......................................................................................................................... 33
15 Technical specifications .............................................................................................................. 34
16 Parts of the boiler........................................................................................................................ 35
17 Installation examples .................................................................................................................. 36
17. 1 Radiator installation without thermostatic radiator valves .................................................. 36
17. 2 Radiator installation with underfloor heating zone ............................................................. 37
18 Error indication............................................................................................................................ 38
19 Declaration of conformity............................................................................................................. 39
The appliance should only be installed by a Competent Gas Installer.
Work on the boiler must be carried out by a competent person, (Ref: Gas
Safety Installation, Use and Regulations ) using correctly calibrated
instruments with current test certification.
Installation & Servicing Instructions ATAG
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1 Introduction
These instructions describe the functioning, installation, use and primary maintenance
of ATAG central heating units for the United Kingdom and Ireland. Where necessary the
different regulations for each country are separately described.
These instructions are intended for the use by Corgi registered installers or registered
Bord Gais installers in connection with the installation and putting into operation of ATAG
units. It is advisable to read these instructions thoroughly, well in advance of installation.
Separate instructions for use are supplied with the unit for users of ATAG central heating
units. ATAG is not liable for the consequences of mistakes or shortcomings which have
found their way into the installation instructions or user’s manual. Further, ATAG
reserves the right to alter its products without prior notification.
When delivering the unit, give the customer clear instructions concerning its
use; present the customer with the user’s manual and card.
Each unit is fitted with an identification plate. Consult the details on this plate to verify
whether the unit is compliant with its intended location, e.g.: gas type, power source
and exhaust classification.
On completion of the installation the installer or commissioning engineer must fill out and
complete the Benchmark commission section of the boiler log book and hand to customer
or end user for future record keeping. The Benchmark log book must also be filled out and
completed by the service agent following each service call, and returned to the customer.
A copy of the Benchmark commissioning certificate must be returned to ATAG Heating UK
Ltd along with the warranty registration card to register the appliance for the standard
warranty benefits
Relevant Installation, Service and User manuals:
- ATAG Cascade Hydraulic cascade system
- ATAG Monopass Flue system individual
- ATAG PP Overpressure Flue system cascade
- ATAG BrainQ Digital room thermostat
- ATAG MadQ Cascade-/Zone controller
2 Regulations
The following regulations apply to installation of ATAG central heating units:
Legislation and Regulations.
Gas Safety (Installation and Use). All gas appliances must by law, be installed by a
competent person, eg. Members of CORGI and in accordance with the current Gas Safety
Regulation. Failure to install appliance correctly could lead to prosecution.
In addition to the above regulations this appliance must be installed in compliance with the
current IEE Regulations, the Building Standards (Scotland Consolidation) Regulations.
Regulations and bye laws of the Local Water Authority and the Current Health and Safety
Regulation.
Ireland:
- Irish standard 813
- Domestic gas installations
Installation & Servicing Instructions ATAG
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The current, Electricity at Work Regulation must be complied with and also be in
accordance with the relevant and current editions of the British Standards.
The ATAG Q boiler is a certified appliance and must not be modified or installed in any
way contrary to this Installation Manual.
Manufacturers instructions must not be taken in any way as overriding statutory
obligations.
The ATAG Q is a central heating unit with an optional integrated hot water function.
These units must be connected according to these instructions and all installation
norms in respect of the part of the unit to be connected.
Observe the following rules of safety:
- All work on the unit must take place in a dry environment.
- ATAG units may never be in operation without their housing, except in connection
with maintenance or adjustments (see Chapter 13 and 14).
- Never allow electrical or electronic components to come into contact with water.
Carry out the following tasks in connection with maintenance, etc. to an already-
installed unit:
- Shut down all programmes
- Close the gas tap
- Remove the plug from the wall socket
- Close the stop cock of the unit’s intake connection
Take note of the following when maintenance or adjustments are needed:
- The unit must be able to function during these activities; for this reason, the unit’s
supply voltage, gas pressure and water pressure must be maintained. Ensure that
these is not a source of potential danger during these activities.
Following maintenance or other activities; always check the installation of all
parts through which gas flows (using leak-search spray).
Following maintenance or other activities, always replace the housing and
secure it with the screw behind the door at the front of the casing.
The following (safety) symbols may be encountered in these installation instructions
and on the unit:
This symbol indicates that the unit must be stored away from frost.
This symbol indicates that the packaging and/or contents can be damaged as
a result of insufficient care taken during transport.
This symbol indicates that, whilst still in its packaging, the unit must be
protected from weather conditions during transport and storage.
KEY-symbol. This symbol indicates that assembly or dismantling, must be
carried out.
ATTENTION symbol. This symbol indicates that extra attention must be paid
in connection with a particular operation.
Useful tip or advice
Installation & Servicing Instructions ATAG
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3 Scope of the supply
The boiler is supplied ready for use. The supply kit is composed as follows:
• Boiler with casing; • Template on the package wrapper;
• Automatic vent (inside the boiler); • Installation instructions
• Safety valve (inside the boiler); • Operating manual;
• Suspension bracket • Warranty card;
• Draining valve with T-piece; • Benchmark logbook.
• Fixing material consisting of plugs and
screws;
4 Description of the boiler
The ATAG Q boiler is a room sealed, condensing and modulating central heating
boiler, with or without an integrated hot water facility.
The boiler is provided with a compact stainless steel heat exchanger with smooth
tubes. A well thought out principal using durable materials.
The boiler burns gas for supplying warmth. The heat is transferred in the heat
exchanger to the water in the central heating system. By cooling down the flue gasses
condensate is formed. This results in high efficiency. The condensate, which has no
effect on the heat exchanger and the function of the boiler, is drained through an
internal siphon.
The boiler is provided with an intelligent control system (CMS Control Management
System). The boiler anticipates the heat demand of the central heating system or the
hot water facility.
When an outside sensor is connected to the boiler works weather dependantly. This
means that the boiler control measures the outside temperature and flow temperature.
With this data the boiler calculates the optimal flow temperature for the installation.
Explanation of the type indication: ATAG Q 51C
Q = Type
51 = Nominal load in kW
C = Combi (S = Solo)
The boiler has been tested according to valid CE* standards and has a CE* certificate
and SEDBUK A-rating.
Statement: No banned materials including asbestos, mercury, CFC's have not or will not
be included in the product.
Room sealed boiler
The boiler retreives its
combustion air to
outside then discharges the flue
gasses to the outside.
Condensing
Retrieves heat from the
flue gasses. Water
condensates on the
heat exchanger.
Modulating
Higher or lower burning
according to the heat
demand.
Stainless
Super solid kind of
steel which keeps its
quality for life. It will not
rust or erode in contrast to composition
materials, like aluminium.
Installation & Servicing Instructions ATAG
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5 Mounting the boiler
The room where the boiler will be placed must always be frost free.
It is NOT necessary to have a purpose provided air vent in the room or internal space in
which the boiler is installed. Neither is it necessary to ventilate a cupboard or
compartment in which the boiler is installed, due to the extremely low surface
temperature of the boiler casing during operation. Therefore the requirements of BS 6798,
Clause 12, and BS5440:2 may be disregarded.
The boiler can be mounted practically to any wall with the suspension bracket and the
enclosed fixing equipment. The wall must be flat and of sufficient strength in order to be able
to carry the boiler weight with its water content.
Above the boiler there must be at least 250 mm working space in order to be able to fit
a coaxial flue system or a twin supply. On the left side of the boiler at least 50 mm and
on the right side 10 mm must be reserved to allow fitting or removing of casing. The
location of the boiler can be determined by using the template located inside the boiler
packaging.
Lift the boiler only by the boilers rear wall
Lifting and carrying precautions:
- Lift only a manageable weight, or ask for help.
- When lifting the boiler, bend the knees, and keep the back straight and feet apart.
- Do not lift and twist at the same time.
- Lift and carry the boiler close to the body.
- Wear protective clothing and gloves to protect from any sharp edges.
Installation & Servicing Instructions ATAG
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Q
Solo Combi
Boile r ty pe
Q25S
Q38S
Q51S
Q60S
Q25C
Q38C
Q51C
mm mm mm mm
A Height
680 680 680 680
BWidth
500 660 840 1000
C Depth
385 385 385 385
D Left side / flue gas exhaust
335 495 335 495
E
Centre to centre / flue gas exhaust
and supply
120 120 120 120
F back / flue gas exhaust
270 270 270 270
G Left side / gas pipe
65 65 65 65
H Left side / flow pipe
185 185 185 185
J Left side / return pipe
285 445 285 445
K Left side / condensate pipe
370 530 370 530
L Left side / expansion pipe
430 430 590
M Left side / return pipe DHW
475
N Left side / cold water pipe
725 885
O Left side / hot water pipe
795 955
P Pipe length of g*
18 18 18 18
Q Pipe length of c*
50 50 50 50
R Pipe length of f, r, e, d, k and w*
60 60 60 60
S Back / Centre of pipe c*
25 25 25 25
T Back / Centre of pipe g*
40 40 40 40
U Back / Centre of pipe f, r, e, d, k and w*
50 50 50 50
5.1 Dimensions
dimensions talel 1
dimensions (in mm) figure 1
wall
C
E
F
A
U
T
S
wall
B
M
N
PQR
B
wall
D
H
J
K
1050
G
L
H
J
K
G
D
ceiling
Minimal 250mm
L
P
Installation & Servicing Instructions ATAG
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Solo Combi
Boiler type
Q25S
Q38S
Q51S
Q60S
Q25C
Q38C
Q51C
Combustion air supply / flue gas
system
mm 80/125 80/125 80/125 80/125
Gas pipe - g
½" fe male ¾" fem a le ½" fe male ¾" fem a le
Flow pipe - f
mm 28 35 28 35
Return pipe - r
mm 28 35 28 35
Condensate pipe - c
mm 24 24 24 24
Expansion pipe - e
mm 22 22
Cold water pipe - k
mm 15 15
Hot water pipe - w
mm 15 15
Return pipe DHW - d
mm 28
connection diameters table 2
boiler connections figure 2
g a r c e k wg a r c
Installation & Servicing Instructions ATAG
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6 Connecting the boiler
The boiler has the following connection pipes;
- The central heating pipes.
These can be connected to the installation by means of compression fittings;
- The gas pipe.
It is provided with a female thread into which the tail piece of the gas valve can be
screwed;
- The condensation drain pipe.
It consists of an oval 24 mm plastic pipe. The drain pipe can be connected to this
by means of an open connection. If the open connection is fitted in a different location,
then the pipe can be lengthened by means of a 32 mm PVC sleeve;
- The flue gas exhaust system and air supply system.
It consists of a concentric connection 80/125 mm.
- Cold and hot water pipes.
Only Combi boilers: These consist of 15 mm copper pipe and can be connected
to the installation by means of compression fittings.
It is recommended that isolation valves are fitted to all heating and hot water
connections to facilitate ease of future maintenance.
It is advisable to spray-clean all of the unit’s connecting pipes and/or to
spray-clean/blow-clean the installation before connecting it to the unit.
6.1 Central heating system
Connect the central heating system according to the actual regulations.
The boiler pipes can be connected to the installation by means of compression fittings.
Reducers should be used for connecting to thick-walled pipe (welded or threaded).
When removing the plastic sealing caps from the pipes, contaminated testing
water may be released.
The boiler has a self-adjusting and self-protecting control system for the load and the pump
capacity. By this means the temperature difference between the flow and return water is
checked. Table 3 shows the water displacement which supplies th e circulation pump at
certain installation resistance.
A low velocity header must be connected to the Q51C, Q51S and Q60S to
prevent flow problems over the boiler.
ATAG supplies the AA1OV09U Low velocity header for 1 boiler. This can be connected
directly under the boiler on the flow and return pipe.
Boiler type pump type water flow ra te permissible installation
resistance
UPER l/min l/h kPa mbar
Combi
Q25C
20-60 16,2 972 29 290
Q38C
20-70 24,6 1478 20 200
Q51C
20-70 30,1 1803
Solo
Q25S
20-60 9,7 583 47 470
Q25S
20-60 1 6,2 972 32 320
Q38S
20-70 24,6 1478 22 220
Q51S
20-7030,11803
Q60S
20-70 38,9 2333
Installation resistance table 3
Installation & Servicing Instructions ATAG
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If the installation resistance is higher than the stated value the pump will rotate at
maximum pump capacity and the load will be adjusted until an acceptable temperature
difference between flow and return water has been obtained. If, after this, the
temperature difference remains to much then the boiler will switch itself off and wait
until an acceptable temperature has arisen.
If an unacceptable temperature is detected, then the control will repeatedly try to
achieve water flow, and if this does not work then the boiler will switch off.
If the capacity of the boiler pump is insufficient, an extra external pump can be installed
in combination with a low velocity header in series with the boiler. The electrical side of
this external circulation pump can be connected in the Control Tower, by which means
this pump switches at the same times as the boiler pump.
The maximum absorbed current consumption of the external circulation pump may be
230 W (1 Amp). The extra external pump must be selected according the installation
resistance and required flow.
pump index lines graph 1
Q(m³/h)
100%
UPER 20-70
Q25C, Q38C
Q25S, Q38S
100%
UPER 20-60
H(m)
25%
UPER 20-60
25%
UPER 20-70
As standard the boiler is provided with a water filter in the return pipe of the boiler. With
this, possible contamination of the central heating water is prevented from ending up
in the boiler. The boiler is also provided with an internal safety valve set at 3 bar. This
is connected to the waste discharge together with the condensation discharge.
If all, or a large part of the radiators are provided with thermostatic radiator valves it is
advisable to use a pressure difference control (bypass) in order to prevent flow problems
in the installation.
The boiler is designed to be used on sealed system only.
Additives in the installation water are only permitted in consultation with the
country distributor.
When using more than one boiler in an installation please refer to the cascade
installation instructions.
external installation pump
with low velocity header
figure 3
Installation & Servicing Instructions ATAG
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6.2 Expansion vessel
The central heating system must be provided with an expansion vessel. The expansion
vessel which is used should be geared to the water content of the installation. The precharge pressure depends on the installation height above the mounted expansion
vessel. See table 4.
All Combi boilers are provided with an expansion vessel connection. This pipe is
connected with the three way valve and boiler pump. This prevent the expanding
water, during hot water production, is being closed off from the expansion vessel, when
the thermostatic radiator valves are fully closed. A second expansion vessel in the
installation is not a problem.
The Solo boilers Q15S, Q25S and Q38S are provided with an expansion vessel
connection. When this boiler is combined with a cylinder, the expansion vessel
connection is included in the internal piping of the cylinder circuit, to which the expansion
vessel can be connected.
In connection with correct functioning of the boiler it is necessary for the
expansion vessel to be connected to the expansion vessel pipe of the boiler.
The Solo boilers Q51S and Q60S are not provided with an expansion vessel
connection. When one of these Solo boilers is combined with a cylinder then one has
to take into account that the expansion vessel should be connected between the threeway valve and the boiler circulation pump.
choice of expansion vessel table 4
insta lla tio n heigh t a bove
the expansion vessel
pre-charge pressure
of the expansion vessel
5 m 0,5 bar
10 m 1,0 bar
15 m 1,5 bar
Installation & Servicing Instructions ATAG
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side view of the module with boiler (dimensions in mm) figure 5
540
wall
155
385
front view of the module with boiler (dimensions in mm) figure 6
660
105
6.2 Expansion vessel module
The ATAG Q25S and Q38S boilers can be provided with an expansion vessel module.
By this means the external expansion vessel is not required. This expansion vessel
module is placed behind the ATAG Q boiler, by which means the expansion vessel is not
noticeable. The content of the two expansion vessels is 20 litres. The pre-charge pressure
is 1 bar.
The expansion vessel module can be supplied with the necessary pipes to connect with
the ATAG Q boiler. The connecting pipes for the installation correspond with those of
the boiler and have the same centre-to-centre distance to the wall.
When checking the expansion vessels these are accessible via the left, right and upper
sides. From these sides the tanks are also removable and the boiler does not have to
be dismantled.
The space which is required for mounting the expansion vessel module corresponds
with the required space for mounting an ATAG Q boiler. They included template and
mounting strip for the boiler which can be used for the expansion vessel module. The
boiler is fitted on to this after the expansion vessel module has been mounted. The
necessary mounting strip for the boiler is present on the module.
Article numbers:
- the expansion vessel module without pipe connections AA1EM09U
- pipe connections for expansion vessel module AA1LE04U
480
expansion vessel module
figure 4
Installation & Servicing Instructions ATAG
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6.3 6.3 Underfloor heating system (plastic pipes)
When connecting or using an underfloor heating system, designed with plastic pipes,
or plastic pipes are used elsewhere in the installation,one should ensure that the plastic
pipes used comply with the DIN 4726/4729 standard. It is set out in this standard that
the pipes may not have oxygen permeability higher than 0.1 g/m³.d at 40°C. If the system
does not comply with this DIN standard, the underfloor heating component will have to
be separated from the central heating appliance by means of a plate exchanger.
No recourse can be made to the terms of the warranty in the event of failure
to observe the regulations pertaining to plastic underfloor heating pipes.
6.4 Gas connection
The appliance pipe is fitted with an internal thread, into which the tail piece of the gas
tap can be screwed.
United Kingdom:
The gas supply must comply to the current Gas Safety Regulations.
Ireland:
- Irish standard 813
- Domestic gas installations
The connection to the appliance must include a suitable method of disconnection and a
gas control cock must be installed adjacent to the appliance for isolation purposes. The
nominal inlet working gas pressure measured at the appliance should be 20 mbar for Nat
gas (G20).
Make sure that the gas pipe work does not contain dirt, particularly with new
pipes.
When the boiler has to be converted from natural gas to LPG, ATAG provides special
kits for this purpose. Special instructions are supplied with the kit.
Always check the installation of all of the parts through which gas flows
(using leak-search spray)
6.5 Hot water supply
Connection of the drinking water installation should be done according to the national
water laws.
The sanitary water pipes can be connected to the installation by means of compression
fittings. The cold water inlet on the Combi boilers must be provided with the following
(counted in the water flow direction):
Dosing valve (supplied), Safety group, Expansion vessel 6bar (potable water, blue).
A dosing valve must be fitted in the cold water pipe. The dosing valve ensures that a
quantity of water is supplied which has a guaranteed outlet temperature of 60°C
(assuming a cold water temperature of 10°C). The quantity of water is virtually
unaffected by the water pressure.
With a water pressure lower than 1.5 bar it is advisable to remove the inside mechanism
of the dosing valve.
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