Atlantic Varmax Twin Instructions For Installation, Use And Maintenance Manual
Document No. 00BNO9132-# / 23.02.2015
VARMAX TWIN
GAS CONDENSING BOILER
550 to 900 kW
with modulating burner for
natural gas
ENFR DE ES IT NL
Instructions
for installation,
use and main-
tenance
MANUFACTURER:
R
P
O
E
D
V
I
U
T
C
E
L
L
O
C
C
T
PONT DE VAUX
(FRANCE) SITE
1 route de Fleurville - BP 55
FR - 01190 PONT-DE-VAUX
VARMAX TWIN - Installation, Use and Maintenance
SOMMAIRE
1. AVERTISSEMENTS ET RECOMMANDATIONS ....................................................................4
1.1. Limite de fourniture de la VARMAX TWIN .....................................................................................................4
1.2. Transport et stockage ....................................................................................................................................4
1.3. Symboles utilisés dans ce document ............................................................................................................4
1.4. Qualifi cation du personnel pour l'installation, le réglage, l'utilisation et l'entretien ........................................5
1.5. Consignes de sécurité ................................................................................................................................... 5
1.6. Caractéristiques de l'eau ...............................................................................................................................5
2. HOMOLOGATIONS ................................................................................................................6
2.1. Conformités aux Directives Européennes .....................................................................................................6
2.2. Conditions réglementaires d’installation pour la France ...............................................................................6
2.3. Conditions réglementaires d'installation pour la Belgique .............................................................................6
2.4. Conditions réglementaires d'installation autres pays ....................................................................................7
2.5. Compatibilité environnementale ....................................................................................................................7
2.6. Catégorie gaz ................................................................................................................................................7
2.7. Pressions d'alimentation gaz ......................................................................................................................... 7
3. SPÉCIFICATIONS TECHNIQUES ..........................................................................................8
3.1. Dimensions ...................................................................................................................................................8
3.2. Passage de porte ..........................................................................................................................................9
3.3. Combustion à 15°C et 1013 mbar .................................................................................................................9
3.4. Conditions d'utilisation .................................................................................................................................10
3.5. Raccordement électrique ............................................................................................................................10
4. INSTALLATION .....................................................................................................................11
4.1. Mise en place des fi ltres à air et des nappes fi ltrantes ............................................................................... 1 1
4.2. Mise en place de la chaudière .................................................................................................................... 11
4.3. Mise en place des goulottes de passage câble bus LPB ............................................................................13
4.4. Ouverture / fermeture des portes d'habillage .............................................................................................. 14
4.5. Démontage des panneaux de commande (IHM) ........................................................................................14
4.6. Démontage / remontage des portes d'habillage..........................................................................................14
4.7. Démontage / remontage des panneaux latéraux ........................................................................................14
4.8. Démontage / remontage des panneaux supérieurs ....................................................................................14
4.9. Marchepied .................................................................................................................................................14
4.10.Changement de gaz (de G20 à G25) .........................................................................................................14
4.11.Raccordement fumées ...............................................................................................................................15
4.12.Raccordement hydraulique ........................................................................................................................19
4.13.Raccordement gaz .....................................................................................................................................22
4.14.Raccordement électrique ...........................................................................................................................22
5. MISE EN SERVICE ...............................................................................................................24
6. CONTRÔLES APRÈS LA MISE EN SERVICE.....................................................................24
7. OPÉRATIONS D'ENTRETIEN ..............................................................................................24
8. SCHÉMAS HYDRAULIQUES ET PARAMÉTRAGES ..........................................................25
9. LISTE DES PIÈCES DÉTACHÉES .......................................................................................55
Edition: 02 / 2015 Page 3 / 56
VARMAX TWIN - Installation, Use and Maintenance
1. WARNINGS AND RECOMMENDATIONS
PLEASE READ THIS MANUAL CAREFULLY BEFORE INSTALLING,
MAINTAINING AND USING THE BOILER. IT CONTAINS IMPORTANT
SAFETY INFORMATION.
1.1. VARMAX TWIN supply limits
The VARMAX TWIN boiler you have received is composed of:
• 2 VARMAX type generators with the same power to be connected to each
other
• 1 450 mm common exhaust fl ue between the generators
• 4 T efl on plates (to help position the generators)
• 2 LPB bus cable trays with holding screws
• 1 LPB bus cable
• 2 OCI 345 communication modules with holding screws
• 1 QAZ 36 fl ow sensor
INFORMATION:
The hydraulic connection elements to be added according to the
diagram are not supplied (refer to chapters 4.12 and 8).
This manual describes the specifi c features of the assembly. Everything
which relates to one of the 2 generators (internal accessibility, settings,
maintenance, spare parts, etc.) is described in the particular generator's
manual. The following data must therefore be used:
- For the VARMAX TWIN 550, see the information for the VARMAX 275,
- For the VARMAX TWIN 640, see the information for the VARMAX 320,
- For the VARMAX TWIN 780, see the information for the VARMAX 390,
- For the VARMAX TWIN 900, see the information for the VARMAX 450.
1.2. Transport and storage
The generators:
- must be arranged horizontally in a place where the temperature is between
0 °C and +50 °C and whose relative humidity is between 5% and 95%.
- must not be stacked,
- must be protected from humidity.
1.3. Symbols used in this document
INFORMATION: This symbol draws attention to comments.
Failure to comply with these instructions may
IMPORTANT:
!
Page 4 / 56 00BNO9132-#
cause damage to the installation or to other
objects.
VARMAX TWIN - Installation, Use and Maintenance
WARNING:
!
WARNING:
Failure to comply with these instructions may
cause injury and serious material damage.
Failure to comply with these instructions may
cause electrocution.
1.4. Qualifi cation of personnel for installation, adjustment, use and mainte-
nance
The operations to install, adjust and maintain the boiler must be carried out
by qualifi ed and approved professionals in accordance with current local
and national regulations. These operations may required intervention under
voltage, with the casing doors (located on the front of the generators) open.
The basic usage operations must be carried out with the casing doors closed.
1.5. Safety instructions
• Always remove the power supply to the boiler and shut off the overall gas
supply to it before carrying out any work on it.
!
!
WARNING:
WARNING:
WARNING:
• Check that there are no gas leaks on the installation after any intervention
on the boiler (maintenance or repair).
If you smell gas:
• Do not use any naked fl ames, smoke or activate any contacts or
electric switches.
• Switch off the gas supply.
• Ventilate the premises.
• Look for the leak and correct it.
If any smoke is released:
• Switch off the generators.
• Ventilate the premises.
• Look for the leak and correct it.
This boiler's earth continuity is provided by link cables (green/yellow)
and specifi c holding screws. During any disassembly operations,
make sure that the cables in question are reconnected; you MUST
also reuse the original holding screws.
1.6. Water characteristics
Refer to the V ARMAX generator's installation, use and maintenance manual.
Edition: 02 / 2015 Page 5 / 56
VARMAX TWIN - Installation, Use and Maintenance
2. APPROVALS
2.1. Compliance with European Directives
- Low voltage (2006/95/CE)
This appliance is not intended for use by persons (including children)
whose physical, sensory or mental abilities are reduced, or persons
without experience or knowledge, unless they have been able to
benefi t, through someone responsible for their safety , from supervision
or prior instruction concerning the use of the appliance.
Children must be supervised to ensure they do not play with the
appliance.
- Electromagnetic compatibility (2004/108/CEE)
- Effi ciency (92/42/CEE)
- Gas appliances (2009/142/CE)
2.2. Regulatory installation conditions
The appliance must be installed and maintained by a qualifi ed professional,
in accordance with the regulations and current regulatory practices in the
country where the boiler is installed.
2.3. Environmental compatibility
This appliance contains electrical and electronic elements which must not be
thrown away with household waste.
Local legislation must be complied with.
2.4. Gas category
This boiler has been adjusted in the factory to work with group H (type G20)
natural gas with a supply pressure of 20 mbar.
INFORMATION: Any work on a sealed component will lead to loss of the guarantee.
Category
CZ, DK, EE, FI, GB, GR, HU, IE, LT,
LV, NO, RO, SE, SI, SK, TR
Page 6 / 56 00BNO9132-#
I
2H
2.5. Gas supply pressures
VARMAX TWIN - Installation, Use and Maintenance
INFORMATION:
The pressures provided below must be taken at the input to the gas
valve (20 mbar).
Natural gas H G20
20 mbar
Nominal pressure (mbar) 20
Minimum pressure (mbar) 17
Maximum pressure (mbar) 25
Edition: 02 / 2015 Page 7 / 56
VARMAX TWIN - Installation, Use and Maintenance
3. TECHNICAL SPECIFICATIONS
3.1. Dimensions
3°
D
A
±
10
450
B
3°
E
sleeve for safety valve on
each generator (F 1"1/4)
F
ø
45 min
60 max
C
MODELS
550 640 780 900
A (mm) 2059 2259
B (mm) 1877 2023
C (mm) 2032 2114
D (mm) 2519 2749
E (mm) 1500 1590
Ø F (mm) 250 300
The diameter indicated is the interior
diameter.
fi gure 1 - Dimensional characteristics
The dimension of 450 mm between the 2 generators must be respected
IMPORTANT:
!
Page 8 / 56 00BNO9132-#
to assemble the exhaust fl ue (it is not a minimum or maximum
dimension).
VARMAX TWIN - Installation, Use and Maintenance
3.2. Doorway
Refer to the V ARMAX generator's installation, use and maintenance manual.
3.3. Combustion at 15°C and 1013 mbar
MODELS
550 640 780 900
Nominal power Pn (80/60°C) kW 536 624 762 878
Nominal power when condensing Pn
(50/30°C)
kW 580 676 830 956
Rated heat input Qn kW 550 640 780 900
Min heat input Qmin kW 66 66 87 87
Gas fl ow rate at Pn (15 °C) * m
CO
value range %
2
Exhaust mass fl ow rate at Qn / Qmin
(80/60°C) *
Exhaust mass fl ow rate at Qn / Qmin
(50/30°C) *
Exhaust temperature at Qn / Qmin
(80/60°C) *
Exhaust temperature at Qn / Qmin
(50/30°C) *
Firebox pressure at nominal Qcal
(B23)
3
/h 58.2 67.72 82.6 95.2
g/s
g/s
240.1 and 31257.7 and
225.9 and 26239.5 and
°C 61 and 54.7
°C
35.4 and
30.7
at Qmin: 8.3 % < CO
at Qmax: 8.8 % < CO
30.9
26.6
60.8 and
55.1
37.1 and 31 36 and 29.3 36 and 30.4
< 8.7 %
2
< 9.2 %
2
352 and 43 398 and 44
327 and 41 378 and 42
60.3 and
54.5
62.1 and
55.6
Pa 132 162 152 203
Exhaust outlet interior diameter mm 250 250 300 300
Maximum allowable nozzle pressure
(B23P) at Qn / Qmin (80/60°C)*
Maximum allowable nozzle pressure
(B23P) at Qn / Qmin (50/30°C)*
Combustion air fl ow rate at Qn *
(15°C)
Pa 127 and 3 151 and 3 177 and 3 200 and 3
Pa 104 and 3 123 and 3 149 and 3 178 and 3
3
m
/h 704.8 820.2 999.6 1153.4
NOx class 5
Smoke removal and air inlet type
classifi cations
B23, B23P
* values corresponding to a G20 setting.
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VARMAX TWIN - Installation, Use and Maintenance
3.4. Operating conditions
MODELS
550 640 780 900
Max fl ow temperature setting °C 85
Max fl ow temperature °C 88
Maximum safe temperature °C 110
Max service pressure
Min cold pressure
hPa
(bar)
hPa
(bar)
Hydraulic pressure loss at ∆T 20 per generator
2 or 3 tapping version 820 1185 770 970
4 tapping version
Main exchanger
Condenser
Nominal water fl ow rate (P/20) VARMAX TWIN m
Nominal water fl ow rate (P/20) per generator m
Maximum water fl ow rate (P/10) per generator m
daPa
790
50
3
/h 23 26.8 32.8 37.8
3
/h 11.5 13.4 16.4 18.9
3
/h 23.0 26.8 32.8 37.8
Total water content (2 generators) L 478 478 574 574
Total weight without water (2 generators) kg 1050 1050 1240 1240
Installation premises temperature (min / max) °C 5 and 45
Installation premises relative humidity between 5% and 95%
Protection level IP20
Maximum installation altitude m 2000
1060
65
6000
(6)
1000
(1)
660
190
840
230
3.5. Electrical connection
MODELS
550 640 780 900
Electrical supply V 230 V AC (+10% -15%), 50Hz
Electrical power consumed at Qn (excluding
accessory) VARMAX TWIN
Electrical power consumed in standby mode
VARMAX TWIN
Maximum length of sensor cables m
Power terminal output per generator
W 476 704 960 1320
W10
DHW sensor: 10
Outdoor sensor: 40 in 0.5 mm² (120 in 1.5 mm²)
Ambient thermostat: 200 in 1.5 mm²
Room thermostat: 200 in 1.5 mm²
V 230V AC (+10%, -15%)
A 5 mA at 1A
Page 10 / 56 00BNO9132-#
VARMAX TWIN - Installation, Use and Maintenance
4. INSTALLATION
4.6. Positioning the air fi lters and the fi ltering layers
!
IMPORTANT: The air fi lters provided with the generators MUST be installed.
The air fi lters must be installed before the gas lines are connected.
Refer to the VARMAX generator's installation, usage and maintenance
manual, paragraph "4-1 Positioning the air fi lter and the layer").
4.7. Installing the boiler
The VARMAX TWIN boilers must not be installed on an fl ammable surface
(wooden fl oor , plastic fl oor covering, etc.).
Recommended distances relative to walls and ceiling:
Suffi cient clearances must be provided to permit easy maintenance
operations on the boilers.
The minimum values (in mm) are indicated in fi gure 2 and in the table below.
A* B* C H
550 450 600 263
640 450 600 263
780 450 700 427
MODELS
900 450 700 427
A
±10
C
450
H
B
fi gure 2 - Peripheral clearance
The greyed out zone above the boiler must remain free of any obstacles
to enable the burner to be inspected and cleaned.
These values cannot be substituted for the specifi c regulatory
requirements.
Edition: 02 / 2015 Page 11 / 56
VARMAX TWIN - Installation, Use and Maintenance
• The 2 VARMAX generators must be positioned horizontally using a
spirit level to enable effective gas release for the exchanger body
(use the base as the reference surface).
!
IMPORTANT:
• The space between the 2 VARMAX generators must be 450
• A 2 cm free space must also be left above the side panels to allow
for their disassembly and reassembly.
• The 2 generators must be in the same alignment and on the same
horizontal level.
450
±10
±10
mm.
OK
OK
OK
fi gure 3 - Generator positioning
To adjust the fl ush level, screw or unscrew the 4 adjustable feet, using a 17
mm wrench.
Page 12 / 56 00BNO9132-#
VARMAX TWIN - Installation, Use and Maintenance
4 Tefl on plates are provided to facilitate the introduction of the 2 generators
in relation to each other:
• Put one plate under each of the 4 feet of the generator to be moved,
Tefl on plates (x4)
fi gure 4 - Tefl on plate positioning
• Position the generator,
• Remove the Tefl on plates.
4.8. Installing the LPB bus cable trays
Position the 2 trays for the LPB bus cable on the rear of the 2 generators and
secure them using the 4 self-tapping screws provided.
4 self-tapping screws provided
}
fi gure 5 - cable trays
The roof of each generator must be drilled (Ø 4 bit); to do so, use the trays
as scale.
Edition: 02 / 2015 Page 13 / 56
VARMAX TWIN - Installation, Use and Maintenance
4.9. Opening / closing the casing doors
Refer to the V ARMAX generator's installation, use and maintenance manual.
4.10. Removing the control panels (MMI)
Refer to the V ARMAX generator's installation, use and maintenance manual.
4.11. Installing / removing the casing doors
Refer to the V ARMAX generator's installation, use and maintenance manual.
4.12. Installing / removing the side panels
Refer to the V ARMAX generator's installation, use and maintenance manual.
4.13. Installing / removing the upper panels
Refer to the V ARMAX generator's installation, use and maintenance manual.
4.14. Step
Refer to the V ARMAX generator's installation, use and maintenance manual.
Page 14 / 56 00BNO9132-#
4.15. Exhaust connection
There is a specifi c connection for the exhausts to the VARMAX TWIN
!
IMPORTANT:
INFORMATION:
boilers. Do not refer to the VARMAX generator's installation, use and
maintenance manual.
The size of the chimney pipes must be determined taking account of
combustion gas pressure on boiler output equal to 0 Pa (see table § 3.3).
You must comply with the regulatory texts and rules of the art that apply in
the country where the boiler will be installed, i.e.:
One exhaust temperature sensor per generator guarantees the
protection of the combustion product evacuation ducts.
The VARMAX TWIN boilers are approved to be connected to:
The duct lengths provided below are in linear metres (ml). The total length
of all the ducts is rounded to a straight-line length (the curves have a
straight-line equivalent).
VARMAX TWIN - Installation, Use and Maintenance
• a B23 chimney (all models)
• a B23P chimney (all models)
4.15.1. Installing the exhaust fl ue
The fl ue provided may be installed either to the right or the left of the VARMAX
TWIN boiler.
Example with exhaust outlet to the left:
fi gure 6 - Flue orientation
When assembling the fl ue, we recommend fi tting the assembly on
INFORMATION:
Edition: 02 / 2015 Page 15 / 56
the ground then installing it on the 2 generators. At least 3 people are
required to handle and secure the assembly.
VARMAX TWIN - Installation, Use and Maintenance
Measurement
(upwards)
ITEM
1
2
3
4
5
6
7
8
9
10
11
MODELS
DESCRIPTIONS QTY
550 - 640 kW 780 - 900 kW
AC-250-180 AC-300-200 Offset increase
ED 250-250 CD ED 250-300 CD Straight element length 250
EC 90-250 CD EC 90-300 CD 90° curved element
ER 26/40 250 CD ER 26/40 300 CD Adjustable element length 260-400
T 135-250 CD T 135-300 CD T 135°
EPMF 250 EPMF 300 Measurement element
ER 55/90 250 ER 55/90 300 Adjustable element length 550-900
CEPL 250 CD CEPL 300 CD Side drain buffer
SIPHON 1" SIPHON 1" Siphon
JOINT-CD-250 JOINT-CD-300 Seal
-- -- Tube of grease for seals
support collars
7
2
2
4
2
2
2
1
1
1
1
19
1
8
5
6
4
10
3
11
Indicative values
550 - 640 kW models: 1250 mm
780 - 900 kW models: 1350 mm
1
1
fi gure 7 - Flue assembly
2
2
to condensation
neutraliser
9
The 2 collars delivered with the smoke works kit may be used to
IMPORTANT:
!
support the assembly either on the ceiling or on the ground (their
position is "greyed out" on each T at 135° - fi gure 7).
During fi nal connection to the generator exhaust outlet nozzles, make
IMPORTANT:
!
Page 16 / 56 00BNO9132-#
sure that there are not too many mechanical demands on the 2 offset
increases (item 1) as this may create seal losses for the exhaust.
4.15.2. Connection to a B23 chimney
B23 type connection:
Air from the installation premises, gas evacuation through the roof via a
natural draft pipe.
Check that the boiler installation premises have high and low
!
IMPORTANT:
ventilation, that it conforms to current regulations and that it is not
obstructed.
The size of the chimney pipes must be determined taking account of
combustion gas pressure on boiler output equal to
The exhaust extraction ducts must be made in a material resistant to the
condensate that can form when the boiler is operating. These materials
must also be able to withstand exhaust temperatures up to 120°C. Horizontal
pipes must be avoided to limit condensation build-up.
Check that the combustion gas is evacuated via a sealed connection.
VARMAX TWIN boilers are high performance boilers with very low exhaust
temperatures; consequently to retain a favourable draft the ducts must run
upwards from the boiler outlet.
VARMAX TWIN - Installation, Use and Maintenance
0 Pa (see table § 3.3).
Check:
!
WARNING:
1. That the fl ue is not under pressure, with both generators operating.
2. If one of the generators is operating at minimum power, that the
other generator does not discharge into it.
Dimensioning recommendations based on a POUJOULAT type
(Condensor type) supply:
ø duct
(1 m)
ø connection
hose PROHIBITED
!
for the elbow joint
H
fi gure 8 - Sizing recommendations
Edition: 02 / 2015 Page 17 / 56
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