Atmos InterCombi Installation Instructions Manual
Atmos InterCombi
ATMO
S
ATMO
S
Installation Instructions
Atmos Heating Systems
West March
Daventry
Northants, NN11 4SA
Tel: 01327 871990
Fax: 01327 871905
e-mail:
sales@atmos.uk.com
internet: www.atmos.uk.com
Issue 1.4.05
© 2005 Atmos Heating Systems
The information provided applies to the product in the standard model. Atmos Heating
Systems can therefore not be held liable for any damage resulting from the product
specifications that deviate from the standard model.
The information provided has been compiled with the utmost care. However, Atmos
Heating Systems cannot be held liable for any faults in the information nor for the
consequences thereof.
Atmos Heating Systems cannot be held liable for any damage resulting from the
activities carried out by third parties.
To be changed without prior notice
2
TABLE OF CONTENTS
1. Safety Regulations 7
1.1 General.......................................................................................................................................................................7
1.2 CH system...................................................................................................................................................................7
1.3 Gas system.................................................................................................................................................................7
1.4 Electrical system.........................................................................................................................................................7
1.5 Domestic water system...............................................................................................................................................7
1.6 Flue discharge and air supply.....................................................................................................................................7
2. Description of the Appliance 8
2.1 General.......................................................................................................................................................................8
2.2 Operation....................................................................................................................................................................8
2.3 Operating conditions...................................................................................................................................................8
2.4 PC interface..............................................................................................................................................................10
2.5 Test programmes......................................................................................................................................................11
2.5.1 Frost protection................................................................................................................................................11
3. Main Components 12
3.1 Accessories...............................................................................................................................................................13
4. Installation 14
4.1 Overall dimensions....................................................................................................................................................14
4.2 Unpacking the appliance............................................................................................................................... ............15
4.3 Additional dimensions...............................................................................................................................................15
4.4 Boiler location............................................................................................................................................................16
4.4.1 Installation in a kitchen cupboard.....................................................................................................................16
4.4.2 Installation in an airing cupboard......................................................................................................................16
4.4.3 Remove front panel..........................................................................................................................................16
4.5 Mounting...................................................................................................................................................................17
4.5.1 Fitting the mounting strip..................................................................................................................................17
4.5.2 Fitting the mounting strip and the mounting bracket.........................................................................................17
4.5.3 Fitting the top connecting frame.......................................................................................................................17
4.5.4 Installation connections....................................................................................................................................17
4.6 Mount the appliance..................................................................................................................................................18
4.7 Fit the pipework cover...............................................................................................................................................18
5. Connections 19
5.1 Connect the CH system............................................................................................................................................19
5.1.1 Expansion vessel.............................................................................................................................................19
5.1.2 Thermostatic radiator valves............................................................................................................................19
5.1.3 System bypass.................................................................................................................................................19
5.1.4 Underfloor heating............................................................................................................................................20
5.2 Hot water system......................................................................................................................................................21
5.2.1 Appliance with pre-heating by solar system.....................................................................................................21
5.3 Connecting the gas supply........................................................................................................................................22
5.4 Electrical connection.................................................................................................................................................22
5.4.1 Electrical connections.......................................................................................................................................22
5.4.2 Room thermostat on/off....................................................................................................................................23
5.4.3 Outside temperature sensor.............................................................................................................................23
5.5 Flue discharge and air supply...................................................................................................................................24
5.5.1 Twin-pipe connection.......................................................................................................................................24
5.5.2 Concentric connection......................................................................................................................................24
5.5.3 Pipe, materials and insulation..........................................................................................................................24
5.5.4 Flue terminal clearances..................................................................................................................................25
5.5.5 Flue system......................................................................................................................................................25
5.6 Pipe lengths..............................................................................................................................................................26
5.6.1 Equivalent lengths............................................................................................................................................26
5.6.2 Example of 80mm twin pipe calculation...........................................................................................................26
5.6.3 Example of 80/125mm concentric pipe calculation..........................................................................................26
3
5.6.4 Outlet arrangements.........................................................................................................................................27
5.6.5 Flue discharge pipe and air supply pipe...........................................................................................................27
5.7 Outside wall outlet for twin pipe terminal - horizontal................................................................................................28
5.8 Outside wall and roof outlet concentric terminal horizontal.......................................................................................30
5.9 Roof outlet combination and twin pipe terminal - vertical..........................................................................................31
5.10 Roof outlet prefabricated chimney............................................................................................................................. 34
5.11 Roof outlet and air supply from the outside wall........................................................................................................35
5.12 Air supply from the outside wall and a roof outlet with common discharge system...................................................36
5.13 Roof outlet CLV system............................................................................................................................................37
6. Commissioning 38
6.1 Fill and de-aerate the appliance and the system.......................................................................................................38
6.1.1 CH system........................................................................................................................................................38
6.1.2 Hot water supply...............................................................................................................................................38
6.1.3 Gas supply.......................................................................................................................................................38
6.2 Commissioning of the appliance...............................................................................................................................39
6.3 System Shutdown.....................................................................................................................................................40
6.3.1 Frost protection................................................................................................................................................40
7. Setting and Adjustment 41
7.1 Directly via operating panel.......................................................................................................................................41
7.2 Settings through the service code.............................................................................................................................41
7.3 Parameters................................................................................................................................................................42
7.4 Setting maximum CH power......................................................................................................................................43
7.5 Setting pump position................................................................................................................................................43
7.6 Weather-dependent control.......................................................................................................................................44
7.7 Conversion to other gas type....................................................................................................................................44
7.8 Gas-air control...........................................................................................................................................................44
7.9 Setting gas-air control...............................................................................................................................................45
8. Faults 47
8.1 Burner does not ignite...............................................................................................................................................48
8.2 Burner ignites with much noise.................................................................................................................................48
8.3 Burner resonates.......................................................................................................................................................49
8.4 No heating (CH)........................................................................................................................................................49
8.5 Reduced output.........................................................................................................................................................50
8.6 CH does not reach the correct temperature..............................................................................................................50
8.7 No hot water (HW)....................................................................................................................................................50
8.8 Hot water does not reach the correct temperature....................................................................................................51
9. SERVICING THE BOILER 52
10. Technical Specifications 53
10.1 Electrical diagram......................................................................................................................................................54
11. CE Declaration 55
4
This manual
Using this manual you can safely install and maintain this appliance.
Carefully follow the instructions.
In case of doubt, contact Atmos Heating Systems.
Keep these instructions near the appliance.
Abbreviations and names used
Description To be referred
to as
High Efficiency HE
Atmos InterCombi wall-mounted gas heater Appliance
Appliance with piping for central heating CH system
Appliance with piping for domestic water HW system
Icons
The following symbols are used in this manual:-
CAUTION
Procedures that, when not carried out with due care,
may result in damage to the product or the
environment or in personal injury.
Service and technical support
For information about specific adjustments, installation, maintenance
and repair activities, please contact:
Atmos Heating Systems,
West March,
DAVENTRY,
Northants, NNII 4SA
www.atmos.uk.com
5
Guarantee conditions
Considering the conditions mentioned below, Atmos guarantees towards
the recognised installer the soundness of the materials used, as well as
the good operation of its Central Heating products, if applied for their
intended use. When the occasion arises, we should be given the
opportunity to ascertain ourselves, if necessary on the spot, of the validity
of the guarantee claim.
The guarantee includes:
1. The guarantee is limited to the free redelivery of the parts showing material
or manufacturing faults that are not the result of normal wear and the like
during the guarantee period, entirely at our discretion. These parts should be
returned to us prepaid mentioning the defect and they will be our property
after replacement.
2. The guarantee period for parts is 2 years as from the date of installation.
However, the following parts have been excluded from guarantee: ignition
probe, ionisation pin, glass fuse, thermocouple and de-aerator.
3. The period of guarantee for the heat exchanger of the appliance is 5 years,
provided that if corrosion leaks occur that can, at our discretion, not be
remedied on the spot, we only deliver this part of the boiler for a fee of old for
new, calculated from the installation date at the time of replacement.
4. A copy of the completed Benchmark Boiler Commission Certificate must be
returned as proof of correct commissioning.
5. The guarantee shall no longer be valid when it is established that the
defects, damage or excessive wear are due to improper use or injudicious
treatment or to unskilful repair, adjustment, installation or maintenance by
non-approved installers.
6. The guarantee is no longer valid when the defect is the result of deposition of
scale (harmful to the appliance and the system). Surface damage and
transport damage are outside the scope of the guarantee. The right to
guarantee lapses if the boiler has not had a yearly service by an approved
service agent. The instructions of installation and use that we supply for the
respective appliances must be fully observed.
7. The guarantee is only valid if the return slip of the certificate of guarantee
has been returned to us within 8 days after the installation, signed by the
buyer. By signing the guarantee card, the buyer declares that he agrees with
the good state of the delivery.
8. If the installer's company was terminated before expiration of the guarantee
period, the user can make an appeal to our guarantee obligations towards
the installer.
Environment
When the appliance needs replacement, your installer may
arrange for disposal. Should this not be possible, then
make enquiries with your local council about the
possibilities for re-use or environmental-friendly processing
of the materials used, or contact a scrap dealer about
disposal.
Various plastics and metals have been used in producing
the appliance. Also, the appliance contains electronic
components that are electronic waste.
Intended use
The appliance as described in this documentation is intended for heating
rooms with a central heating system and/or for supplying hot water. Any
other use is outside the scope of intended use for this appliance. Any
liability for damage resulting from improper use shall not be accepted.
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1. SAFETY REGULATIONS
The appliance must be installed in accordance with the Gas Safety
(Installation and Use) Regulations; October 1994. Failure to install appliances
correctly could lead to prosecution.
Atmos Heating Systems does not accept any liability for damage or injury
caused by not (strictly) observing the current safety regulations and
instructions, nor by negligence while installing the Atmos InterCombi wallmounted gas heater and any accompanying accessories.
The manufacturer’s instructions must NOT be taken as overriding statutory
requirements.
The regulations are mentioned separately for the different disciplines.
1.1 General
The entire system should comply with the valid (safety) regulations, as
mentioned in:-
• This installation manual.
• Gas Safety (Installation and Use) Regulations
• The appropriate Building Regulations.
• Health and Safety Document No 635 (Electricity at Work Regulations)
• The Water Fittings Regulations or local Water byelaws.
1.2 CH system
The entire system should comply with the valid (safety) regulations, as
mentioned in:-
•
BS 5449 Central Heating for Domestic Premises.
1.3 Gas system
The entire system should comply with the valid (safety) regulations, as
mentioned in:-
•
BS 6798 Specification for installation of gas fired hot water boilers of rated input
not exceeding 60 kW
.
•
BS 6891 Installation of low pressure gas pipework installations up to 28mm
(R1).
• I.S.813 Installation of Gas Appliances (for installations in Ireland).
• British Gas Guidance Notes for the Installation of Domestic Gas Boilers.
1.4 Electrical system
The entire system should comply with the valid (safety) regulations, as
mentioned in:-
• BS 7671 The IEE Wiring Regulations.
1.5 Domestic water system
The entire system should comply with the valid (safety) regulations, as
mentioned in:-
•
BS 5546 Installation of gas hot water supplies for domestic purposes.
1.6 Flue discharge and air supply
The flue discharge and the air supply system should comply with:-
•
BS 5440 Flues and Ventilation for gas appliances of rated input not exceeding
60 kW. (Part 1 Flues and Part 2 Ventilation).
7
2. DESCRIPTION OF THE APPLIANCE
2.1 General
The Atmos InterCombi wall-mounted gas boiler is a balanced flue
appliance, designed for delivering heat to the water of a CH system and
the domestic hot water.
The air supply and flue discharge can be connected to the appliance by
means of two separate pipes. A concentric connection can be delivered
upon request. The appliance has been inspected together with the
Atmos combination lead-through, but the appliance can also be
connected to combination terminals that comply with the universal test
requirements for combination terminals and that have a gas certification.
The appliance can also be fitted to an optional mounting bracket, a
frame with top connection and various connecting sets. These are
supplied separately.
The Atmos InterCombi wall-mounted gas boiler has the CE quality mark
and the Gas certification labels HE (Sedbuck A), SV , NZ (Solar
compatible) and CW Class 5 (Hot water performance rating 1 to 6,
where 6 is the highest) and IP44.
It is possible to use the appliance for hot water or for heating only. The
system that is not used does not need to be connected.
The appliance as delivered is suitable for natural gas (G20). A
conversion kit for propane (G31) can supplied upon request.
2.2 Operation
The Atmos InterCombi wall-mounted gas heater is a modulating high
efficiency boiler. This implies that the power is adjusted to the heat
demand.
In the aluminium heat exchanger two separate copper circuits have been
integrated.
Because of the separated circuits for central heating and hot water, the
heating and the hot water supply can operate independently of each
other. The hot water supply has priority over the heating. They cannot
work simultaneously.
The appliance has been provided with an electronic burner controller
that controls the fan with each heat demand from the heating system or
the hot water supply, opens the gas valve and ignites the burner and
continuously monitors the flame and controls it dependent on the power
required.
2.3 Operating conditions
A code indicates the operating condition of the appliance on the service
display of the operating panel.
- Off
The appliance is not operating, but there is electrical power. There is no
response to any demand for hot domestic hot water or CH water. The
frost protection is active though. This means that the pump starts
running and the heat exchanger is heated when the temperature of the
water present here drops below 4 °C. When the frost protection is
activated, code
7 appears (heating of the heat exchanger).
8
Waiting position
The LED of the on/off key and if necessary one of the LED’s of the
domestic hot water comfort function are on. The appliance is ready for
responding to the demand for CH or domestic hot water.
0 Pump overrun
After the operation of the CH, the pump has an overrun. This overrun time
is set to the value according to table 4 at the factory. This setting can be
changed. Also, the controller will automatically run the pump for 10
seconds, once every 24 hours, to prevent it from getting stuck. This
activation of the pump takes place at the time of the last heat demand. In
order to change this time, set the room thermostat higher for a while at the
desired time.
1 Required temperature reached
The burner controller can temporarily block the heat demand and stop the
burner. This blocking takes place because the required temperature has
been reached. When the temperature has dropped sufficiently, the
blocking is cancelled.
2 Self-test
The burner controller regularly checks the connected sensors. During the
check, the controller does not carry out any other tasks.
3 Ventilate
At starting the appliance the fan is first brought to the starting speed.
When reaching the starting speed, the burner is ignited. Code
3 is also
visible when after stopping the burner post-purge takes place.
4 Ignite
When the fan has reached the ignition speed, the burner is ignited by
means of electric spark ignition. During ignition the code
4 appears. If
the burner is not ignited, another ignition attempt is made after about
5 seconds. If the burner has still not fired after the fourth ignition attempt,
the controller indicates a fault. See § 8.1.
5 CH operation
An on/off thermostat can be connected to the controller, if necessary in
combination with an outside sensor. See Electrical diagram. When heat is
demanded by a thermostat signal, the fan runs (code
3 ) and the burner is
ignited (code 4 ), followed by the CH operating condition (code 5 ).
During CH operation, the fan speed and hence the power of the appliance
is adjusted. This is done in such a way, that the temperature of the CH
water is controlled towards the set CH supply temperature. In the case of
an on/off thermostat, the CH supply temperature is set at the operating
panel. In the case of an outside sensor, the CH supply temperature is
determined by the weather dependent control programmed in the burner
controller.
9
During CH operation, the demanded CH supply temperature is displayed
on the operating panel. The resistance R in the Electrical diagram can
be removed when the room thermostat does not need any anticipation
current.
During CH operation, the CH supply temperature can be set between
30ºC and 90ºC and the set CH supply temperature is displayed on the
operating panel. During CH operation, the actual CH supply temperature
can be read by pressing the service key.
6 Domestic hot water operation
The hot water supply has priority over the heating. When the flow switch
detects a domestic hot water demand of more than 2 l/min, the CH
demand is interrupted. After starting the fan (code
3 ) and ignition of the
burner(code 4 ), the controller goes to domestic hot water operation
(code 6 ).
During domestic hot water operation, the fan speed and hence the
power of the appliance is controlled by the controller on the basis of the
set domestic hot water temperatures. The domestic hot water
temperature can be set between 50ºC and 60ºC. The set temperature is
displayed on the operating panel.
During domestic hot water operation, the actual domestic hot water
supply temperature can be read by pressing the service key.
7 Heating the appliance
For a quick supply of domestic hot water, a comfort function has been
provided in the controller. This function keeps the heat exchanger at the
correct temperature. This comfort function has the following settings:-
• Off: (Both LEDs off.) The heat exchanger is not kept warm,
delaying the supply of domestic hot water. When there is no
demand for domestic hot water, the comfort function can be
switched off.
• On: The comfort function of the appliance is continuously
activated. The appliance always supplies domestic hot water
immediately.
• Eco: The comfort function is self-learning. The appliance is
inactivated during the night or after a long absence. The appliance
adjusts to the user pattern of the domestic hot water requirements.
The eco mode is the most efficient hot water method.
2.4 PC interface
The controller has an interface for a PC. With a special cable and
accompanying software, a PC can be connected. This provision makes it
possible to follow the behaviour of the controller, the appliance and the
heating system during a long period.
10
2.5 Test programmes
In the burner controller, there is provision for putting the appliance into a
test status.
By activating a test programme, the appliance will become active with a
fixed fan speed without intervention of the control functions. The safety
functions remain active though.
Simultaneously press + and – to switch off the test programme.
Test programmes
Description of programme Key combinations Display
reading
Burner on with minimum CH
power
"service" and "-" “L”
Burner on with maximum
CH power
"service" and “+” (1x) “h”
Burner on with maximum
HW power
"service" and "+" (2x) "H"
Switch off test programme "+" and "-" Current
operating
condition
2.5.1 Frost protecti on
The boiler has provision for protecting its heat exchanger as described
below.
NOTE! However to avoid the condensate freezing, the boiler must be
installed in a FROST-FREE room.
• In order to avoid freezing of the appliance (heat
exchanger), it has an appliance frost protection.
When the temperature of the heat exchanger drops
to 5ºC, the burner will be activated and the pump
will start running until the temperature of the heat
exchanger reaches10ºC.
Code
7 is given when the appliance frost
protection intervenes (heating heat exchanger).
• When the system (or a part thereof) can freeze, a
frost thermostat should be installed in the area to
be protected. Connect this according to the wiring
diagram. See § 10.1.
Remark
When the appliance is out of action (
- on the service display), the
appliance frost protection is still active. However, there will be no
response to heat demand from an (external) frost thermostat.
11
3. MAIN COMPONENTS
A CH pump L Air supply
B Gas valve M Flue discharge
C Burner controller with operating panel N Connecting block / terminal list X
D Supply sensor S1 O Condensate discharge
E Return sensor S2 P Hot water sensor S3
F Fan Q Siphon
G Flow switch R Heat exchanger
H Pressure gauge S Operating panel and display
I 1m connecting cable 230 V ~
( Note: Plug must be removed)
T Ionisation/ignition probe
J Manual air vent U Position type plate
K Sight glass and mirror
Additional Components supplied :T-piece & ½" Pressure relief safety valve, 3 bar (supplied in boiler box)
Valve set (supplied separately with boiler)
12
3.1 Accessories
Description
Pipe mounting bracket
• Connection supply and return 22 mm diameter
• Connection cold and hot water 15 mm diameter
• Connection gas ½" female thread
• Mounting strip boiler
• Bag with fixings
Mounting frame for top pipe connection
Pipework cover
Outside sensor
Conversion set to Propane (LPG or G31)
Interface cable
13
4. INSTALLATION
4.1 Overall dimensions
A= CH flow 22 mm diameter h= 710mm InterCombi HE 32
B= CH return 22 mm diameter I
C= Gas 15 mm diameter H= 810mm InterCombi HE 32
D= Cold water 15 mm diameter
E= Domestic hot water 15 mm diameter Z= Flue gas outlet 80 mm diameter
F= Condensate 32 mm dia (after siphon 25 mm dia flexible) Y= Air supply inlet 80 mm diameter
14
4.2 Unpacking the appliance
1. Unpack the appliance.
2. Check the content of the packaging. This consists of:-
• Appliance (A)
• Mounting strip (B)
• Siphon (C)
• T-piece & ½" Pressure relief safety valve, 3 bar
• Installation instructions
• Guarantee card
• Valve set (supplied separately with boiler)
3. Check the appliance for any damage: report damage to the Supplier
immediately.
4.3 Additional dimensions
The diagram shown below gives additional dimensions primarily for the
mounting arrangement using the OPTIONAL mounting bracket.
15
4.4 Boiler location
The appliance can be fitted to a mounting frame. The assembly or just
the appliance should be mounted to a wall with sufficient bearing
strength.
In case of light wall constructions, resonance sounds may occur. There
must be an earthed electrical supply within a distance of 1 m from the
appliance. If the appliance is installed as an open appliance, the
installation room should have been provided with the required openings
for the boiler air supply.
In order to avoid freezing of the condensate discharge, the appliance
should be installed in a frost-free room.
Keep 5 cm free space above the appliance in order to be able to remove
the front panel from the casing.
4.4.1 Installation in a kitch en cupboard
Make sure there is sufficient ventilation above and below the appliance.
When the appliance is placed in a small cupboard, ventilation openings
of at least 50 cm
2
must be made.
4.4.2 Installation in an airing cup board
Compartment ventilation is not required for a standard airing cupboard
(eg 0.6 x 0.6 x 2.3m high).
4.4.3 Remove front panel
Remove the pipework cover and the front panel for carrying out work on
the appliance as follows:-
1. Remove the pipework cover (A), if used, forwards.
2. Unscrew both screws (B) at the bottom of the appliance.
3. Lift the front panel (C) and remove it forwards.
16
4.5 Mounting
A
B
B
C
Depending on the mounting option ordered, the following mounting
methods are available:-
Mounting strip (A) alone,
OR mounting strip (A) and optional pipe mounting bracket (B),
OR top connecting frame (C) and pipe mounting bracket (B), which are
both optional items. This arrangement allows for vertical pipes from
above at the rear.
Note that when the pipe mounting bracket is used, the pipes can be
connected before installing the appliance.
4.5.1 Fitting the mounting strip
1. Fasten the mounting strip horizontally to the wall, using the
fastening materials supplied.
2. Mount the appliance.
3. Mount the parts of the various connecting sets.
Note that the 3 bar pressure relief valve must be installed on the
boiler side of the CH flow valve (see diagram).
4.5.2 Fitting the mounting strip and the mounting bracket
1. Fasten the mounting strip and the pipe mounting bracket
horizontally to the wall according to the drilling pattern, using the
fastening materials supplied.
2. Mount the parts of the various connecting sets.
Note that the 3 bar pressure relief valve must be installed on the
boiler side of the CH flow valve (see diagram).
4.5.3 Fitting the top connecting frame
1. Fasten the frame vertically to the wall, using the fastening materials
supplied.
2. Fasten the pipe mounting bracket to the frame using the fastening
materials supplied.
3. Mount the parts of the various connecting sets.
Note that the 3 bar pressure relief valve must be installed on the
boiler side of the CH flow valve (see diagram).
4. Slide the connecting pipes into the frame.
Caution
The appliance is wider than the frame.
4.5.4 Installation co nnections
1. Make the various connections to the valves (see diagram).
2. Install a filling loop (not supplied) between the cold water inlet pipe
and the CH return connection.
3. Install an overflow pipe from the pressure relief valve, using 2 x 90
0
bend to step the pipe to the rear so that it will enter the condensate
discharge pipe.
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