Atmos Energy HE32 User Manual

Atmos InterCombi
Installation & Servicing Instructions for HE32
(GC 47-249-01)
Atmos Heating Systems
West March
Daventry
Tel: 01327 871990
Fax: 01327 871905
e-mail:
internet: www.atmos.uk.com
sales@atmos.uk.com

Issue 22.01.10 (Main revision)

© 2010 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
Building Regulations and the Benchmark Checklist
Building Regulations (England & Wales) require notification of the installation of a heating appliance in a dwelling to the relevant Local Authority Building Control Dept. This can be achieved via a Competent Persons Self Certification Scheme as an option to notifying the Local Authority directly. Similar arrangements apply in Scotland and Northern Ireland. Atmos Heating Systems is a member of the Benchmark Scheme and the Benchmark Checklist is included at the back of these Instructions. The Benchmark Checklist provides a Commissioning Checklist and Service Record to be completed by the Installer/ Service Engineer.
Benchmark places responsibilities on both manufacturers and installers. The purpose is to ensure that customers are provided with the correct equipment for their needs, that it is installed, commissioned and serviced in accordance with the manufacturer’s instructions by competent persons and that it meets the requirements of the appropriate Building Regulations. The Benchmark Checklist can be used to demonstrate compliance with Building Regulations and should be provided to the customer for future reference.
Installers are required to carry out installation, commissioning and servicing work in accordance with the Benchmark Code of Practice which is available from the Heating and Hotwater Industry Council who manage and promote the Scheme. Refer to
www.centralheating.co.uk for more information.
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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
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
4.5 Mounting and General Information............................................................................................................................ 17
4.6 Mount the appliance..................................................................................................................................................18
4.7 Fit the pipework cover (optional item) .......................................................................................................................18
4.8 Condensate disposal................................................................................................................................................. 19
5. Connections 20
5.1 Connect the CH system ............................................................................................................................................20
5.2 Hot water system ......................................................................................................................................................21
5.3 Connecting the gas supply........................................................................................................................................22
5.4 Electrical connection .................................................................................................................................................22
5.5 General Flue Requirements...................................................................................................................................... 25
5.6 Flue discharge and air supply ...................................................................................................................................26
5.7 Roof outlet prefabricated chimney.............................................................................................................................32
5.8 Atmos MS System..................................................................................................................................................... 33
5.9 Atmos Communal Flue System (CFS) ...................................................................................................................... 34
6. Commissioning 35
6.1 Fill and de-aerate the appliance and the system.......................................................................................................35
6.2 Commissioning of the appliance ...............................................................................................................................36
6.3 System Shutdown .....................................................................................................................................................37
7. Setting and Adjustment 38
7.1 Directly via operating panel.......................................................................................................................................38
7.2 Settings through the service code............................................................................................................................. 38
7.3 Parameters................................................................................................................................................................ 39
7.4 Setting maximum CH power......................................................................................................................................40
7.5 Setting pump position................................................................................................................................................ 40
7.6 Weather-dependent control....................................................................................................................................... 41
7.7 Conversion to other gas type ....................................................................................................................................41
7.8 Gas-air control...........................................................................................................................................................41
7.9 Setting gas-air control ...............................................................................................................................................42
7.10 Carbon monoxide : carbon dioxide ratio....................................................................................................................43
8. Faults 44
8.1 Burner does not ignite ...............................................................................................................................................45
8.2 Burner ignites with much noise .................................................................................................................................45
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8.3 Burner resonates....................................................................................................................................................... 46
8.4 No heating (CH) ........................................................................................................................................................46
8.5 Reduced output.........................................................................................................................................................47
8.6 CH does not reach the correct temperature.............................................................................................................. 47
8.7 No hot water (HW) ....................................................................................................................................................47
8.8 Hot water does not reach the correct temperature....................................................................................................48
9. SERVICING THE BOILER AND COMPONENT REPLACEMENT 49
9.1 SERVICING THE BOILER........................................................................................................................................ 49
9.2 COMPONENT REPLACEMENT............................................................................................................................... 51
10. Technical Specifications 54
10.1 Electrical diagram...................................................................................................................................................... 55
11. CE Declaration 56
NOTE The Benchmark Checklist & Service Record are included at the back of the Manual.
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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 Tel: 01327 871990; fax: 01327 871905
sales@atmos.uk.com; internet: www.atmos.uk.com
Email:

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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Atmos Warranty – Short version

1. Atmos Warranty is against any material, construction or operation faults
that are found to be of original manufacturing origin. A full statement of the Atmos Warranty is available (www.atmos.uk.com or 01327 871990).
2. Atmos boiler warranty is, subject to conditions; two years from date of
invoice, or 12 months from date of installation; whichever is the later. The warranty shall be 2 years for replacement parts and associated labour, thereafter any warranty period shall cover parts only. The heat exchanger warranty is 10 years in total, including the first two years parts and labour warranty. For purchases before 01/01/08 this extended period was 5 years.
3. We guaranty the free redelivery of parts covered by the warranty. Any
alleged faulty part must be returned to Atmos carriage prepaid. Carriage will be credited if the part is found to be manufacturer’s fault.
4. Any claim must be accompanied with the serial number of the product.
5. All products must be used in an appropriate application and manner.
This includes but is not limited to; correct boiler sizing, system design, system cleansing and use of corrosion inhibitors. Where appropriate and always in areas of “hard water” (in excess of 200 ppm) an approved water conditioner device must be fitted (in accordance with Building Regulations)
6. Completion of the Benchmark Checklist & Service Record is a condition
of the boiler warranty (Customer’s statutory rights not affected); which must be completed and supplied to Atmos if required. The Warranty card must be completed and the signed Atmos copy received within 8 days of installation. By signing the Warranty card the buyer agrees that the goods have been delivered in a satisfactory condition.

Exceptions

7. In the event of full payment for a product not being received, Atmos
shall be discharged from all further contractual or warranty obligations.
8. Surface and/or transport damage are outside the scope of this warranty.
9. Any warranty provision shall not apply if Atmos determine that the fault
is due to improper application, use, neglect, accidental damage or injudicious treatment, non-observance of instructions contained in Atmos Manuals; or due to improper repair, adjustment, installation or maintenance; or due to work carried out by unqualified engineers. The warranty also lapses if the Atmos boiler has not had a yearly service in accordance with instructions.
10. This warranty shall not apply if the fault is caused by scale, failure or
abnormality of gas or water supply, or impact of any external influence that adversely affects the normal operation of the product. This shall include but not be restricted to dehydration, abnormal or high voltage, and hard water.
11. Excluded parts: ignition & ionisation probe, glass fuse, and air vent.
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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).
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2. DESCRIPTION OF THE APPLIANCE

2.1 General

The Atmos InterCombi wall-mounted gas boiler is 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 or a concentric connection.
The appliance has its own wall mounting strip, but can also be fitted to an optional wall mounting frame that allows top connections. An optional pipe mounting bracket for use with the wall mounting strip is available. These are supplied separately.
The Atmos InterCombi wall-mounted gas boiler has the CE quality mark and the Gas certification labels HE (Sedbuk A), SV , NZ (Solar compatible) and CW Class 5 (Hot water performance rating 1 to 6, where 6 is the highest) and IP44 Protection class.
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 be supplied upon request.

2.2 Operation

The Atmos InterCombi wall-mounted gas heater is a modulating high efficiency boiler. This means 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 controller that controls the fan with the heat demand from the heating system or the hot water supply, opens the gas valve and ignites the burner, 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 heat exchanger drops to 5°C.
When the frost protection is activated, code heat exchanger).
7 appears (heating of the
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Waiting position
The LED of the on/off button and if necessary one of the LED’s of the
domestic hot water Keep hot 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 parameter 8 (see § 7.3; factory setting is 1 min). This setting can be changed. Note: If there is a hot water demand during this period, the overrun time is cancelled. 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 24hrs later. In order to change this time, set the room thermostat higher for a while at the desired time.
1 Required temperature reached
The 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 controller regularly checks the connected sensors. During the check, the controller does not carry out any other tasks.
3 Ventilate (Fan)
On starting, the fan is first brought to the starting speed. When the starting speed has been reached, the burner is ignited. Code
3 is also visible
after stopping the burner, when 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 the Electrical diagram § 10.1.
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
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determined by the weather dependent control programmed in the controller.
During CH operation, the demanded CH supply temperature is displayed on the operating panel.
During CH operation, the actual CH supply temperature can be read by pressing the service button.
Note: Instead of an on/off thermostat, an OpenTherm thermostat can be
connected to the controller as described in §5.4.1. In this case, the desired CH temperature is set by the thermostat. The minimum temperature and the operation mode can be set with parameters [E] and
[E.] (refer to §7.3)
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 fan starts
running (code controller goes to domestic hot water operation (code 6 ). When a
domestic hot water demand is detected during a CH demand, the CH demand is interrupted (pump stops), and the controller switches from
CH(code water demand, the CH demand is still required, the pump starts again and the controller switches back to CH. 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 demanded 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 button.
3 ) and ignition of the burner follows (code 4 ), and the
5 ) to DHW (code 6 ). When after ending the domestic hot
7 Keep Hot Facility
For a quick supply of domestic hot water, a Keep hot function has been provided in the controller. This function keeps the heat exchanger at the correct temperature. This Keep hot function has the following settings:-
Off: (HW Store - Both LED’s off.) The heat exchanger is not kept
warm, delaying the supply of domestic hot water, except when CH operation has recently occurred.
On: (HW Store – On LED on.) The Keep hot function of the
appliance is continuously activated. The appliance always supplies domestic hot water immediately.
Eco: (HW Store - Eco LED on) The Keep hot 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.
Note: The initial ‘slug’ of hot water may be in excess of 60ºC irrespective
of the settings.

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.
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2.5 Test programmes

In the 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 Button
combinations
Burner on with minimum CH power Burner on with maximum CH power Burner on with maximum HW power Switch off test programme "+" and "-" Current
"service" and "-" “L”
"service" and “+” (1x) “h”
"service" and "+" (2x) "H"

2.5.1 Frost protection

Display reading
operating condition
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 reaches 10ºC.
7 is given when the appliance frost
Code 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 ( appliance frost protection is still active. However, there will be no response to heat demand from an (external) frost thermostat.
- on the service display), the
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3. MAIN COMPONENTS

A CH pump M Flue discharge (or concentric connection) B Gas valve N Connecting block / terminal list X C Clamping plate O Condensate discharge D Supply sensor S1 P Hot water sensor S3 E Return sensor S2 Q Condensate trap F Fan R Heat exchanger G Hot water flow switch S Controller operating panel and display H Pressure gauge T Ionisation/ignition probe I 1m connecting cable 230 V ~ U Position type plate J Manual air vent V Expansion vessel (shown in broken lines) K Sight glass and mirror W Pressure relief safety valve, 3 bar L Air supply (left or right)
Additional Components supplied :­Valve set (supplied separately with boiler)
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3.1 Accessories

Description Part Ref 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
Rear mounting frame for top pipe connection 092507 Bottom Pipework cover 092527 Outside sensor for weather compensation 203.207 Conversion set to Propane (LPG or G31) 075537 Interface cable (for Installers) 230677
092.537
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4. INSTALLATION

4.1 Overall dimensions

A= CH flow 22 mm diameter h= 670mm InterCombi HE 32 B= CH return 22 mm diameter 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 trap 25 mm dia flexible) Y= Air supply inlet 80 mm diameter
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4.2 Unpacking the appliance

1. Unpack the appliance.
2. Check the content of the packaging. This consists of:-
Appliance (A)
Mounting strip (B)
Condensate trap (C)
Installation Instructions
User Operating Instructions
Warranty card
3. Valve set (supplied separately with boiler) comprising 2 x 22mm
isolation valves, 1 x 15mm isolation valve with blue lever (for cold water), 1 x gas valve.
4. Check the appliance for any damage: report damage to the Supplier
immediately.
CAUTION: This appliance should be lifted and handled by 2 people. (Weight: 39 kg)

4.3 Additional dimensions

The diagram shown below gives additional dimensions primarily for the
mounting arrangement using the OPTIONAL mounting bracket.
Note: The centre line of the hexagonal notch in the mounting bracket is
also the centre line of the flue hole.
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4.4 Boiler location

Clearances
Above casing 200mm min Below casing 230mm min RH 30mm min LH 30mm min (in operation) LH 140mm min (servicing) Front 30mm min (in operation) Front 450mm min (servicing)
Keep 50 mm free space above the front panel in order to be able to remove the front panel from the casing. Allow 140 mm on the left side for swinging out the expansion vessel during commissioning/service.
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.
The appliance is suitable for mounting on a combustible wall (eg stud wall).
There must be an earthed electrical supply within a distance of 1 m from the appliance.
In order to avoid freezing of the condensate discharge, the appliance should be installed in a frost-free room.

4.4.1 Installation in a kitchen cupboard

Make sure there is sufficient ventilation above and below the appliance. When the appliance is placed in a small cupboard, ventilation openings
2
of at least 50 cm
must be made.

4.4.2 Installation in an airing cupboard

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 optional 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 recessed crosshead screws (B) at the bottom of the
appliance.
3. Lift the front panel (C) vertically upwards and remove it forwards.
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C
A A

4.5 Mounting and General Information

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 rear mounting frame (C) and pipe mounting bracket (B), which are
both optional items. This arrangement allows for vertical pipework
behind the boiler.
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 screws
and plugs supplied.
2. Mount the appliance.

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 screws and plugs supplied.

4.5.3 Fitting the rear mounting frame

1. Fasten the frame vertically to the wall, using screws and plugs.
2. Fasten the optional pipe mounting bracket to the frame using the
fixings supplied.
Caution The appliance is wider than the frame by 20mm.
B
B
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4.5.4 Installation connections

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. For most installations, the flexible tube for the safety discharge will
be long enough to fit into the condensate discharge waste pipe (see below). In cases where this does not apply, install a 15 mm copper safety discharge pipe to fit into the waste pipe (as shown in the diagram, §5.1) or run separately to a safe discharge position on the outside wall of the building.
Note Where appropriate and always in areas of Hard Water (hardness in excess of 200ppm), an approved water conditioner device must be fitted in accordance with the Building Regulations. Atmos can supply a suitable conditioner for fitting to the cold feed of the boiler. In areas of hard water, failure to fit a suitable conditioner will invalidate the warranty.

4.6 Mount the appliance

1. Check whether the compression rings of the optional mounting
bracket are straight in the connectors.
2. Place the appliance: slide it top-down over the mounting strip. Make
sure that the pipes simultaneously slide into the compression fittings of the optional mounting bracket.
3. The flexible tube from the condensate trap should be inserted into
an open waste pipe of not less than 32 mm diameter. If connected to a soil pipe or waste system, the waste pipe must include a trap (similar to arrangement for washing machine). For more information on condensate disposal, please refer to §4.8.
4. The flexible tube from the pressure relief safety valve should be
inserted into the waste pipe, or pushed over the 15 mm copper discharge pipe if provided.
5. Tighten the compression fittings to the optional mounting bracket.
6. Mount the air supply and the flue discharge.
7. Close the air supply opening that is not used with the plug supplied.

4.7 Fit the pipework cover (optional item)

1. Insert the four hooks of the pipework cover in the slots of the
appliance.
2. Slide the cover backwards, sliding the hooks into the slots and
locking the cover.
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