hamworthy Varmax 120 User guide

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Document No. 00BNO9061-J / 06.06.2015

VARMAX

GAS CONDENSING BOILER

120 to 450 kW

with modulating burner

for natural gas and propane gas

FR EN DE ES IT NL

Installation,

use and

maintenance

instructions

MANUFACTURER:

00BNO3000-#

SITE DE PONT-DE-VAUX

1 route de Fleurville - BP 55

FR - 01190 PONT-DE-VAUX

VARMAX - Installation, Use and Maintenance

CONTENTS

1. WARNINGS AND RECOMMENDATIONS ..............................................................................6

1.1. Transport and storage ................................................................................................................................... 6

1.2. Symbols used in this document. ................................................................................................................... 6

1.3. Qualiﬁ cation of personnel for installing, adjusting, using and maintaining the equipment ............................ 6

1.4. Safety instructions ......................................................................................................................................... 6

1.5. Water characteristics ..................................................................................................................................... 7

2. APPROVALS ........................................................................................................................10

2.1. Compliance with European Directives ........................................................................................................ 10

2.2. Regulatory installation conditions ................................................................................................................ 10

2.3. Gas category ............................................................................................................................................... 10

2.4. Gas supply pressures ................................................................................................................................. 11

3. TECHNICAL SPECIFICATIONS ...........................................................................................12

3.1. Dimensions ................................................................................................................................................. 12

3.2. Doorways .................................................................................................................................................... 14

3.3. Combustion at 15°C and 1013 mbar ........................................................................................................... 15

3.4. Conditions of use ........................................................................................................................................ 17

3.5. Electrical connection ................................................................................................................................... 17

4. INSTALLATION .....................................................................................................................18

4.1. Installation of the air ﬁ lter and ﬁ lter matting ................................................................................................. 18

4.2. Installing the boiler ...................................................................................................................................... 19

4.3. Opening / closing of casing doors ............................................................................................................... 20

4.4. Removing the control panel (MMI) .............................................................................................................. 20

4.5. Removing / reﬁ tting the casing doors .......................................................................................................... 21

4.6. Removing / reﬁ tting side panels .................................................................................................................. 22

4.7. Removing / reﬁ tting the top panel ............................................................................................................... 22

4.8. Step ............................................................................................................................................................. 23

4.9.Changing the gas type (G20 to G31) ........................................................................................................... 24

4.10.Exhaust connection .................................................................................................................................... 26

4.11.Hydraulic connection .................................................................................................................................. 34

4.12.Gas connection ..........................................................................................................................................36

4.13.Electrical connection .................................................................................................................................. 36

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VARMAX - Installation, Use and Maintenance

5. COMMISSIONING .................................................................................................................40

5.1. Unlocking the boiler ..................................................................................................................................... 40

5.2. Pre-commissioning checks ......................................................................................................................... 40

5.3. Commissioning ............................................................................................................................................ 41

6. POST-COMMISSIONING CHECK ........................................................................................42

6.1. Condensate removal ................................................................................................................................... 42

6.2. Gas supply .................................................................................................................................................. 42

7. MAINTENANCE OPERATIONS ...........................................................................................43

7.2. Veriﬁ cation of the boiler's environment ........................................................................................................ 44

7.3. Replacing the air ﬁ lter matting ..................................................................................................................... 44

7.1. Boiler draining ............................................................................................................................................. 44

7.4. Veriﬁ cation of ignition and ionisation electrodes ......................................................................................... 45

7.5. Siphon cleaning ........................................................................................................................................... 46

7.6. Checking the combustion circuit's gas-tightness ......................................................................................... 46

7.7. Checking combustion quality ...................................................................................................................... 47

7.8. Setting the gas valve ................................................................................................................................... 48

7.9. Gas ﬁ lter cleaning ....................................................................................................................................... 50

7.10.Cleaning exchangers and changing seals .................................................................................................. 51

7.11.Cleaning the burner and changing the seals .............................................................................................. 53

8. END-OF-LIFE CYCLE OF THE APPARATUS ......................................................................56

8.1. Environmental compatibility ........................................................................................................................ 56

8.2. Dismantling, recycling and elimination of the apparatus ............................................................................. 56

9. HYDRAULIC DIAGRAMS AND SETTINGS .........................................................................57

9.1. Selection ﬂ ow diagram ................................................................................................................................ 57

9.2. Symbols used in the diagrams .................................................................................................................... 59

9.3. List of diagrams ........................................................................................................................................... 59

10. LIST OF SPARE PARTS .....................................................................................................116

11. TABLE OF CUSTOMER SETTINGS ..................................................................................127

12. ANNEX A .............................................................................................................................144

Page 4 / 146 00BNO9061-J



VARMAX - Installation, Use and Maintenance

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VARMAX - Installation, Use and Maintenance

1. WARNINGS AND RECOMMENDATIONS

PLEASE READ THIS MANUAL CAREFULLY BEFORE INSTALLING, CARRYING OUT MAINTENANCE AND USING THE BOILER. IT CONTAINS IMPORTANT SAFETY INFORMATION.

VARMAX boilers are available with 2/3 tappings or 4 tappings. It is not

INFORMATION:

1.1. Transport and storage

possible to transform a version with 2/3 tappings into a version with 4 tappings and vice versa.

The boiler:

- must be stored vertically in an environment where the temperature is between -20°C and +55°C, and where relative humidity is between 5% and 95%;

- must not be stacked,

- must be protected from humidity.

1.2. Symbols used in this document.

INFORMATION: This symbol draws attention to comments.

Not following these instructions may lead to damage when installing or to other objects.

Not following these instructions may cause injuries and serious material damage.

Not following these instructions may cause electrocution.

WARNING:

DANGER:

1.3. Qualiﬁ cation of personnel for installing, adjusting, using and maintaining the equipment

Boiler installation, adjustment and maintenance operations must be conducted by a qualiﬁ ed and approved professional in accordance with prevailing local and national regulations. These operations may require work to be carried out with the power turned on and the casing doors (on the front of the boiler) open. Basic utilisation operations must be carried out with the casing doors closed.

1.4. Safety instructions

• Always switch the boiler off and shut off the general gas supply before carrying out any work on the boiler.

• After performing work on the boiler (maintenance or breakdown), check that there are no gas leaks from the installation.

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DANGER:

VARMAX - Installation, Use and Maintenance

If you smell gas:

• Do not use a naked ﬂ ame, do not smoke, do not turn on electrical contacts or switches.

• Cut off the gas supply.

• Air the premises.

• Look for the leak and repair it.

If you see smoke:

• Switch off the boiler.

• Air the premises.

• Look for the leak and repair it.

This boiler's earth bonding is ensured with connecting cables (green/ yellow) and speciﬁ c attachment screws. During any dismantling work, make sure you reconnect the cables concerned; it is IMPERATIVE to reuse the original attachment screws.

1.5. Water characteristics

The following rules apply as soon as the boiler is commissioned and remain valid until the product's end-of-life.

DANGER: It is forbidden to use water containing glycol.

1.5.1. Preparation of the water circuit before commissioning the boiler

For all installation work (new or renovation), the water network pipes must be meticulously cleaned. The purpose of cleaning prior to commissioning is to remove germs and residues which are the cause of deposits. In new installations in particular, residue from grease, oxidised metal and even copper micro deposits must be removed. In renovated installations, cleaning should focus on removing sludge and the products of corrosion formed when the unit was last in operation. There are two types of methods for cleaning and removing sludge: a high intensity approach that takes a few hours and a slower, more gradual approach that takes several weeks. This ﬁ rst type of cleaning must be done before connecting the new boiler, and with the second type, a ﬁ lter should be installed on the back of the boiler to capture loosened deposits. Cleaning prior to commissioning helps to improve the equipment's performance, reduce energy consumption and ﬁ ght against scaling and corrosion. This operation must be done by a professional (water treatment).

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VARMAX - Installation, Use and Maintenance

1.5.2. Protecting the unit against scaling

Water naturally contains dissolved calcium ions and carbonates that cause scaling (calcium carbonate) to form. To prevent excessive deposits, take

precautions with regard to the water used to ﬁ ll the unit TH < 10°f

Water must be added during the life of the boiler. The new water adds scaling to the water system. The amount of ﬁ ll water and the amount of make-up water added throughout the unit's lifecycle must not be more than three times the water capacity of the heating system. Also, the hardness of the make-up

water must be controlled. Make-up water: TH < 5°f

Adding a large amount of untreated water always contributes a signiﬁ cant amount of scaling. To monitor this and to detect problems, a system water meter must be installed. Failure to comply with these guidelines (such that the ﬁ ll water plus the make- up water is more than three times the water capacity of the heating system) requires a full cleaning (to remove sludge and scaling) to be performed.

Additional precautions are required for operation:

- When the unit has a water softener, the equipment must be inspected on a regular basis in order to ensure that it is not outputting chloriderich water into the system. The concentration of chlorides must always remain below 50 mg/litre.

- To prevent the build-up of calcium deposits (such as on exchange surfaces), the unit should be brought into service slowly, starting by operating at a low power with high primary water ﬂ ow.

- When the tap water lacks the desired qualities (e.g. high level of hardness), water treatment is required. The ﬁ ll water must be treated, and whenever new water is added, the make-up water must also be treated.

- Installations with multiple boilers require all of the boilers to be started simultaneously at minimal power. Doing this prevents the calcium in the water from depositing on the exchange surfaces of the ﬁ rst boiler.

- When working on the unit, avoid draining it completely; only the required parts of the system are to be drained.

The rules listed above are designed to minimise scaling on the exchange surfaces and thus to increase the life of the boilers. To optimise the equipment's operation, remove lime scale deposits. This must be done by a specialised company. Also, before putting the unit into service, verify that the heating system is not damaged (e.g. leaks). If it has excessive scaling, the unit's settings for operation and for water treatment must be adjusted.

1.5.3. Protecting steel and stainless steel boilers against corrosion

Corrosion can affect the iron components used in boilers and heating systems, which is directly related to the presence of oxygen in the water heater's water. Dissolved oxygen that enters the unit when it is being ﬁ lled for the ﬁ rst time reacts with the equipment materials and quickly disappears. Without refreshing the oxygen through signiﬁ cant contributions of water, the unit might not experience any damage whatsoever. However, it is important to follow the sizing rules and installation guidelines in order to prevent oxygen from continuously ﬂ owing into the heating water.

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VARMAX - Installation, Use and Maintenance

These rules include:

- Opt for an expansion vessel with a membrane rather than an open expansion vessel that allows direct passage.

- Make sure pressure in the equipment is more than 1 bar when cold.

- Remove non-gas-tight components (permeable) and use gas-tight equipment instead.

If the guidelines above are followed, the unit's system water has the proper characteristics to last a long time: 8.2 < pH < 9.5 and concentration in dissolved oxygen < 0.1 mg/litre.

If there is a chance that oxygen could enter the unit, you must take additional precautions. Adding an oxygen scavenger (e.g. sodium sulphite) is highly recommended. We recommend you contact specialised companies for water treatment issues, which will be able to suggest:

- the appropriate treatment based on the characteristics of the installation,

- a monitoring and performance warranty contract.

For units in which the water comes into contact with heterogeneous materials, such as copper or aluminium, appropriate treatment is recommended in order to ensure that the unit will last. In most cases, this consists of adding corrosion inhibitors (in the form of chemical solutions) to the unit. It is recommended to contact water treatment specialists.

1.5.4. Unit monitoring

If the above recommendations are followed (new installation or renovation), it should be sufﬁ cient to:

- check the amount of make-up water (ﬁ ll water volume + make-up water volume < 3 times the unit volume.

- check the pH level (stable or slightly increasing).

- check the TH (stable or slightly decreasing).

We recommend these checks are carried out 2 to 3 times a year. Note that monitoring the quantity of make-up water is critical to the long life of the unit. If any of these three parameters deviates from the above recommendations, refer to a water treatment specialist to correct the problem.

1.5.5. Installation of the plate exchanger

If the recommendations above cannot be met, you can set up a plate exchanger to separate the primary system from the secondary system, which protects the boiler from undesirable effects.

1.5.6. Installation of a ﬁ ltration system

A ﬁ ltration system (ﬁ lter, sediment well, etc.) on the back of the boiler is recommended in order to remove suspended particles from the unit.

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VARMAX - 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)

- Gas appliances (2009/142/CE)

- Efﬁ ciency (92/42/CEE) until 26/09/2015

- Eco-design (2009/125/EC): from 26/09/2015

In application of the directive and according to the requirements of the EU regulation No. 813/2013 of 02 August 2013, the technical parameters of condensation boilers with a power of less than or equal to 400 kW are available in appendix A.

2.2. Regulatory installation conditions

The appliance must be installed by an approved professional in accordance with regulations and current professional practices.

2.3. 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 element leads to loss of warranty.

VARMAX 120 to 225

VARMAX 275 to 320

VARMAX 390 to 450

B23 - B23 P

C13 - C33 - C53

B23 - B23 P

C53

B23 - B23 P

C53

Category

DK, EE, FI, HU, LV, NO, SE, TR

CZ, GR, GB, IE,

LT, RO, SI, SK

2H3P

Page 10 / 146 00BNO9061-J

2.4. Gas supply pressures

INFORMATION: The pressures given below must be read at the gas valve inlet.

VARMAX - Installation, Use and Maintenance

Natural gas H G20

20 mbar

G31 Propane gas

(for relevant models

and countries only)

Nominal pressure (mbar) 20 37

Minimum pressure (mbar) 17 25

Maximum pressure (mbar) 25 45

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VARMAX - Installation, Use and Maintenance

3. TECHNICAL SPECIFICATIONS

3.1. Dimensions

ø AA

3°

45 mini

60 maxi

ø U

ø V

ø W ø X

ø X

Condensate removal

ø X

ø U

(B23-B23P)

U0501956-#

ﬁ gure 1 - Dimensions

Page 12 / 146 00BNO9061-J

VARMAX - Installation, Use and Maintenance

MODELS

120 140 180 225 275 320 390 450

A (mm) 734 734 812 912

B (mm) 1530 1780 1877 2023

C (mm) 1189 1218 1341 1392

D (mm) 148 169 169 168

E (mm) 103 150 109 92

F (mm) 510 630 680 750

G (mm) 138,5 138,5 138,5 138,5

H (mm) 115 192 241 274,5

I (mm) 350,5 350,5 399,5 449,5

J (mm) 150,5 150,5 200 209,5

K (mm) 166,5 150,5 179 192

L (mm) 1256 1564 1672 1874

M (mm) 165 165 165 165

N (mm) 182 197,5 196,5 206,5

O (mm) 926 1171 1265 1402

P (mm) 1062 1315 1413 1577,5

Q (mm) 1298 1606 1661 1933

R (mm) 212 212 244 244

S (mm) 163 163 163 183

Ø T(*): Smoke outlet (mm) 150 150 180 200

Ø U: Purge connecting sleeve 1 " 1 " 1 " 1 "

Ø V(*): Air inlet (mm) 150 150 180 180

Ø W: Gas connecting sleeve G20

G31

1 " 1/4 1 " 1/4

1 " 1/2 1 " 1/2

2 " 2 "

2 "

Ø X: Out / In connecting sleeve 2 " DN 65 DN 80 DN 80

Y (mm) 250,5 247 276 289,5

Z (mm) 237 224,5 270,5 283,5

Ø AA: Valve connecting sleeve 1 " 1 " 1 " 1/4 1 " 1/4

(*) The diameter indicated is the inside diameter (only for Ø T and Ø V).

Edition: 06 / 2015 Page 13 / 146

VARMAX - Installation, Use and Maintenance

3.2. Doorways

VARMAX 120 to 225 boilers ﬁ t through doors 700 mm wide with the casing on (boiler with doors and side jackets).

VARMAX 275 to 320 boilers ﬁ t through doors 735 mm wide without the casing on (boiler without doors, without side jackets and without side insulating panels). However, it is possible to pass through the 700 mm doors if the following parts are removed, in addition to the parts mentioned above:

• the two inspection doors with their 16 fastening clamps,

• the two lower hinge lugs of the front housing doors (with the step),

• the two upper hinge lugs of the front housing doors (with the step),

• all the cable clamps at the inlet of the high- and low- current wiring gutter.

VARMAX 390 to 450 boilers ﬁ t through doors 800 mm wide without the casing on, which means that the following parts must be removed:

• the two front housing doors,

• the side insulating jackets,

• the side insulating panels

• the two lower hinge lugs of the front housing doors (with the step),

• the two upper hinge lugs of the front housing doors (with the step),

• all the cable clamps at the inlet of the high- and low- current wiring gutter.

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3.3. Combustion at 15°C and 1013 mbar

3.3.1. G20 Natural Gas

120 140 180 225 275 320 390 450

VARMAX - Installation, Use and Maintenance

MODELS

Nominal power Pn (80/60°C)

Nominal power when condensing P (50/30°C)

kW 117 136 175 219 268 312 381 439

kW 127 148 191 238 290 338 415 478

Nominal heat input Qn kW 120 140 180 225 275 320 390 450

Minimum heat input Qmin

Gas ﬂ ow rate at Pn m

value ranges %

Flue-gas mass ﬂ ow rate at Qn / Qmin (80/60°C)

Flue-gas mass ﬂ ow rate at Qn / Qmin (50/30°C)

Flue-gas temperature at Qn / Qmin (80/60°C)

Flue-gas temperature at Qn / Qmin (50/30°C)

Appliance pressure at nominal Qcal (B23)

Inside diameter of ﬂ ue- gas output

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

kW 28 28 43 43 66 66 87 87

/h 12,7 14,81 19,05 23,81 29,1 33,86 41,3 47,6

g/s

°C

52,8 / 1361,3 /

13,1

49,1 /

12,3

60,8 /

56,9

35,7 /

28,8

57,6 /

12,2

62,1 /

57,3

37,7 /

30,2

Qmin : 8,3 % < CO

Qmax : 8,8 % < CO

80,4 /

20,8

75,9 /

19,5

61,0 /

56,6

33,7 /

30,0

99,5 /

21,1

93,0 /

19,5

62,3 /

57,7

36,9 /

30,2

< 8,7 %

< 9,2 %

113,9 /

26,9

108,7 /

17,1

61,7 /

58,3

36,3 /

29,8

133,2 /

29,1

126,3 /

27,1

63,4 /

57,2

36,2 /

28,3

169 /

39,2

159,6 /

36,7

62,5 /

57,4

200,7 /

35,6

191 /

33,4

64,8 /

57,1

36,7 / 3041,7 /

30,2

Pa 88 108 103 147 132 162 152 203

mm 150 150 150 150 180 180 200 200

200 /5200 / 5115 /5165 /5122 /

166 /5164 /

/h 153,8 179,4 230,7 288,3 352,4 410,1 499,8 576,7

92 /

128 /

97 /

176 /5180 /5193 /

145 /5155 /5173 /

NOx class 5

Flue-gas removal and air inlet type classiﬁ cations

Edition: 06 / 2015 Page 15 / 146

B23, B23P

C13, C33, C53

B23, B23P

C53

VARMAX - Installation, Use and Maintenance

3.3.2. G31 Propane Gas (for relevant models and destination countries)

MODELS

120 140 180 225 275 320

Nominal power Pn (80/60°C) kW 117 136 175 219 268 312

Nominal power when condensing P (50/30°C)

kW 127 148 191 238 290 338

Nominal heat input Qn kW 120 140 180 225 275 320

Minimum heat input Qmin kW 39 39 63 63 90 90

Gas ﬂ ow rate at Pn m

value ranges %

Flue-gas mass ﬂ ow rate at Qn / Qmin (80/60°C)

Flue-gas mass ﬂ ow rate at Qn / Qmin (50/30°C)

Flue-gas temperature at Qn / Qmin (80/60°C)

Flue-gas temperature at Qn / Qmin (50/30°C)

/h 4,91 5,73 7,36 9,21 11,25 13,09

g/s

°C

53 /

18,3

50,2 /

17,3

60,3 /

56,7

34,6 /

30,6

Qmin : 9,8 % < CO

Qmax : 10,4 % < CO 61,8 /

18,3

58,7 /

17,3

62,6 /

56,7

37,1 /

80 /

60,3 /

57,1

37,1 / 3137 /

28,9

< 10,2 %

< 10,8 %

100 /29122 /42142 /

96 /

117 /39136 /

62,2 /

63 / 5865,4 /

57,6

40 /2941,4 /

29,4

58,4

31,3

Appliance pressure at nominal Qcal (B23) Pa 68 95 102 140 123 165

Inside diameter of ﬂ ue-gas output mm 150 150 150 150 180 180

Maximum allowable nozzle pressure (B23P) at Qn / Qmin (80/60°C)

Maximum allowable nozzle pressure (B23P) at Qn / Qmin (50/30°C)

167 / 12200 /8103 /4136 / 7118 / 11157 /

140 / 16169 / 1166 /

104 /7104 / 16138 /

Combustion air ﬂ ow rate at Qn m3/h 153,8 179,4 230,7 288,3 352,4 410,1

NOx class 5

Flue-gas removal and air inlet type classiﬁ cations

B23, B23P

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VARMAX - Installation, Use and Maintenance

3.4. Conditions of use

MODELS

120 140 180 225 275 320 390 450 Maximum start setting temperature °C 85 Start maximum temperature °C 88 Safety temperature °C 110

Maximum service pressure

Minimum cold pressure

hPa

(bar)

hPa

(bar)

Hydraulic pressure loss at ∆T20

version with 2 or 3 tappings 600 750 570 810 820 1185 770 970 version with 4 tappings

Main exchanger

Condenser Nominal water ﬂ ow rate (P/20) m Maximal water ﬂ ow rate (P/10) m

daPa

500 110

/h 5,0 5,8 7,5 9,4 11,5 13,4 16,4 18,9

/h 10,0 11,6 15,0 18,8 23,0 26,8 32,8 37,8

650 120

440556607579050106065660

Water content L 116 116 151 151 239 239 287 287 Weight without water kg 340 340 393 393 502 502 592 592 Sound power at P Sound power at 1 m at P Temperature of installation room

(min. / max.)

(Lw) * dB(A) 80 76 77 84

max

(Lp) * dB(A) 65 61 61 68

max

°C 5 / 45

Relative humidity of installation room between 5% and 95% Protection level IP20 Maximum altitude of installation m 2000

6000

(6)

1000

(1)

190

840 230

* The sound power level is a laboratory measurement of the emitted sound power but contrary to the noise level, it doesn't correspond to the perceived measurement.

3.5. Electrical connection

MODELS

120 140 180 225 275 320 390 450 Electrical supply V 230 V AC (+10% -15%), 50Hz Electrical power consumption at Qn

(without accessories) Electrical power consumption in

standby mode

Max length of sensor cables

Power terminal output

W 204 311 179 320 238 352 480 660

DHW sensor: 10

External sensor: 40 in 0.5 mm² (120 in 1.5 mm²)

Ambient thermostat: 200 in 1.5 mm²

Ambient sensor: 200 in 1.5 mm²

V 230V AC (+10%, -15%)

A 5 mA - 1A

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VARMAX - Installation, Use and Maintenance

4. INSTALLATION

Manipulation of the boiler using a hoist requires the use of a frame

DANGER:

4.1. Installation of the air ﬁ lter and ﬁ lter matting

(not supplied). This is COMPULSORY. Refer to the label stuck onto the boiler's packaging.

protective label

WARNING:

If connecting CHIMNEY B23 or B23P, it is COMPULSORY to ﬁ t the air ﬁ lter supplied with the boiler.

screws (x4)

ﬁ gure 2 - Air ﬁ lter

air ﬁ lter

- Remove the protective "air intake" label.

- Insert the air ﬁ lter and attach it to the boiler using the 4 screws supplied with the ﬁ lter.

U0502530-#

Models 120 to 320:

Models 390 and 450:

ﬁ gure 3 - Filter matting

U0038318-B

mountings

U0024791-B

All models:

- Insert the rectangular ﬁ lter matting between the ﬁ lter's protective grille and the mounting (see

opposite).

Ensure that the link between both ends of the matting is under one of the mountings.

Models 390 and 450:

- Insert the square ﬁ lter cloth on the back gate of the ﬁ lter.

Page 18 / 146 00BNO9061-J

4.2. Installing the boiler

VARMAX boilers must not be installed on an inﬂ ammable surface (wooden ﬂ oor, plastic ﬂ oor covering, etc.).

Recommended distances from walls and the ﬂ oor:

Ensure there is sufﬁ cient clearance so that work may be carried out easily on the boilers. The minimum values (in mm) are indicated in ﬁ gure 4 and in the table below.

VARMAX - Installation, Use and Maintenance

ABCDH 120 450 500 150 140 450 500 150 180 450 500 320 225 450 500 320 275 450 600 500 263

MODELS

320 450 600 500 263 390 450 700 500 427 450 450 700 500 427

00BET9005-#

ﬁ gure 4 - Peripheral clearance

The hashed zone above the boiler must remain free of obstacles to allow for inspections and cleaning of the burner.

WARNING:

A 2 cm free space must also be left above the side panels to allow for their disassembly and reassembly.

These values cannot be replaced by speciﬁ c regulatory requirements.

The boiler must be positioned horizontally using a spirit level to

Edition: 06 / 2015 Page 19 / 146

WARNING:

promote effective ventilation of the heat exchanger (use the base as a reference surface).

To adjust the level, screw or unscrew the 4 adjustable feet as required using a 17 mm wrench.

VARMAX - Installation, Use and Maintenance

4.3. Opening / closing of casing doors

Opening:

Put the handle locking system in a horizontal

position (mark 1) then press down on it.

The handle is released from its housing; you can

now open the right-hand door, followed by the left-

hand door.

Closing:

Close the left-hand door, followed by the right-

hand door.

Press the door's lever.



U0503482-#

ﬁ gure 5 - Opening casing doors

4.4. Removing the control panel (MMI)



Put the handle locking system in a vertical position

(mark 1).

The control panel (MMI: Man Machine Interface)

may be removed from the casing door to:

• remove the left-hand casing door;

• view the display when setting or carrying out maintenance work on the boiler;

Open the casing doors.

Remove the locking screw back of the left-hand casing door.

accessible on the







ﬁ gure 6 - Unlocking the control panel

Page 20 / 146 00BNO9061-J

VARMAX - Installation, Use and Maintenance

You can:

• put the control panel back

• ﬁ t the control panel to the boiler (see opposite,





ﬁ gure 7 - Positions of the control panel

4.5. Removing / reﬁ tting the casing doors

With the doors open, remove the pin on the top of the door to be removed.

-

-

or carrying out maintenance), or

so that the left-hand casing door can be removed without any risk to the control panel).

(to view data displayed when adjusting

in its place

Support the door during this operation because once the pin has been removed, the door is no longer attached to the boiler.

When reﬁ tting, ﬁ rstly position the bottom of the door on the lug, and then the top, making sure to fully insert the pin into its housing.

lug

U0502515-#

ﬁ gure 8 - Removing casing doors

Edition: 06 / 2015 Page 21 / 146

WARNING:

Before removing the left-side casing door, do not forget to remove the control panel (see next paragraph).

VARMAX - Installation, Use and Maintenance

4.6. Removing / reﬁ tting side panels

locking screw

Open the casing doors.

Remove the locking screw accessible via the inside of the boiler.

Use the handle in the centre of the panel for this.

Lift up the panel vertically and remove.

When reﬁ tting, re-fasten the locking screws from inside the boiler after ﬁ tting the panels.

handle

rear side panel

U0501963-#

ﬁ gure 9 - Removing side panels

4.7. Removing / reﬁ tting the top panel

removable part

Note: It may be necessary to remove the rear side

panels in order to ﬁ t through doors. To do this, unscrew the ﬁ xing screws which hold the panel onto the boiler's structure and remove the panel.

Open the casing doors.

Loosen the 2 thumbscrews on the top of the boiler (1 or 2 turns will be enough. It is not necessary or recommended to unscrew them completely).

Slightly lift up the panel and remove it from the front.

To reﬁ t it, follow the procedure in reverse.

U0502250-#

ﬁ gure 10 - Removing the upper panel

Page 22 / 146 00BNO9061-J

4.8. Step

ﬁ gure 11 - Installing the step

VARMAX - Installation, Use and Maintenance

WARNING:

The step is a means to access the burner. It cannot be used as a work platform.

There are steps on models 180 and above.

On models 180 to 320:

Open the doors.

Unfold the step.

U0502519-#

ﬁ gure 12 - Installing the step on models 180-320

On models 390 and 450:

Open the doors.

Remove the blocking element of the step

Unfold the step.

Pull the lower step.

blocking element of the step

U0502519-#

ﬁ gure 13 - Installing the step on models 390 and 450

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VARMAX - Installation, Use and Maintenance

4.9. Changing the gas type (G20 to G31)

The boiler has been adjusted in the factory to work with group H (type G20) natural gas with a supply pressure of 20 mbar.

INFORMATION:

Its adaptation to suit any other type of gas must take place in compliance with the regulations in effect in the country in which the appliance is installed.

WARNING:

Any operations involving changing the type of gas used must be performed by a qualiﬁ ed professional.

ONLY for relevant boilers (see paragraph 2.6, page 13) and boilers connected to B23 and B23P.

4.9.1. Changing prepurging, ignition, minimum and maximum speeds

Place the boiler in standby mode (see § 3.3.1 of the NAVISTEM B3000 boiler command table instructions).

If necessary, press the ESC button to return to the main screen.

Access the Settings menu.

Adjust the prepurging speed (9504), ignition speed (9512), minimum speed (9524) and maximum speed (9529) settings:

Models Gas 9504 9512 9524 9529

120

140

180

225

275

320

G20 1690 6490 G31 2040 5800 G20 1690 7460 G31 2040 6800 G20 2390 2390 1280 4410 G31 2575 2575 1640 4240 G20 2390 2390 1280 5400 G31 2575 2575 1640 5060 G20 1360 4620 G31 1700 4500 G20 1360 5450 G31 1700 5300

Page 24 / 146 00BNO9061-J

4.9.2. On VARMAX 120, 140, 275 and 320

VARMAX - Installation, Use and Maintenance

The type of gas is changed by installing the diaphragm (brass part) provided with the boiler (engraved B1P for 120 and 140 models or engraved B3P for 275 and 320 models).

Unscrew the 4 nuts or screws depending on the model (see opposite). Install the diaphragm provided. Screw the 4 nuts back in place.

nut (x4)

ﬁ gure 14 - Diaphragm (120 and 140 models)

diaphragm

U0524542-#

Check the CO

settings (see § 7.7, page 52).

After changing the type of gas:

- Check the sealing of the gas line.

- Stick the label provided in place of the

original label (G20).

Note: In order to facilitate the operation, the mounting ﬂ ange located at the entrance to the gas line (on the side nearest the network connection) may require unscrewing.

nut (x4)

diaphragm

U0503708-#

ﬁ gure 15 - Diaphragm (275 and 320 models)

Edition: 06 / 2015 Page 25 / 146

VARMAX - Installation, Use and Maintenance

4.9.3. On VARMAX 180 and 225

The type of gas is changed by replacing the diaphragm located on the gas line.

Unscrew the 4 nuts (see opposite), then remove the diaphragm in place (brass part). Replace this with that provided with the boiler (engraved B2P). Screw the 4 nuts back in place.

diaphragm

ﬁ gure 16 - Diaphragm

4.10. Exhaust connection

Exhaust system works and national and prefectoral regulations must be complied with.

A smoke temperature sensor guarantees the protection of exhaust ducts for type B and C combustion products.

nut (x4)

U0503708-#

Check the CO

After changing the type of gas:

- Check the sealing of the gas line.

- Stick the label provided in place of the

original label (G20).

Note: In order to facilitate the operation, the mounting ﬂ ange located at the entrance to the gas line (on the side nearest the network connection) may require unscrewing.

settings (see § 7.7, page 52).

VARMAX boilers are approved to be connected to:

• a B23 chimney (all models)

• a B23P chimney (all models)

• a C13 air vent (models 120 to 225) except for propane gas (G31)

• a C33 air vent (models 120 to 225) except for propane gas (G31)

• a C53 air vent (all models) except for propane gas (G31)

The lengths of the ducts provided below are in linear metres (lm). The total

INFORMATION:

length of all ducts is reduced to a straight length (elbows having a straight equivalence).

4.10.1. Connection to a B23 chimney

Type B23 connection:

Air from the unit's premises, extraction of gases through the roof via a ﬂ ue with natural ventilation.

Check that there are top and bottom ventilations in the boiler premises,

WARNING:

that they comply with applicable regulations and that they are not obstructed.

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VARMAX - Installation, Use and Maintenance

Chimney ﬂ ues must be dimensioned considering the combustible gas pressure at the boiler outlet of 0 Pa (see table § 3.3, page 15).

The ﬂ ue-gas 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 capable of supporting temperatures up to 120°C. Horizontal duct runs must be avoided so as not to cause condensate retention.

Check that the fuel gas is extracted via a gas-tight duct.

VARMAX boilers are efﬁ cient boilers with very low ﬂ ue-gas temperatures; as a result, to maintain favourable ventilation, the ducts must run upwards from the boiler outlet.

If several boilers are connected to a single ﬂ ue, check:

1. that the ﬂ ue is not under pressure when all the boilers are in

IMPORTANT:

operation.

2. If one of the boilers is operating at minimum power, that the others do not discharge into it.

Sizing recommendations based on a POUJOULAT system (Condensor type):

ø duct

ø connection

3 m

ﬁ gure 17 - B23 sizing recommendations

Edition: 06 / 2015 Page 27 / 146

VARMAX - Installation, Use and Maintenance

Height of ﬂ ue-gas duct H in linear metres (lm)

(operating at 50/30°C)

connection

duct

Type of gas G20 G31 G20 G31 G20 G31 G20 G31 G20 G31

120 2 to 52 -- -- 3 to 39 -- -- -- -- -- -140 7 180 -- -- 10 225 -- -- -- -- 1 275 -- -- -- -- -- -- 4

MODELS

320 -- -- -- -- -- -- 5 390 -- -- -- -- -- -- -- -- 2 450 -- -- -- -- -- -- -- -- 2

180 mm 200 mm 250 mm 250 mm 300 mm

to 39 -- 3 to 94 4 to 38 -- -- -- -- -- --

150 mm 180 mm 200 mm

to 29 -- 1 to 100 4 to 73 -- -- -- --

to 100 3 to 65 -- -- -- --

to 99 4 to 61 -- -- to 81 6 to 53 -- --

to 100 -- to 100 --

IMPORTANT:

The above values are provided for information purposes only. It is important to check them with a calculation.

The weight of ﬂ ue-gas ducts must not be supported by the part connecting to the boiler.

4.10.2. Connection to a B23P chimney

Type B23P connection:

Air coming from the boiler premises, extraction of gases through the roof via a pressurised duct.

Check that there are top and bottom ventilations in the boiler premises,

WARNING:

IMPORTANT:

that they comply with applicable regulations and that they are not obstructed.

For the B23P type connection, it is MANDATORY to use ducts which have pressurised duct certiﬁ cation, such as CONDENSOR (Poujoulat) or rigid or ﬂ exible CHEMILUX CONDENSATION (Ubbink).

The duct extracting combustion products must be sized using the parameters provided in the table in paragraph 3.3. Depending on the duct's actual conﬁ guration, a calculation is

Page 28 / 146 00BNO9061-J

IMPORTANT:

necessary to check that the pressures at the boiler outlet do not exceed the maximum normative values authorised (200 Pa). Values corresponding to the 50/30°C regime are to be used for this calculation.

VARMAX - Installation, Use and Maintenance

Cascade installation case

In this case, where boilers with different powers are connected, the most powerful models must be closest to the chimney.

The boiler is equipped with an internal check valve smoke diverter, replacing any other external and functionally identical system.

Sizing recommendations on the basis of a POUJOULAT system (Condensor type):

ø duct

ø connection

3 m

ﬁ gure 18 - B23P (Poujoulat) sizing recommendations

Height of ﬂ ue-gas duct H in linear metres (lm)

(operating at 50/30°C)

connection

duct

Type of gas G20 G31 G20 G31 G20 G31 G20 G31

120 79 60 -- -- -- -- -- -140 87 39 -- -- -- -- -- -180 -- -- 74 23 -- -- -- -225 -- -- 69 20 -- -- -- -275 -- -- -- -- 100 73 -- --

MODELS

320 -- -- -- -- 100 64 -- -390 -- -- -- -- -- -- 100 -450 -- -- -- -- -- -- 100 --

130 mm 150 mm 180 mm 200 mm

150 mm 180 mm 200 mm

Edition: 06 / 2015 Page 29 / 146

IMPORTANT:

IMPORTANT: The weight of ﬂ ue-gas ducts must not be supported by the boiler.

The above values are provided for information purposes only. It is important to check them with a calculation.

VARMAX - Installation, Use and Maintenance

Sizing recommendations on the basis of a UBBINK system:

Using a Ubbink duct in PPTL (reference 041432) at the boiler outlet.

ﬁ gure 19 - B23P (Ubbink) sizing recommendations

ø160 requires a Male 150 / Female 160 adaptor

ø 160

Height of ﬂ ue-gas duct H in linear metres (lm)

(operating at 50/30°C)

duct

Type of gas G20 G31 G20 G31

120 100 100 100 86

140 100 100 86 65

MODELS

IMPORTANT:

IMPORTANT: The weight of ﬂ ue-gas ducts must not be supported by the boiler.

The above values are provided for information purposes only. It is important to check them with a calculation.

180 64 32 30 --

225 58 40 28 --

rigid ﬂ exible

160 mm

4.10.3. Rules for installing air vent terminals

Please refer to national standards and regulations.

Page 30 / 146 00BNO9061-J

4.10.4. Connection to a C13 or C33 air vent

Type C13 connection:

Air inlet and gas extraction via separate ducts connected to a horizontal concentric terminal (air vent).

Type C33 connection:

Air inlet and gas extraction via separate ducts connected to a vertical concentric terminal.

Connecting a VARMAX boiler in C13 or C33 conﬁ guration requires use of

IMPORTANT:

the "Terminal kit" comprising a terminal, a dual-ﬂ ow adaptor and a male adaptor

ø150 / female adaptor ø160 (reference 041421).

VARMAX - Installation, Use and Maintenance

Ensure the slope from the concentric terminal is 3°.

ø160 ø150

ﬁ gure 20 - Type C13 connection ﬁ gure 21 - Type C33 connection

450 mm maxi

U0501471-#

450 mm maxi

ø160

ø150

U0501398-#

The table below shows the maximum straight lengths authorised for air and ﬂ ue-gas ducts.

MODELS

120 140 180 225

L1 (air) 16.5 lm 13.5 lm

L2 (ﬂ ue-gases) 17.5 lm 14.5 lm

The lengths indicated include the lengths of the concentric terminal.

Edition: 06 / 2015 Page 31 / 146

VARMAX - Installation, Use and Maintenance

In addition, in the duct length calculation, the following equivalences must be used;

- 90° elbow = 1.5 m of straight duct

- 45° elbow = 0.8 m of straight duct

The terminal's installation must comply with the rules in § 4.10.3, page 30.

To facilitate mounting of ﬂ ue-gas ducts (PPTL), coat the joints with liquid soap or a suitable grease (provided in the "terminal kit").

IMPORTANT:

The weight of the ducts (air and ﬂ ue-gas) must not be supported by the boiler's connecting parts.

4.10.5. Connection to a C53 air vent

Type C53 connection:

Air inlet and gas extraction via 2 separate ducts.

IMPORTANT:

Connecting a VARMAX boiler in a C53 conﬁ guration requires the use of accessory kits.

The table below gives the reference of the available kits depending on the boiler model and the maximum straight lengths authorised for the air and ﬂ ue-gas ducts.

MODELS

120 140 180 225 275 320 390 450

Accessory kit reference 041422 041422 041423 041424

L1 (air) 10 lm 8 lm 10 lm 10 lm

L2 (ﬂ ue-gas) 40 lm 39 lm 40 lm 40 lm

ø A (air duct) ø F (ﬂ ue-gas duct)

The lengths given include the lengths of the ﬂ ue-gas terminal but do not include the air terminal (measure taken on the outside of the wall).

In addition, in the duct length calculation, the following equivalences must be used;

For ducts with diameters 150 mm and 160 mm:

- 90° elbow = 1.5 m of straight duct

- 45° elbow = 0.8 m of straight duct

For ducts with diameters 180 mm and 200 mm:

- 90° elbow = 2 m of straight duct

- 45° elbow = 1.1 m of straight duct

150 mm 150 mm 180 mm 180 mm

160 mm 160 mm 180 mm 200 mm

Page 32 / 146 00BNO9061-J

VARMAX - Installation, Use and Maintenance

The ﬂ ue-gas terminal's installation must comply with rules in § 4.10.3, page

30.

Ensure the slope towards the boiler is at least 3° (ﬂ ue-gas side). On the air duct side, adjust a slope to the outside to avoid the risk of rainwater in the boiler.

To facilitate mounting ﬂ ue-gas ducts for models 120 to 225, coat the joints in liquid soap or a suitable grease (provided in the "terminal kit").

450 mm maxi

øF

øA

450 mm maxi

øF

450 mm maxi

øA

U0501350-#

ﬁ gure 22 - Type C53 connection (VARMAX

models 120 to 225)

Edition: 06 / 2015 Page 33 / 146

IMPORTANT: The weight of ﬂ ue-gas ducts must not be supported by the boiler.

ﬁ gure 23 - Type C53 connection (VARMAX

models 275 to 450)

U0501496-#

VARMAX - Installation, Use and Maintenance

4.11. Hydraulic connection

The presence of an integrated irrigation pump in the boiler and an intelligent control logic enables optimal operation up to IUP/30 (IUP = Instant Useful Power expressed in Th/h - 1Th/h = 1.163 kilowatts). Below this throughput of IUP /30, the boiler will continue to operate, but will gradually lose power (boiler stops below IUP /46). In connector sleeves 3 and 4, there is no minimum throughput constraint on the condenser. In the main heat exchanger, as in the condenser, you must ensure that you never exceed the throughput prescribed in section 3.4 (boiler nominal useful power / 10).

Sizing the pipes connecting the boiler to the installation must be done carefully, to minimise the pressure losses and so avoid oversized circulating pumps. In some cases the diameter of the connection pipes will be greater than the diameter of the boiler tappings. The diameter can then be usefully increased after the union connectors, the stop valves, and/or the hydraulic balancing valves. VARMAX boilers are equipped with the following elements:

• main exchanger drain valve,

• condenser drain valve.

It is mandatory to ﬁ t the boiler and its installation with the following elements:

• isolating valves on the ﬂ ow and return tappings,

• an expansion vessel,

• an efﬁ cient bleed device,

• a safety valve set to 6 bar,

• A shut-off on the boiler's ﬁ ll circuit in relation to the main supply.

VARMAX boilers are available with 2/3 tappings or 4 tappings. It is not possible to transform a version with 2/3 tappings into a version with 4 tappings and vice versa.

4.11.1. Boiler with 2 or 3 tappings

Clamp obstructing

2nd return

Flow

2 tappings

If all the circuits have the same return temperatures, the return tapping located in the lower part must be used.

Return

U0501961-#

ﬁ gure 24 - Connection with 2 tappings

Page 34 / 146 00BNO9061-J

Flow

return

hot return (high temperature circuit)

VARMAX - Installation, Use and Maintenance

3 tappings

VARMAX boilers are ﬁ tted with 2 returns and an optimised internal water circuit allowing effective separation of high temperature returns (coming from DHW preparation circuits, radiators, etc.) from low temperature circuits (underﬂ oor heating circuits, low temperature radiator circuits, etc.). This circuit separation encourages the condensation of ﬂ ue-gases in the lower part of the condenser throughout the year, and therefore considerably increases the boiler's performance.

cold return (underﬂ oor heating and low temperature radiators)

ﬁ gure 25 - Connection with 3 tappings

4.11.2. Boiler with 4 tappings

1st return

U0501961-#

Main exchanger

ﬂ ow

Condenser ﬂ ow

To use the 2

return, the clamp obstructing the

tapping must be removed.

VARMAX boilers are ﬁ tted with 2 internal water circuits allowing separation of high temperature returns (coming from DHW preparation circuits, radiators, etc.) from low temperature circuits (underﬂ oor heating circuits, low temperature radiator circuits, etc.).

main exchanger return

Condenser return

ﬁ gure 26 - Connection with 4 tappings

WARNING:

Do not connect DHW (domestic hot water) or swimming pool water to the condenser circuit.

In some installations, additional improvement may be obtained using 4 tappings. This separates the condenser (low temperatures) from the main exchanger (high temperatures).

There are no throughput constraints regarding the condenser.

U0501961-#

Edition: 06 / 2015 Page 35 / 146

VARMAX - Installation, Use and Maintenance

4.11.3. Condensate removal

Removal to the drains, via a drain hopper, using a P.V.C tube (minimum diameter 32 mm) is mandatory because the condensates are acidic and thus aggressive (pH between 3 and 5). Use a sufﬁ cient slope of 3% to ensure correct ﬂ ow of the condensates.

WARNING:

4.12. Gas connection

Neutralise these condensates before removal according to regulations in force.

Before installing the boiler, it is necessary to clean the inside of the installation's gas line (metallic particles, soldering residue, etc.). This helps to improve the product's longevity. Before commissioning the boiler, check that the natural gas supply pressure corresponds to the boiler's nominal pressure mentioned on the identiﬁ cation plate. Before feeding gas to the installation, ensure that the different connections are correctly made and gas tight.

In particular, check the presence of a removable connector between the isolating valve and the boiler gas supply tapping. The value read at the gas valve input must be between the limits indicated in the table in chapter 2.5, page 11 for the type of gas used.

The boiler's gas line connection must not be subject to any mechanical

WARNING:

stress (risk of loss of gas tightness of the gas valve). Check that the natural gas supply corresponds to the nominal boiler pressure stated on the identiﬁ cation plate.

4.13. Electrical connection

DANGER:

WARNING: Observe the phase polarity - neutral for electrical connections.

WARNING:

Ensure that the general electrical power supply has been cut off before starting any work.

It is mandatory to connect this boiler correctly to earth and to comply with applicable standards for low voltage electrical installations in the United Kingdom. Provide a two pole circuit breaker upstream of the boiler (distance between contacts: 3.5 mm minimum). It is strongly recommended to ﬁ t the electrical installation with a 30 mA differential protection.

Page 36 / 146 00BNO9061-J

4.13.1. Control panel

VARMAX - Installation, Use and Maintenance

Refer to the instructions of installation and use of the NAVISTEM B3000 boiler command table for information concerning electrical connections to the control panel (characteristics of the electrical power supply, cable section and connection to terminal blocks).

To access the control panel, open the casing doors on the front of the boiler.

The control panel is on the upper front left of the boiler.

Unscrew the turn screw at the bottom of the cover.

Cover

Turn screw

ﬁ gure 27 - Opening the electrical box

4.13.2. Cable bushing

Cable clamp

U0501960-#

High voltage tray (power supply)

Lift up the cover and pull backwards.

Use the cable trays located on the top left of the boiler to insert the connection cables:

• The upper tray must be reserved for the power connections (boiler power supply, alarm feedback or circulating pump control).

• The lower tray is dedicated to signal connections (sensors, communication bus, etc.).

Low voltage tray (sensors / buses)

Use the cable clamp located at the inputs to the trays to lock the cable mechanically.

U0501963-#

ﬁ gure 28 - Electrical cable bushing

Edition: 06 / 2015 Page 37 / 146

VARMAX - Installation, Use and Maintenance

4.13.3. Connection of the boiler command table to the terminal blocks

To connect the boiler command table, refer to the relevant instructions of installation and use.

ATTENTION :

For connection, comply with the wiring diagram, in particular the phase, neutral and earth polarities.

4.13.4. Connection of AVS75 extension module(s) (optional)

To install AVS75 module(s) (3 max), refer to the instructions provided with the accessory (reference 059751).

AVS75 location (behind side door)

U0501963-#

ﬁ gure 29 - AVS75 location

4.13.5. Connection of OCI345 communication module (optional)

To install the OCI345 module, refer to the instructions provided with the accessory (reference 059752).

4.13.6. Fuses

The VARMAX boiler is ﬁ tted with 4 fuses on the boiler command table (refer to the sticker on the protective cover for their locations and characteristics).

3 spare fuses are also available on the boiler command table.

Page 38 / 146 00BNO9061-J

OCI 345

AVS75

B2 B7

4.13.7. Electrical wiring diagram

VARMAX - Installation, Use and Maintenance











Refer to the boiler command table instructions of installation and use.



Refer to the instructions supplied with the optional accessory AVS75.



Refer to the instructions supplied with the optional accessory OCI 345



ﬁ gure 30 - Electrical wiring diagram

Edition: 06 / 2015 Page 39 / 146

00BET9008-#

VARMAX - Installation, Use and Maintenance

5. COMMISSIONING

5.1. Unlocking the boiler

During commissioning, the unlocking of the boiler can only be achieved

WARNING:

if the hydraulic system is compliant with the recommendations mentioned in the hydraulic diagrams (see section 8.3, page 54). The person in charge of this operation must ensure such compliance.

Unlocking the temperature:

Modify parameter 2212 from 70° C to the desired value (Maximum 85°C).

Unlocking the power:

Increase the value of parameter 9529 up to the value of parameter 9530 (corresponding with the nominal power of the boiler).

Adjusting the boiler to operate using propane results in the

Parameter 9529 value 120 140 180 225 275 320 390 450

WARNING:

power locked 4610 5300 3180 3870 3360 3930 3440 3900

power unlocked 6490 7460 4410 5400 4620 5450 4810 5480

modiﬁ cation of parameter 9529; the boiler power locking function is therefore no longer active.

MODELS

5.2. Pre-commissioning checks

For a cascade installation, check the hydraulic balance of the boilers.

Check that pressure when cold is at least 1 bar.

If this is a boiler room renovation, ensure that ﬂ ushing and if necessary silt removal from the installation have been correctly done (see paragraph 1.5, page 7 of these instructions).

Check the ﬂ ue-gas connections depending on the type of chimney (refer to paragraph 4.9, page 24).

Check that the gas pressure and type are suitable for the products.

DANGER: It is forbidden to use water containing glycol.

Page 40 / 146 00BNO9061-J

WARNING:

If connecting CHIMNEY B23 or B23P, it is COMPULSORY to ﬁ t the air ﬁ lter supplied with the boiler.

5.3. Commissioning

VARMAX - Installation, Use and Maintenance

Before being packed up, all boilers are tested in the factory operating on group H natural gas (type G20), during which all settings are made.

For commissioning, carry out the following operations:

1. Switch on the main power.

Flue-gas sample

point

ﬁ gure 31 - Taking a sample

U0501961-#

2. Create a request for heat via the comfort mode using the customer interface (see chapter "3 Interface utilisateur" of the LMS boiler command table instructions).

3. After starting up the burner, check the gas tightness of the gas line connections using a foaming product. Check combustion health using a ﬂ ue-gas analyser via a sample taken from the ﬂ ue outlet (see diagram opposite).

value range:

G20:

at Qmin: 8,3 % < CO at Qmax: 8,8 % < CO

< 8,7 %

< 9,2 %

G31:

at Qmin: 9,8 % < CO at Qmax: 10,4 % < CO

< 10,2 %

< 10,8 %

4. Adjust the boiler setting (refer to the table summarising customer parameters at the end of this manual).

WARNING: Any work on a sealed element leads to loss of warranty.

Edition: 06 / 2015 Page 41 / 146

VARMAX - Installation, Use and Maintenance

6. POST-COMMISSIONING CHECK

6.1. Condensate removal

Check that the removal of condensates is not obstructed, on both the boiler side and the pipe side

6.2. Gas supply

Check that the gas pipe diameter is correctly sized:

It is necessary to stop all the boilers together abruptly using the boiler room main circuit breaker to check that the gas pressure regulator safety device is not triggered.

If this is triggered, the gas pipe is undersized. After this operation, reengage the circuit breaker. The boilers must start automatically, if not, consult the supplier of the gas pressure regulator.

Page 42 / 146 00BNO9061-J

7. MAINTENANCE OPERATIONS

There are two types of maintenance operations:

• yearly maintenance

DANGER:

• in-depth maintenance every 3 years.

The table below shows which actions to undertake depending on the type of maintenance to be performed. In all events, these operations must be performed by a qualiﬁ ed professional.

Before carrying out the following operations:

• Switch off the main power

• Close the gas supply shut-off valve.

VARMAX - Installation, Use and Maintenance

No. of

paragraph to

consult

7.2 Veriﬁ cation of the boiler's environment X

7.3 Replacing the air ﬁ lter matting X

7.4 Veriﬁ cation of ignition and ionisation electrodes X

7.5 Siphon cleaning X

7.6 Checking the combustion circuit's gas-tightness X

7.7 Checking combustion quality X

7.9 Gas ﬁ lter cleaning X

7.10 Cleaning exchangers and changing of seals on service doors X

Maintenance

every

year

every

three

years

7.11

Edition: 06 / 2015 Page 43 / 146

Check the condition of the gas manifold coating Cleaning the burner and changing the seals

VARMAX - Installation, Use and Maintenance

7.1. Boiler draining

Main exchanger drain valve

(front of boiler)

Condenser drain valve (rear of boiler)

ﬁ gure 32 - Drain valves

• Close the shut-off valves of the ﬂ ow and return tappings.

• Connect the drain valves (main exchanger and condenser) to the drain with a suitable hose.

• Create an air intake on the "main exchanger" ﬂ ow nozzle (open the safety valve).

• Open the drain valve.

U0502206-#

7.2. Veriﬁ cation of the boiler's environment

Before carrying out any maintenance work, it is necessary to perform a certain number of checks concerning the installation's use.

• Water pressure: check that the water pressure is higher than 1 bar when cold.

• Read the makeup water meter. This operation helps to identify any hydraulic leaks. If consumption of makeup water changes, seek the cause and repair.

7.3. Replacing the air ﬁ lter matting

DANGER:

To make sure this task is performed in safety, switch off the boiler and cut off the upstream power.

Page 44 / 146 00BNO9061-J

DANGER:

INFORMATION:

Use personal protective equipment (mask and gloves) to remove the used air ﬁ lter.

The air ﬁ lter is only present on boilers connected to a B23 or B23P chimney.

INFORMATION:

VARMAX - Installation, Use and Maintenance

The air ﬁ lter is an important element of the boiler. It limits the burner and the exchangers becoming sooty. Changing it regularly (at least every year) makes burner and exchanger cleaning operations considerably easier.

Models 120 to 320:

Models 390 and 450:

ﬁ gure 33 - Filter matting

mountings

U0038318-B

U0024791-B

- Remove the used ﬁ lter matting (no tool required).

- Be careful not to let any dust or other foreign bodies enter the air duct (see opposite).

- Insert the new rectangular ﬁ lter matting between the ﬁ lter's protective grille and the mountings (see opposite).

Ensure that the link between both ends of the matting is under one of the mountings.

- For models 390 and 450, insert the square ﬁ lter cloth on the back gate of the ﬁ lter.

7.4. Veriﬁ cation of ignition and ionisation electrodes

Ionisation electrode

Ignition electrode

U0502214-#

ﬁ gure 34 - Position of electrodes

2.5-3.5 mm

U0502273-#

ﬁ gure 35 - Spacing

Electrode removal

Unscrew the two M4 Torx screws holding the electrode that needs to be removed.

If necessary and if there is a large amount of oxidation, clean the electrodes by rubbing them with an emery cloth.

Check the space between the ignition electrode and the ground electrode (see diagram opposite). It must be between 2.5 and 3.5 mm. If this is not the case, replace the electrode.

Edition: 06 / 2015 Page 45 / 146

VARMAX - Installation, Use and Maintenance

ﬁ gure 36 - Geometry

7.5. Siphon cleaning

Siphon

Hatch

13.8 mm

U0502273-#

U0502274-#

Check the geometry of the arc electrode: If deformed more than ±3 mm, replace the electrode.

Re-assemble the electrode block(s). Tightening torque of the block ﬁ xing screws = 2.5 N.m.

Check the siphon and clean if necessary. The siphon must be located between the main exchanger and the condenser on the right-hand side (it can be accessed via the hatch without removing the side panel). To do this:

• Dislodge the siphon by pulling it downwards.

• Clean with water.

• Re-assemble the siphon after checking the presence and the possibility of free movement of the ﬂ oat (ball). Also check that the seal is not damaged.

ﬁ gure 37 - Siphon

7.6. Checking the combustion circuit's gas-tightness

Check the gas-tightness of the 3 service doors using the foaming product. The areas to check are shown on the diagram opposite. The check must be performed when the boiler is off, but with the ventilator operating at its maximum

seal checking zone

exchanger service door (check the other 2 doors)

U0502275-#

ﬁ gure 38 - Gas-tightness of the service door

speed (obtained by disconnecting the PWM signal connector).

If a leak is detected, replace the seal with the appropriate kit.

It is recommended to replace the seals each time the exchanger service doors are removed. If they are not replaced, do not cross the doors when reassembling.

Page 46 / 146 00BNO9061-J

7.7. Checking combustion quality

Flue-gas sample

point

U0501961-#

ﬁ gure 39 - Sample taking

VARMAX - Installation, Use and Maintenance

This check is performed using a calibrated combustion case. To do this, insert the measuring stick into the ﬂ ue outlet (see diagram opposite).

The boiler's starting temperature must be above 70°C.

Do not forget to re-position the stopper on the oriﬁ ce from where the sample is taken afterwards.

For the G20, the CO

content measured in these circumstances must be

between 8.3% and 8.7% at Qmini (0% on display) and between 8.8% and

9.2% at Qmaxi (100% on display).

If this is not the case, it is necessary to alter the setting of the gas valve (see next paragraph). After this check, it is necessary to either take a measurement of the "gas" throughput or the ∆P valve. These measurements check the state of soiling of the combustion circuit (burner, body, exchanger(s)).

For the G31 (relevant modls only), the CO

content measured in these

circumstances must be between 9,8% and 10,2% at Qmini (0% on display) and between 10,4% and 10,8% at Qmaxi (100% on display).

For installations with B23 and B23P, we recommend you take this measurement using a new air ﬁ lter.

The measurement must be done for a duration of more than 3 minutes to obtain a sufﬁ ciently precise measurement. If the gas throughput is less than 20% in relation to the value indicated in paragraph 3.3, page 15, it is necessary to clean the main exchanger and the burner (see § 7.10 and 7.11). If you choose to take a measurement of the ∆P valve, refer to the next paragraph to ﬁ nd out how to do it. If the value measured is lower than the values deﬁ ned in the table on page 49, it is necessary to clean the main exchanger and the burner (see § 7.10 and 7.11).

Edition: 06 / 2015 Page 47 / 146

VARMAX - Installation, Use and Maintenance

7.8. Setting the gas valve

This VARMAX boiler has been adjusted in the factory to operate with group H natural gas (type G20) with inlet gas pressure of 20 mbar.

WARNING:

Any work on adjusting the gas valve must be performed by a qualiﬁ ed professional.

The valve must be adjusted with the boiler working at maximum and minimum pressure. To do this, use the operating "Manual operating" mode (see § 3.3.4 of the NAVISTEM B3000 boiler command table instructions), which makes it possible to switch directly to the minimum or maximum value (0% or 100%).

7.8.1. For models 120 and 140

Start the burner up at maximum power.

Using the combustion analyser, measure the rate of CO

in the ﬂ ue-gases in the ﬂ ue outlet (see

ﬁ gure 39).

Check the CO

value at Maximum power and, if

necessary, manipulate the valve's gas throughput adjustment screw to obtain CO

values between

8.8% and 9.2% or between 10,4% and 10,8% (G31).

Offset regulator

Gas throughput adjustment screw

U0501967-#

ﬁ gure 40 - VARMAX gas valve models 120 and 140

Move to Minimum power and check that the CO

value is between 8.3% and 8.7% (G20) or between 9,8% and 10,2% (G31). If necessary, adjust the Offset regulator by removing the stopper using a ﬂ at screwdriver and adjust the screw with a Philips screwdriver.

If changing the setting while on minimum power, switch back to Maximum power and check the CO

value again. Repeat until both values conform.

Go back to standard operating mode.

Air relay pipe connection points

Page 48 / 146 00BNO9061-J

7.8.2. For models 180 to 450

VARMAX - Installation, Use and Maintenance

Hexagonal 3 mm wrench

Offset regulator

Pvalve

Pupstream

ﬁ gure 41 - Gas valve setting

Cover

U0501967-#

The measurements for setting the valve must be taken using the pressures indicated Pvalve and Pupstream (see diagram opposite).

Air relay pipe connection points

(Models 180 and 225)

Air relay pipe connection points

(Models 275 and 320)

Air relay pipe connection points

(Models 390 and 450)

Edition: 06 / 2015 Page 49 / 146

VARMAX - Installation, Use and Maintenance

Models

Valve

type

Type of

gas

G20 3,8

180 VR420

G31 1,6 G20 5,9

225 VR420

G31 2,4 G20 3,6

275 VR432

G31 1,7 G20 5,2

320 VR432

G31 2,4 390 VR434 G20 5,4 450 VR434 G20 7,1

∆P

valve

= (P

upstream

- P

valve

)

∆P

Schieber

(mbar)

Setting at maximum power: Start the burner up at maximum power. Remove the cover (see ﬁ gure 41). Measure the inlet gas pressure (Pupstream). Adjust the valve pressure (Pvalve) taking into account ∆P

valve

= (P

upstream

- P

) given in the table

valve

opposite (set the pressure by manipulating the adjustment screw on the top of the valve underneath the black cover, 3 mm hexagonal wrench). If necessary, adjust the valve pressure to obtain a CO

rate between 8.8% and 9.2% (G20) or between

10,4% and 10,8% (G31).

Then switch to minimum power: Adjust the offset regulator (see ﬁ gure 41) to get a CO

rate at minimum power between 8.3% and

8.7% (G20) or between 9,8% and 10,2% (G31). Use a ﬂ at screwdriver to remove the protective stopper

and a Torx wrench to adjust. To validate the correct setting of the valve increase to Pmaxi (HMI = 100%) and check the CO

rate in

the ﬂ ue-gases in the ﬂ ue outlet (see ﬁ gure 39). If the setting is not correct, perform the above steps again.

7.9. Gas ﬁ lter cleaning

- Unscrew the 4 screws that hold the gas ﬁ lter in place.

- Carefully remove the gas ﬁ lter.

- Clean the gas ﬁ lter ONLY with a blower.

- Reﬁ t the ﬁ lter and tighten the 4 M5 screws (tightening torque = 5 N.m).

Gas ﬁ lter

screws

(x4)

screws (x4)

Gas ﬁ lter

U0503716-# U0503711-#

ﬁ gure 42 - Gas ﬁ lter on VARMAX 120 and 140

Page 50 / 146 00BNO9061-J

WARNING: Check gas-tightness after reﬁ tting.

ﬁ gure 43 - Gas ﬁ lter on VARMAX 180 to 450

7.10. Cleaning exchangers and changing seals

Removal of exchanger doors:

- Remove the front and side cladding to access the 3 service doors.

- Using a 13mm wrench, unscrew the service door attachment screws until the tightening bolts turn.

VARMAX - Installation, Use and Maintenance

ﬁ gure 44 - Removal of exchanger doors



6 screws

U0502425-#

- Then remove the door.

- Repeat for the other 2 service doors.

Removal of bafﬂ es:

- Open the fastenings (mark 1) that close the 2 ﬂ ue-gas bafﬂ e strappings (mark 2).





ﬁ gure 45 - Removal of bafﬂ es

Edition: 06 / 2015 Page 51 / 146

- Remove the 2 strappings (mark them in some way so that you can reﬁ t them in the same order) and then remove the ﬂ ue-gas bafﬂ es (marks 3). Mark these too so that you can reﬁ t them in the same position.

Cleaning bafﬂ es and exchangers:

- Brush the ﬂ ue-gas bafﬂ es with a stainless steel or plastic brush, so as not to geometrically deform them.

- Clean by brushing or if the exchanger is very dirty, wash with water and then dry. If washing with water, be careful of the electrical parts.

VARMAX - Installation, Use and Maintenance

Changing door seals:

service door

groove

- Remove the seals from their groove and replace with new seals from the maintenance kit (see ﬁ gure 46).

seal

U0502445-#

ﬁ gure 46 - Changing door seals

Reﬁ tting:

wire spring

- Insert the bafﬂ es under the wire spring between the top part of the exchanger tubes (see detail).

Replace the bafﬂ es holding the strappings (mark

3) as shown on the diagram opposite.

- Position the strappings inside the pins of the bafﬂ es holding the strappings.

bafﬂ es

ﬁ gure 47 - Reﬁ tting

- Tighten the fastenings and ensure the bafﬂ es are correctly ﬁ tted to the exchanger tubes and check

that each of the bafﬂ es are correctly ﬁ tted on the exchanger tubes at their lower and upper ends.

Note: It is normal that the bafﬂ es are not ﬁ tted tightly in the area between the 2 strappings.

U0503496-#

Checking gas-tightness:

- After reﬁ tting the 3 service doors (tightening

torque of screws = 15 N.m), check the gas tightness using the foaming product around the service doors before starting the boiler up again (see chapter 7.6).

Page 52 / 146 00BNO9061-J

VARMAX - Installation, Use and Maintenance

7.11. Cleaning the burner and changing the seals

To facilitate access to the spool piece and then the

removable part

U0502250-#

ﬁ gure 48 - Removable upper door

gas tube, part of the upper door is removable.

spool piece

cover

ﬁ gure 49 - Removal of spool piece cover

removal / mounting tool

U0502457-#

Spanner of 24

Removing the burner tube:

- Remove the 2 electrode blocks before removing the burner tube (see chapter 7.4).

- Unscrew the attachment screws from the spool piece cover to remove it.

- Put the burner tube's removal / mounting tool in position (the tool is located under the gas line to the right of the sleeve cover).

- Position the tool in the slots of the tightening ﬂ ange and compress on it (by pressing down) .

U0503721-#

ﬁ gure 50 - Release the burner tube

Edition: 06 / 2015 Page 53 / 146

VARMAX - Installation, Use and Maintenance

Plastic valve

Lug

- Rotate the tool anticlockwise to unlock the ramp.

Unlocked

Locked

U0516842-#

ﬁ gure 51 - Positions of the fastening clamps

- Remove the clamp from the burner tube.

- Remove the burner tube.

WARNING:

Remove the plastic valve on the spool piece before removing the burner tube. Do not forget to put it back when reﬁ tting.

When removing the burner tube, be careful not to rub metal mesh against the spool piece.

Cleaning the burner tube:

gas tube

U0502459-#

ﬁ gure 52 - Cleaning the gas tube

Page 54 / 146 00BNO9061-J

- Suck out the entire surface in metal mesh using a vacuum cleaner.

VARMAX - Installation, Use and Maintenance

Keep a distance of 10 mm between the suction nozzle and the metal

WARNING:

mesh. Any rubbing of the boiler tube may cause damage. NEVER USE A METAL BRUSH.

WARNING: Replace the seal under the clamp on the burner tube.

Reﬁ tting:

- Put the burner tube into the spool piece (be careful not to rub the metal mesh on the spool piece). A directional pin enables the burner tube to be correctly positioned.

- Position the clamp (the word "UP" must be visible and the inner lug must be positioned on the rear axis of the boiler - see ﬁ gure 47)

- Position the burner tube's removal / mounting tool in the slots in the clamp.

- Compress by pushing downwards and rotate the tool in a clockwise direction to lock the tube (see ﬁ gure 47).

- Check the seal on the spool piece's cover and replace if necessary.

- Position the cover over the spool piece.

- Screw the cover onto the spool piece using the screws (tightening torque = 5 N.m).

- Reﬁ t the 2 electrode blocks.

WARNING:

Check the different seals after mounting. If using a foaming product, be careful of the ionisation electrode's electrical connection.

Edition: 06 / 2015 Page 55 / 146

VARMAX - Installation, Use and Maintenance

8. END-OF-LIFE CYCLE OF THE APPARATUS

8.1. Environmental compatibility

This appliance contains electrical and electronic elements which must not be thrown away with household waste. Local legislation must be complied with.

8.2. Dismantling, recycling and elimination of the apparatus

Regulatory disposal and managed recycling of this product can prevent damage to the environment and health risks.

a) For the disposal of the product and the component parts, the services of

an accredited waste disposal company should be used.

b) For more information on waste disposal/management, contact the Local

Authority responsible for waste management or the point of sales where the product was purchased

Page 56 / 146 00BNO9061-J

VARMAX - Installation, Use and Maintenance

9. HYDRAULIC DIAGRAMS AND SETTINGS

9.1. Selection ﬂ ow diagram

Without management

Single boiler

With management of

secondary networks

of secondary

systems

Not

communicating

Communicating via

signal 0…10V

Communicating via

LPB bus

direct circuit

1, 2 or 3

regulated

networks

without DHW

With

3-channel

valve

Accumulated

DHW

Non communicating existing

secondary system

VX101

Page 60

Secondary networks via

existing communicating

system

VX111

Page 75

Secondary networks via

existing communicating

system

VX111

Page 75

1 direct heating network

VX100

Page 60

Networks (1, 2 or 3) regula-

ted by 3-channel valve

without DHW

VX102

Page 64

Networks (1, 2 or 3) regulated by 3-channel valve with

accumulated DHW

VX110

Page 70

regulated

network + low

level direct circuit

regulated network +

consumer circuit constant

T° and throughput

semi-instanta-

neous DHW

Networks (1, 2 or 3) regulated by 3-channel valve with

instantaneous DHW

VX112

Page 64

1 network regulated by

3-channel valve, 1 direct

circuit with low level

VX113

Page 78

1 network regulated by

3-channel valve, 1 consumer

circuit with constant T° and

throughput

VX120

Page 82

Edition: 06 / 2015 Page 57 / 146

VARMAX - Installation, Use and Maintenance

Management of secon-

dary systems by

external regulation

Cascade

management by

ATLANTIC

Cascade manage-

ment by external

regulation

direct circuit

regulated network +

consumer circuit constant

T° and throughput

Not

communicating

Communicating

via signal

0…10V

Communicating via

LPB bus

Not

communicating

No communication with the

secondary system

VX201

Page 86

Secondary networks regula-

ted by communicating

external regulation

VX211

Page 100

Secondary networks regula-

ted by communicating

external regulation

VX211

Page 100

No communication with the

secondary system

Contact the before-sales service

1 direct network

VX200

1 network regulated by 3-channel

valve and 1 circuit with constant

temperature and throughput

VX220

Page 86

Page <?>

arrangement

Boiler cascade

Management of

secondary systems

by A TLANTIC

Mixed

1 regulated network

with accumulated DHW

3 or 4 regulated

networks

...

3 or 4 regulated networks with

semi-instantaneous DHW

...

1 network regulated by V3V

with accumulated DHW

VX210

Page 92

3 or 4 networks regulated by

3-channel valve, without DHW

VX202

Page 106

3 or 4 networks regulated by

3-channel valve, with semi-

instantaneous DHW

VX212

Page 106

with TRAD

Contact the before-sales service

with LMU

Contact the before-sales service

Page 58 / 146 00BNO9061-J

VARMAX - Installation, Use and Maintenance

9.2. Symbols used in the diagrams

Symbol Function Symbol Function

Open isolating valve Balancing valve

Motorised 2 channel valve Motorised 3 channel valve

Filter Non-return valve

Safety unit Pump

Sediment well Drain valve

External sensor Temperature sensor

9.3. List of diagrams

Operation at constant temperature with variable ﬂ ow and immediate

WARNING:

SINGLE BOILER .........................................................................................................................60

1 direct heating network or existing non-communicative secondary system ...................................................... 60

VX100, VX101

3 regulated networks with or without DHW production ....................................................................................... 64

VX102, VX112

1 network regulated by a 3-channel valve, and DHW production ...................................................................... 70

VX110

Secondary networks with existing regulation communicating by LPB bus or 0...10V ........................................ 75

VX111

1 network regulated by a 3-channel valve, 1 direct circuit with 60°C low level ..................................................78

VX113

1 network regulated by a three-channel valve, 1 circulation circuit with constant temperature and throughput 82

VX120

DHW production directly on heat plate exchanger without buffer tank forbidden.

BOILERS IN A CASCADE CONFIGURATION ...........................................................................86

1 direct network, no communication with the secondary network ...................................................................... 86

VX200, VX201

1 network regulated by a three-channel valve, DHW production or 1 direct circuit with constant temperature

and throughput ................................................................................................................................................... 92

VX210, VX220

Secondary networks regulated by external regulated communicating by LPB bus or 0...10V ......................... 100

VX211

3 or 4 networks regulated by a three-channel valve with or without DHW production ..................................... 106

VX202, VX212

Edition: 06 / 2015 Page 59 / 146

VARMAX - Installation, Use and Maintenance

SINGLE BOILER

1 direct heating network or existing non-communicative

secondary system

A. MAIN AND ALTERNATIVE HYDRAULIC DIAGRAMS

B3000

Diagrams

VX100 VX101

page 1 / 4

B3000

ﬁ gure 53 - Diagram VX100

NON-COMMUNICATING

REGULATEUR

REGULATOR

NON COMMUNICANT

SAFETY BY-PASS IF

BY-PASS DE SECURITE

HEATED FLOOR

SI PLANCHER CHAUFFANT

ﬁ gure 54 - Diagram VX101 (alternative)

Page 60 / 146 00BNO9061-J

VARMAX - Installation, Use and Maintenance

Diagrams: VX100 / VX101

page 2 / 4

B. NECESSARY ADJUSTMENT ACCESSORY

Quantity

External sensor kit 1 QAC 34 059260

Appliance

reference

Order No.

C. CUSTOMER ELECTRICAL CONNECTION

Mains supply 230

VAC 50 Hz

Diagram VX100:

Circulation pump on

direct circuit Q2

L NY1 NY2L NL NL N

QX2 QX3 QX1 AUX2 AUX1

}

Alarm relay

}

D. SPECIFIC START-UP PROCEDURE

Fit the accessories and make their electrical connections.



Start up the boiler alone.



Make the following settings:



BX2 Gnd BX3 Gnd

Gnd

Line No. Value

External sensor B9

}

• Time and date menu

Set the time

Set the date

Set the year

• Configuration menu

Start up the heating circuit 1

Deﬁ ne the pump outlet Q2 (diagram VX100)

Edition: 06 / 2015 Page 61 / 146

Time / minute (1) HH.MM

Day / month (2) DD.MM

Year (3) YYYY

Heating circuit 1 (5710) On

QX2 relay outlet (5891) Pump CC1 Q2

VARMAX - Installation, Use and Maintenance

Diagrams: VX100 / VX101

• Heating circuit 1 menu

Set the comfort setting

Set the curve slope

• Switch the heating mode to permanent comfort

Comfort setting temperature (710) - - -

Heating curve slope (720) - - -

E. ELECTRICAL AND HYDRAULIC VALIDATION

• Input/output test menu

Check the outputs

Alarm relay

Heating circuit No. 1 pump (diagram VX100)

Reset outputs

page 3 / 4

Line No. Value

Relay test (7700) Relay output QX1

Relay test (7700) Relay output QX2

Relay test (7700) No test

Check sensor values

External sensor B9

• Configuration menu

Check the hydraulic diagram

F. OPTIMISATION OF SETTINGS

• Heating circuit 1 menu

Set the reduced setting

• CC1 time programme menu

Preselection

External T° B9 (7730) in °C

Generator 1 check (6212) 14

Generator 2 check (6213) 0

Information on DHW (6215) 0

Information on heating circuits 3, 2 and 1 (6217) 1 (for VX101)

2 (for VX100)

Reduced temperature setting (712) - - -

Preselection (500) - - -

Adjust the time programme

• Circuit CC1 holiday menu

Preselection

Adjust the time programme

• Switch the heating mode to automatic

Page 62 / 146 00BNO9061-J

On / Off phases (501...506) - - -

Preselection (641) - - -

On / Off phases (642-643) - - -

AUTO

VARMAX - Installation, Use and Maintenance

Diagrams: VX100 / VX101

page 4 / 4

Maintenance optimisation:

It is possible to generate a maintenance message without harming the boiler. This maintenance message may appear when the 3 following meters have elapsed:

• Time since last maintenance (or commissioning): set parameter 7044 to 12 months

• Operating hours of the burner (parameter 7040)

• Number of start-ups (parameter 7042)

The last 2 parameters depend on the boiler room's hydraulic installation. It is recommended to use at least parameter 7044 for yearly maintenance.

Edition: 06 / 2015 Page 63 / 146

VARMAX - Installation, Use and Maintenance

SINGLE BOILER

Diagrams

VX102

3 regulated networks with or without DHW production

A. MAIN AND ALTERNATIVE HYDRAULIC DIAGRAMS

B12

B3000

Y1/Y2

Y5/Y6

VX112

page 1 / 6

B14

Q20

Y11/ Y12

B3000

ﬁ gure 55 - Diagram VX102

Y1/Y2

Y5/ Y6

B12 B14

Y11/ Y12

bouclage

bouclage ECS

ECS

Q20

ECS

Cold

Entrée

water inlet

eau froide

ﬁ gure 56 - Diagram VX112 (alternative)

Page 64 / 146 00BNO9061-J

VARMAX - Installation, Use and Maintenance

Diagrams: VX102 / VX112

page 2 / 6

B. NECESSARY ADJUSTMENT ACCESSORIES

Quantity

Extension module kit (delivered with a QAD 36 network sensor)

External sensor kit 1 QAC 34 059260 Ambient sensor kit (diagram VX102) 3 QAA 75 040954 DHW sensor kit (diagram VX112) 1 QAZ 36 059261

3 AVS 75 059751

Appliance

reference

Order No.

C. CUSTOMER ELECTRICAL CONNECTION

Alarm

relay

}

Mains supply 230

VAC 50 Hz

L NY1 NY2L NL NL N

QX2 QX3 QX1 AUX2 AUX1

G+ CL- CL+ G+ CL- CL+

Diagram VX102:

Ambient sensor QAA 75 for

}

heating circuit No. 3

Diagram VX102:

Ambient sensor QAA 75 for

}

heating circuit No. 2

Diagram VX102:

Ambient sensor QAA 75 for

}

heating circuit No. 1

BX2 Gnd BX3 Gnd

Gnd

Diagram VX112:

}

DHW sensor B3

External sensor B9

}

Diagram VX112 only

Edition: 06 / 2015 Page 65 / 146

VARMAX - Installation, Use and Maintenance

Mixing valve for heating

circuit No. 1 Y1/Y2

Circulator for heating circuit

No. 1 Q2

Mixing valve for heating

circuit No. 2 Y5/Y6

Circulator for heating circuit

No. 2 Q6

Diagrams: VX102 / VX112

QX21

}

QX22

}

QX23

QX21

}

QX22

}

QX23

AVS75

BX21

Gnd

BX22

Gnd

BX21

Gnd

BX22

Gnd

page 3 / 6

Module 1

}

Flow sensor for regulated circuit

}

Module 2

}

Flow sensor for regulated circuit

}

B12

QX21

Mixing valve for heating

circuit No. 3 Y11/Y12

Circulator for heating circuit

No. 3 Q20

}

QX22

}

QX23

AVS75

D. SPECIFIC START-UP PROCEDURE

Fit the accessories and make their electrical connections.



WARNING:

Start up the boiler alone.



Make the following settings:



Ensure the switches on the extension modules AVS75 are properly conﬁ gured.

BX21

Gnd

BX22

Gnd

Module 3

}

Flow sensor for regulated circuit

}

B14

Line No. Value

• Time and date menu

Set the time

Set the date

Set the year

• Configuration menu

Start up the heating circuit 1

Start up the heating circuit 2

Start up the heating circuit 3

Page 66 / 146 00BNO9061-J

Heating circuit 1 (5710) On

Heating circuit 2 (5715) On

Heating circuit 3 (5721) On

Time / minute (1) HH.MM

Day / month (2) DD.MM

Year (3) YYYY

VARMAX - Installation, Use and Maintenance

Diagrams: VX102 / VX112

Diagram VX112 only:

Deﬁ ne a low level

Install a shunt on H1 OR reverse

the direction of contact

For the DHW to be effective, it is necessary to deﬁ ne a trigger, even if it is not connected.

Conﬁ gure the extension modules

page 4 / 6

Line No. Value

Input function H1 (5950) Circulation circuit

demand 1

Type of contact (5951) Rest contact

Output via relay QX2 (5891) Pump/valve ECS

Function of extension module 1 (6020) Heating circuit 1

Function of extension module 2 (6021) Heating circuit 2

Function of extension module 3 (6022) Heating circuit 3

• Heating circuit 1 / 2 / 3 menu

For each circuit

Set the comfort setting

Set the curve slope

• Switch the heating mode to permanent comfort

Diagram VX112 only:

• Circulation circuit 1 menu

Set the starting value to use in the event of a demand from the circulation circuit

• Domestic hot water menu

Set the comfort setting

Temperature of comfort setting (710/1010/1310) - - -

Slope of the heating curve(720/1020/1320) - - -

Starting value in case of circuit demand

60°C (depends on

(1859)

Comfort setpoint (1610) 55 °C

Rubis setting)

Set the DHW release mode

• Activate DHW mode

Edition: 06 / 2015 Page 67 / 146

DHW release (1620) 24/7

VARMAX - Installation, Use and Maintenance

Diagrams: VX102 / VX112

E. ELECTRICAL AND HYDRAULIC VALIDATION

• Input/output test menu

Check the outputs

Alarm relay

All relays of extension modules

Reset outputs

Check sensor values

External sensor B9

DHW sensor B3

Flow sensor B1

Flow sensor B12

Flow sensor B14

Temperature sensor BX21 module 1 (7830) in °C

Temperature sensor BX21 module 2 (7832) in °C

Temperature sensor BX21 module 3 (7834) in °C

DHW temperature B3/B38 (7750) in °C

page 5 / 6

Line No. Value

Relay test (7700) Relay output QX1

Relay test (7700) Relay output QX

Relay test (7700) No test

External T° B9 (7730) in °C

Diagram VX112 only:

Check the condition of contact H1

• Configuration menu

Check the hydraulic diagram

F. OPTIMISATION OF SETTINGS

Optimisation of the heating circuits:

• Heating circuit 1 / 2 / 3 menu

Set the reduced setting

Condition of contact H1 (7841) Closed if the shunt

is in place

Generator 1 check (6212) 14

Generator 2 check (6213) 0

Information on DHW (6215) 0

Information on heating circuits 3, 2 and 1 (6217) 30303

Line No. Value

Reduced temperature setting (712/1012/1312) - - -

(diagram VX102)

(diagram VX112)

• Time programme CC1 / CC2 / CC3 menu

Preselection

Adjust the time programme

Page 68 / 146 00BNO9061-J

Preselection (500/520/540) - - -

On / Off phases (501...506)

(521...526) (541...546)

- - -

VARMAX - Installation, Use and Maintenance

Diagrams: VX102 / VX112

• Holiday circuit CC1 / CC2 / CC3 menu

Preselection

Adjust the time programme

• Switch the heating mode to automatic

Optimisation of DHW:

• DHW storage tank menu

Adjust the boost

Line No. Value

Preselection (641/651/661) - - -

On / Off phases (642-643)

(652-653) (662-663)

Line No. Value

Starting value of boost temperature (5020) 16 °C

- - -

AUTO

page 6 / 6

Maintenance optimisation:

It is possible to generate a maintenance message without harming the boiler. This maintenance message may appear when the 3 following meters have elapsed:

• Time since last maintenance (or commissioning): set parameter 7044 to 12 months

• Operating hours of the burner (parameter 7040)

• Number of start-ups (parameter 7042)

The last 2 parameters depend on the boiler room's hydraulic installation. It is recommended to use at least parameter 7044 for yearly maintenance.

G. SETTING AMBIENT SENSORS

Connect each sensor to a heating circuit:

Line No. Value

• User interface menu of each ambient sensor

Conﬁ gure the ambient sensor with a heating circuit

Use (40) Ambient appliance

1 or 2 or 3

Each ambient sensor allows its heating circuit to be conﬁ gured. Ambient sensors 1, 2 and 3 respectively set parameters 712 (heating circuit 1), 1012 (heating circuit 2) and 1312 (heating circuit 3).

Edition: 06 / 2015 Page 69 / 146

VARMAX - Installation, Use and Maintenance

SINGLE BOILER

1 network regulated by a 3-channel valve, and DHW production

A. HYDRAULIC DIAGRAM

Y1/Y2

Diagram

VX110

page 1 / 5

B3000

ﬁ gure 57 - VX110 diagram

B. NECESSARY ADJUSTMENT ACCESSORIES

Quantity

Extension module kit (delivered with a QAD 36 network sensor)

1 AVS 75 059751

DHW sensor kit 1 QAZ 36 059261 External sensor kit 1 QAC 34 059260

Appliance

reference

Order No.

Page 70 / 146 00BNO9061-J

VARMAX - Installation, Use and Maintenance

Diagram VX110

C. CUSTOMER ELECTRICAL CONNECTION

DHW

circulator

Alarm

relay

}

Mains supply 230

VAC 50 Hz

L NY1 NY2L NL NL N

QX2 QX3 QX1 AUX2 AUX1

}

BX2 Gnd BX3 Gnd

Gnd

page 2 / 5

DHW sensor B3

}

External sensor B9

}

QX21

}

QX22

}

QX23

AVS75

Mixing valve for heating

circuit No. 1 Y1/Y2

Circulator for heating circuit

No. 1 Q2

D. SPECIFIC START-UP PROCEDURE

BX21

Gnd

BX22

Gnd

Module 1

}

Flow sensor for regulated circuit

}

Fit the accessories and make their electrical connections.



WARNING:

Start up the boiler alone.



Make the following settings.



Edition: 06 / 2015 Page 71 / 146

Ensure the switches on the extension modules AVS75 are properly conﬁ gured.

VARMAX - Installation, Use and Maintenance

• Time and date menu

Set the time

Set the date

Set the year

• Configuration menu

Start up the heating circuit 1

Conﬁ gure the DHW pump

Conﬁ gure extension module 1

• Heating circuit 1 menu

Set the comfort setting

Diagram VX110

Function of extension module 1 (6020) Heating circuit 1

page 3 / 5

Line No. Value

Time / minute (1) HH.MM

Day / month (2) DD.MM

Year (3) YYYY

Heating circuit 1 (5710) On

Output via relay QX2 (5891) Pump/valve ECS

Comfort setting temperature (710) - - -

Set the curve slope

• Switch the heating mode to permanent comfort

• Domestic hot water menu

Set the comfort setting

• Activate DHW mode

Heating curve slope (720) - - -

E. ELECTRICAL AND HYDRAULIC VALIDATION

• Input/output test menu

Check the outputs

Alarm relay

Comfort setpoint (1610) - - -

Line No. Value

Relay test (7700) Relay output QX1

DHW pump Q3

Opening V3V CC

Closing V3V CC

CC pump

Page 72 / 146 00BNO9061-J

Relay test (7700) Relay output QX2

Relay test (7700) Relay output QX21

module 1

Relay test (7700) Relay output QX22

module 1

Relay test (7700) Relay output QX23

module 1

VARMAX - Installation, Use and Maintenance

Diagram VX110

Line No. Value

Reset outputs...module... Relay test (7700) No test

Check sensor values

External sensor B9

DHW sensor B3

Flow sensor B1

• Configuration menu

Check the hydraulic diagram

DHW temperature B3/B38 (7750) in °C

Temperature sensor BX21 module 1 (7830) in °C

Information on heating circuits 3, 2 and 1 (6217) 3

External T° B9 (7730) in °C

Generator 1 check (6212) 14

Generator 2 check (6213) 0

Information on DHW (6215) 4

page 4 / 5

F. OPTIMISATION OF SETTINGS

Optimisation of heating circuit:

• Heating circuit 1 menu

Set the reduced setting

• CC1 time programme menu

Preselection

Adjust the time programme

• Circuit CC1 holiday menu

Preselection

Adjust the time programme

• Switch the heating mode to automatic

Line No. Value

Reduced temperature setting (712) - - -

Preselection (500) - - -

On / Off phases (501...506) - - -

Preselection (641) - - -

On / Off phases (642-643) - - -

AUTO

Optimisation of DHW:

Line No. Value

• Domestic hot water menu

Set the reduced setting

Set the DHW release mode

Edition: 06 / 2015 Page 73 / 146

Reduced setting (1612) - - -

DHW release (1620) Time programme 4/

DHW

VARMAX - Installation, Use and Maintenance

Diagram VX110

• Time programme 4 / ECS menu

Preselection

Adjust the time programme

• DHW storage tank menu

Adjust the boost

• Domestic hot water menu

Conﬁ gure an anti-legionella function

Line No. Value

Preselection (560) - - -

On / Off phases (561...566) - - -

Starting value of boost temperature (5020) - - -

Anti-legionella function (1640) - - -

Periodic anti-legionella function

(1641)

Day week anti-legionella function (1642) - - -

Anti-legionella temperature setting (1645) - - -

- - -

page 5 / 5

Duration of anti-legionella function (1646) - - -

Maintenance optimisation:

It is possible to generate a maintenance message without harming the boiler. This maintenance message may appear when the 3 following meters have elapsed:

• Time since last maintenance (or commissioning): set parameter 7044 to 12 months

• Operating hours of the burner (parameter 7040)

• Number of start-ups (parameter 7042)

The last 2 parameters depend on the boiler room's hydraulic installation. It is recommended to use at least parameter 7044 for yearly maintenance.

Page 74 / 146 00BNO9061-J

VARMAX - Installation, Use and Maintenance

Secondary networks with existing regulation

communicating by LPB bus or 0...10V

A. HYDRAULIC DIAGRAM

COMMUNICATING REGULATOR

REGULATEUR COMMUNICANT

SIGNAL 0/10 V VERS LMS

ou bus LPB vers OCI345

0/10 V SIGNAL TO NAVISTEM B3000

or LPB bus to OCI345

SINGLE BOILER

Diagram

VX111

page 1 / 3

B3000

ﬁ gure 58 - Diagram VX111

B. NECESSARY ADJUSTMENT ACCESSOR Y

Quantity

Communication kit for LPB bus 1 OCI 345 059572

Appliance

reference

Order No.

Edition: 06 / 2015 Page 75 / 146

VARMAX - Installation, Use and Maintenance

Diagram VX111

C. CUSTOMER ELECTRICAL CONNECTION

Alarm

relay

Mains supply 230

VAC 50 Hz

LPB bus

L NY1 NY2L NL NL N

QX2 QX3 QX1 AUX2 AUX1

}

DB MB

}

BX2 Gnd BX3 Gnd

Gnd

page 2 / 3

Analogue input

}

0...10V

D. SPECIFIC START-UP PROCEDURE

Fit the accessories and make their electrical connections.



Start up the boiler alone.



Make the following settings:



• Time and date menu

Set the time Set the date Set the year

For a demand via input 0...10V

• Configuration menu

Conﬁ gure input H1

Gnd

Line No. Value

Time / minute (1) HH.MM

Day / month (2) DD.MM

Year (3) YYYY

Input function H1 (5950) Demand from

circulation circuit 1 10V

Voltage value 1 H1 (5953) 0.0

Function value H1 (5954) 0

Voltage value 2 H1 (5955) 10.0

Page 76 / 146 00BNO9061-J

VARMAX - Installation, Use and Maintenance

Diagram VX111

Function value 2 H1 (5956) 1000 (for 10 V = 100

For a demand via LPB (LPB network menu)

• LPB network menu

Check that the boiler has been deﬁ ned as the master generator

Appliance address (6600) 1

Bus supply function (6604) Automatic

E. ELECTRICAL AND HYDRAULIC VALIDATION

For a demand via input 0...10V

• Input/output test menu

Voltage in H1

page 3 / 3

Line No. Value

°C equivalence)

Segment address (6601) 0

Clock function (6640) Slave with

adjustment

Voltage signal H1 (7840) To validate with

the voltage sent by the boiler room machine

For a demand via LPB

If the boiler room regulator is conﬁ gured as the master clock, the boiler command table must recover the date and time.

In both cases

• Configuration menu

Check the hydraulic diagram

Information on heating circuits 3, 2 and 1 (6217) 0

Generator 1 check (6212) 14

Generator 2 check (6213) 0

Information on DHW (6215) 0

F. OPTIMISATION OF SETTINGS

Maintenance optimisation:

It is possible to generate a maintenance message without harming the boiler. This maintenance message may appear when the 3 following meters have elapsed:

• Time since last maintenance (or commissioning): set parameter 7044 to 12 months

• Operating hours of the burner (parameter 7040)

• Number of start-ups (parameter 7042)

The last 2 parameters depend on the boiler room's hydraulic installation. It is recommended to use at least parameter 7044 for yearly maintenance.

Edition: 06 / 2015 Page 77 / 146

VARMAX - Installation, Use and Maintenance

SINGLE BOILER

1 network regulated by a 3-channel valve, 1 direct circuit

with 60°C low level

A. HYDRAULIC DIAGRAM

DIRECT CIRCUIT

Y1/Y2

CIRCUIT DIRECT

WITH LOW LEVEL

AVEC TALON BAS

FOR FLOW AT 60°C

DEPART A 60 °C

Diagram

VX113

page 1 / 4

B3000

ﬁ gure 59 - Diagram VX113

B. NECESSARY ADJUSTMENT ACCESSORIES

Quantity

Extension module kit (delivered with a QAD 36 network sensor)

1 AVS 75 059751

External sensor kit 1 QAC 34 059260

Appliance

reference

Order No.

Page 78 / 146 00BNO9061-J

VARMAX - Installation, Use and Maintenance

Diagram VX113

C. CUSTOMER ELECTRICAL CONNECTION

Direct

circulation

pump Q6

Alarm

relay

}

Mains supply 230

VAC 50 Hz

L NY1 NY2L NL NL N

QX2 QX3 QX1 AUX2 AUX1

}

BX2 Gnd BX3 Gnd

Gnd

page 2 / 4

External sensor B9

}

QX21

}

QX22

}

QX23

AVS75

Mixing valve for heating

circuit No. 1 Y1/Y2

Circulator for heating circuit

No. 1 Q2

D. SPECIFIC START-UP PROCEDURE

BX21

Gnd

BX22

Gnd

Module 1

}

Flow sensor for regulated circuit

}

Fit the accessories and make their electrical connections.



WARNING:

Start up the boiler alone.



Make the following settings.



Edition: 06 / 2015 Page 79 / 146

Ensure the switches on extension module AVS75 are correctly conﬁ gured.

VARMAX - Installation, Use and Maintenance

• Time and date menu

Set the time

Set the date

Set the year

• Configuration menu

Start up the heating circuit 1

Start up the heating circuit 2

Conﬁ gure the pump CC2

Conﬁ gure extension module 1

• Heating circuit 1 menu

Diagram VX113

page 3 / 4

Line No. Value

Time / minute (1) HH.MM

Day / month (2) DD.MM

Year (3) YYYY

Heating circuit 1 (5710) On

Heating circuit 2 (5715) On

Output via relay QX2 (5891) Pump CC2 Q6

Function of extension module 1

(6020)

Heating circuit 1

Set the comfort setting

Set the curve slope

• Heating circuit 2 menu

Set the comfort setting

Set the curve slope

Set the minimum starting temperature

• Switch the heating mode to permanent comfort

Comfort setting temperature (710) - - -

Heating curve slope (720) - - -

Comfort setting temperature (1010) - - -

Heating curve slope (1020) - - -

Minimum starting T° value (1040) 60°C (adjust

E. ELECTRICAL AND HYDRAULIC VALIDATION

• Input/output test menu

Check the outputs

depending on low level)

Line No. Value

Alarm relay

CC2 pump

Opening V3V CC

Closing V3V CC

Page 80 / 146 00BNO9061-J

Relay test (7700) Relay output QX1

Relay test (7700) Relay output QX2

Relay test (7700) Relay output QX21

module 1

Relay test (7700) Relay output QX22

module 1

VARMAX - Installation, Use and Maintenance

Diagram VX113

Line No. Value

CC pump Relay test (7700) Relay output QX23

Reset outputs

Check sensor values

External sensor B9

Flow sensor B1

• Configuration menu

Check the hydraulic diagram

Temperature sensor BX21 module 1 (7830) in °C

Generator 1 check (6212) 14

Generator 2 check (6213) 0

Information on DHW (6215) 0

Information on heating circuits 3, 2 and 1 (6217) 203

Relay test (7700) No test

External T° B9 (7730) in °C

page 4 / 4

module 1

F. OPTIMISATION OF SETTINGS

• Heating circuit 1 / 2 menu

Set the reduced setting

• Time programme CC1 / CC2 menu

Preselection

Adjust the time programme

• Holiday circuit CC1 / CC2 menu

Preselection

Adjust the time programme

• Switch the heating mode to automatic

Maintenance optimisation:

Line No. Value

Temperature of reduced setting (712/1012) - - -

Preselection (500/520) - - -

On / Off phases (501...506)

(521...526)

Preselection (641/651) - - -

On / Off phases (642-643)

(652-653)

- - -

AUTO

It is possible to generate a maintenance message without harming the boiler. This maintenance message may appear when the 3 following meters have elapsed:

• Time since last maintenance (or commissioning): set parameter 7044 to 12 months

• Operating hours of the burner (parameter 7040)

• Number of start-ups (parameter 7042)

The last 2 parameters depend on the boiler room's hydraulic installation. It is recommended to use at least parameter 7044 for yearly maintenance.

Edition: 06 / 2015 Page 81 / 146

VARMAX - Installation, Use and Maintenance

SINGLE BOILER

1 network regulated by a three-channel valve, 1 circulation

circuit with constant temperature and throughput

A. HYDRAULIC DIAGRAM

DIRECT CIRCUIT WITH

CIRCUIT DIRECT AVEC

CONSTANT TEMPERATURE

TEMPERATURE ET DEBIT

AND THROUGHPUT

Y1/Y2

CONSTANT

Q15

Diagram

VX120

page 1 / 4

B3000

ﬁ gure 60 - Diagram VX120

B. NECESSARY ADJUSTMENT ACCESSORIES

Quantity

Extension module kit (delivered with a QAD 36 network sensor)

1 AVS 75 059751

External sensor kit 1 QAC 34 059260

Appliance

reference

Order No.

Page 82 / 146 00BNO9061-J

VARMAX - Installation, Use and Maintenance

Diagram VX120

C. CUSTOMER ELECTRICAL CONNECTION

Direct

circulation

pump Q15

Alarm

relay

}

Mains supply 230

VAC 50 Hz

L NY1 NY2L NL NL N

QX2 QX3 QX1 AUX2 AUX1

}

BX2 Gnd BX3 Gnd

Gnd

page 2 / 4

External sensor B9

}

QX21

}

QX22

}

QX23

AVS75

Mixing valve for heating

circuit No. 1 Y1/Y2

Circulator for heating circuit

No. 1 Q2

D. SPECIFIC START-UP PROCEDURE

Fit the accessories and make their electrical connections.



BX21

Gnd

BX22

Gnd

Module 1

}

Flow sensor for regulated circuit

}

Shunt to install

WARNING:

Start up the boiler alone.



Make the following settings.



Edition: 06 / 2015 Page 83 / 146

Ensure the switches on extension module AVS75 are correctly conﬁ gured.

VARMAX - Installation, Use and Maintenance

• Time and date menu

Set the time

Set the date

Set the year

• Configuration menu

Start up the heating circuit 1

Conﬁ gure pump Q15

Conﬁ gure input H1

Conﬁ gure extension module 1

Diagram VX120

Function of extension module 1 (6020) Heating circuit 1

page 3 / 4

Line No. Value

Time / minute (1) HH.MM

Day / month (2) DD.MM

Year (3) YYYY

Heating circuit 1 (5710) On

Output via relay QX2 (5891) Pump for circulation

circuit 1 Q15

Input function H1 (5891 Demand for

circulation circuit 1

• Heating circuit 1 menu

Set the comfort setting

Set the curve slope

• Circulation circuit 1 menu

Set the starting value to use in the event of demand from the circulation circuit

• Switch the heating mode to permanent comfort

Comfort setting temperature (710) - - -

Heating curve slope (720) - - -

Value of starting temperature for

circulation circuit demand (1859)

E. ELECTRICAL AND HYDRAULIC VALIDATION

• Input/output test menu

Check the outputs

Alarm relay

- - -

Line No. Value

Relay test (7700) Relay output QX1

Constant circuit pump

Opening V3V CC

Closing V3V CC

CC pump

Reset outputs

Page 84 / 146 00BNO9061-J

Relay test (7700) Relay output QX2

Relay test (7700) Relay output QX21

module 1

Relay test (7700) Relay output QX22

module 1

Relay test (7700) Relay output QX23

module 1

Relay test (7700) No test

VARMAX - Installation, Use and Maintenance

Diagram VX120

Check sensor values

External sensor B9

Flow sensor B1

• Configuration menu

Check the hydraulic diagram

F. OPTIMISATION OF SETTINGS

page 4 / 4

Line No. Value

External T° B9 (7730) in °C

Temperature sensor BX21 module 1 (7830) in °C

Generator 1 check (6212) 14

Generator 2 check (6213) 0

Information on DHW (6215) 0

Information on heating circuits 3, 2 and 1 (6217) 3

Line No. Value

• Heating circuit 1 menu

Set the reduced setting

• CC1 time programme menu

Preselection

Adjust the time programme

• Circuit CC1 holiday menu

Preselection

Adjust the time programme

• Switch the heating mode to automatic

Maintenance optimisation:

Reduced temperature setting (712) - - -

Preselection (500) - - -

On / Off phases (501...506) - - -

Preselection (641) - - -

On / Off phases (642-643) - - -

AUTO

It is possible to generate a maintenance message without harming the boiler. This maintenance message may appear when the 3 following meters have elapsed:

• Time since last maintenance (or commissioning): set parameter 7044 to 12 months

• Operating hours of the burner (parameter 7040)

• Number of start-ups (parameter 7042)

The last 2 parameters depend on the boiler room's hydraulic installation. It is recommended to use at least parameter 7044 for yearly maintenance.

Edition: 06 / 2015 Page 85 / 146

VARMAX - Installation, Use and Maintenance

B3000

REGULATEUR NON COMMUNICANT

BOILERS IN A CASCADE CONFIGURATION

1 direct network, no communication with the secondary

network

A. MAIN AND ALTERNATIVE HYDRAULIC DIAGRAMS

Diagram

VX200 VX201

page 1 / 6

B10

B3000

ﬁ gure 61 - Diagram VX200

NON-COMMUNICATING REGULATOR

Q1.2Q1.1

B10

Q1.2

Q1.1

ﬁ gure 62 - Diagram VX201 (alternative)

Page 86 / 146 00BNO9061-J

VARMAX - Installation, Use and Maintenance

Diagrams: VX200 / VX201

page 2 / 6

B. NECESSARY ADJUSTMENT ACCESSORIES

Quantity

Communication kit 2 OCI 345 059572

Network sensor kit 1 QAx 36

External sensor kit 1 QAC 34 059260

Appliance

reference

Order No.

059261 (QAZ 36)

059592 (QAD 36)

C. CUSTOMER ELECTRICAL CONNECTION

Boiler No. 1:

INFORMATION:

If the insulating valve is not ﬁ tted with an automatic reset, reconnect the Q1.1 insulating valve closing contact on Y2.

Mains supply 230

VAC 50 Hz

LPB bus

}

DB MB

Diagram VX200:

Circulation pump on

direct circuit Q2

}

L NY1 NY2L NL NL N

QX2 QX3 QX1 AUX2 AUX1

Insulating

valve Q1.1

}

Alarm

relay

}

BX2 Gnd BX3 Gnd

Gnd

Flow sensor in

}

cascade B10

External sensor B9

}

Gnd

Boiler No. 2:

INFORMATION:

Edition: 06 / 2015 Page 87 / 146

If the insulating valve is not ﬁ tted with an automatic reset, reconnect the Q1.2 insulating valve closing contact on Y2.

VARMAX - Installation, Use and Maintenance

Mains supply 230

VAC 50 Hz

LPB bus

}

DB MB

Diagrams: VX200 / VX201

Insulating

valve Q1.2

Alarm

relay

}

L NY1 NY2L NL NL N

QX2 QX3 QX1 AUX2 AUX1

page 3 / 6

}

D. SPECIFIC START-UP PROCEDURE

Fit the accessories and make their electrical connections.



Start up the boiler alone.



Make the following settings:



On boiler No. 1: master

• Set the time and date: Time and date menu

Set the time

Set the date

Set the year

• Configuration menu

Start up the heating circuit 1

Diagram VX200 only:

Conﬁ gure the pump Q2

Line No. Value

Time / minute (1) HH.MM

Day / month (2) DD.MM

Year (3) YYYY

Heating circuit 1 (5710) On

QX2 relay outlet (5891) Pump CC1 Q2

All diagrams:

Conﬁ gure ﬂ ow sensor in cascade B10 Sensor input BX2 (5931) Common ﬂ ow

sensor B10

Page 88 / 146 00BNO9061-J

VARMAX - Installation, Use and Maintenance

Diagrams: VX200 / VX201

• Conﬁ gure as master in the cascade: LPB network menu

Appliance number

Segment number

Set the bus power supply.

Set the clock mode

• Set the heating circuit: Heating circuit 1 menu

Set the comfort setting

Set the curve slope

• Switch the heating mode to permanent comfort

Comfort setting temperature (710) - - -

Appliance address (6600) 1

Segment address (6601) 0

Bus supply function (6604) Automatic

Heating curve slope (720) - - -

page 4 / 6

Line No. Value

Clock function (6640) Master

On boiler(s) No. 2 (and later): slave

Line No. Value

• Conﬁ gure as slave in the cascade: LPB network menu

Appliance number

Segment number

Set the bus power supply.

Set the clock mode

• Connect the bus between the boilers (

• Turn off the slave boiler(s) and then turn on again. If communication is successful, the clock is correctly updated.

respect the polarity).

Appliance address (6600) 2 (or later for the

other slaves)

Segment address (6601) 0

Bus supply function (6604) Automatic

Clock function (6640) Slave without

adjustment

E. ELECTRICAL AND HYDRAULIC VALIDATION

On boiler No. 1: master

Line No. Value

• Cascade diagnostic menu

Check that all boilers are present in the cascade

Status of generator 1 (8100) Released / not

released

Status of generator 2 (8101) Released / not

released

Edition: 06 / 2015 Page 89 / 146

VARMAX - Installation, Use and Maintenance

Diagrams: VX200 / VX201

• Input/output test menu

Check the outputs

Alarm relay

Pump Q2 (diagram VX200)

Insulating valve Q1.1

Reset outputs

Check sensor values

External sensor B9

Flow sensor in cascade B10

page 5 / 6

Line No. Value

...............................

Relay test (7700) Relay output QX1

Relay test (7700) Relay output QX2

Relay test (7700) Relay output QX3

Relay test (7700) No test

External T° B9 (7730) in °C

Sensor T° BX2 (7821) in °C

• Configuration menu

Check the hydraulic diagram

Information on heating circuits 3, 2 and 1 (6217) 1

On boiler(s) No. 2 (and later): slave

• Input/output test menu

Check the outputs

Alarm relay

Insulating valve Q1.2

Reset outputs

• Configuration menu

Generator 1 check (6212) 14

Generator 2 check (6213) 0

Information on DHW (6215) 0

Line No. Value

Relay test (7700) Relay output QX1

Relay test (7700) Relay output QX3

Relay test (7700) No test

Check the hydraulic diagram

Information on heating circuits 3, 2 and 1 (6217) 0

Page 90 / 146 00BNO9061-J

Generator 1 check (6212) 14

Generator 2 check (6213) 0

Information on DHW (6215) 0

VARMAX - Installation, Use and Maintenance

Diagrams: VX200 / VX201

F. OPTIMISATION OF SETTINGS

On boiler No. 1: master

Optimisation of heating circuit:

• Heating circuit 1 menu

Set the reduced setting

• CC1 time programme menu

Preselection

Adjust the time programme

• Circuit CC1 holiday menu

Preselection

page 6 / 6

Line No. Value

Reduced temperature setting (712) - - -

Preselection (500) - - -

On / Off phases (501...506) - - -

Preselection (641) - - -

Adjust the time programme

• Switch the heating mode to automatic

On / Off phases (642-643) - - -

AUTO

Optimisation of the cascade:

The cascade may be optimised as required with the parameters of the Cascade menu. Refer to the LMS boiler command table instructions for more details.

Maintenance optimisation:

It is possible to generate a maintenance message without harming the boiler. This maintenance message may appear when the 3 following meters have elapsed:

• Time since last maintenance (or commissioning): set parameter 7044 to 12 months

• Operating hours of the burner (parameter 7040)

• Number of start-ups (parameter 7042)

The last 2 parameters depend on the boiler room's hydraulic installation. It is recommended to use at least parameter 7044 for yearly maintenance.

Edition: 06 / 2015 Page 91 / 146

VARMAX - Installation, Use and Maintenance

BOILERS IN A CASCADE CONFIGURATION

1 network regulated by a three-channel valve, DHW

production or 1 direct circuit with constant temperature and

throughput

A. HYDRAULIC DIAGRAM

B10

B3000

Q1.1

B3000

Q1.2

Y1/Y2

Diagram

VX210 VX220

page 1 / 8

B3000

Q1.1

ﬁ gure 63 - Diagram VX210

B3000

Q1.2

DIRECT CIRCUIT WITH

CIRCUIT DIRECT AVEC

CONSTANT TEMPERATURE

TEMPERATURE ET DEBIT

AND THROUGHPUT

CONSTANT

Q15

Y1/Y2

B10

ﬁ gure 64 - Diagram VX220

Page 92 / 146 00BNO9061-J

VARMAX - Installation, Use and Maintenance

Diagrams: VX210 / VX220

page 2 / 8

B. NECESSARY ADJUSTMENT ACCESSORIES

Quantity

Extension module kit (delivered with a QAD 36 network sensor)

Communication kit 2 OCI 345 059572

Network sensor kit 1 QAx 36

DHW sensor kit (diagram VX210) 1 QAZ 36 059261 External sensor kit 1 QAC 34 059260

1 AVS 75 059751

Appliance

reference

Order No.

059261 (QAZ 36)

059592 (QAD 36)

C. CUSTOMER ELECTRICAL CONNECTION

Boiler No. 1:

INFORMATION:

Diagram VX210:

Diagram VX220:

Mains supply 230

DHW circulation pump Q3

Direct circulation pump Q15

VAC 50 Hz

LPB bus

DB MB

}

If the insulating valve is not ﬁ tted with an automatic reset, reconnect the Q1.1 insulating valve closing contact on Y2.

Insulating

valve Q1.1

}

L NY1 NY2L NL NL N

QX2 QX3 QX1 AUX2 AUX1

}

Alarm

relay

}

BX2 Gnd BX3 Gnd

Gnd

Flow sensor in

}

cascade B10

Diagram VX210:

}

DHW sensor B3

External sensor B9

}

Gnd

Edition: 06 / 2015 Page 93 / 146

Diagram VX220:

Shunt to install

VARMAX - Installation, Use and Maintenance

Mixing valve for heating

circuit No. 1 Y1/Y2

Circulator for heating circuit

No. 1 Q2

Boiler No. 2:

INFORMATION:

Diagrams: VX210 / VX220

Module 1

Gnd

}

Flow sensor for regulated circuit

}

QX21

}

QX22

}

QX23

If the insulating valve is not ﬁ tted with an automatic reset, reconnect the Q1.2 insulating valve closing contact on Y2.

AVS75

BX21

BX22

page 3 / 8

Mains supply 230

VAC 50 Hz

LPB bus

}

DB MB

Insulating

valve Q1.2

L NY1 NY2L NL NL N

QX2 QX3 QX1 AUX2 AUX1

Alarm

}

relay

}

Page 94 / 146 00BNO9061-J

VARMAX - Installation, Use and Maintenance

Diagrams: VX210 / VX220

D. SPECIFIC START-UP PROCEDURE

Fit the accessories and make their electrical connections.



WARNING:

Start up the boiler alone.



Make the following settings:



On boiler No. 1: master

• Time and date menu

Set the time

Set the date

Set the year

Ensure the switches on extension module AVS75 are correctly conﬁ gured.

page 4 / 8

Line No. Value

Time / minute (1) HH.MM

Day / month (2) DD.MM

Year (3) YYYY

• Configuration menu

Conﬁ gure the DHW pump (diagram VX210)

Conﬁ gure pump Q15 (diagram VX220)

Conﬁ gure the ﬂ ow sensor in cascade B10

Conﬁ gure input H1 (diagram VX220)

Conﬁ gure the extension module

• Conﬁ gure as master in the cascade: LPB network menu

Appliance number

Segment number

Set the bus power supply.

Set the clock mode

Function of extension module 1 (6020) Heating circuit 1

QX2 relay outlet (5891) Pump/valve ECS

QX2 relay outlet (5891) Pump for circulation

Sensor input BX2 (5931) Common ﬂ ow

Input function H1 (5977) Demand for

Appliance address (6600) 1

Segment address (6601) 0

Bus supply function (6604) Automatic

circuit 1 Q15

sensor B10

circulation circuit 1

Clock function (6640) Master

• Heating circuit 1 menu

Set the comfort setting

Set the curve slope

• Switch the heating mode to permanent comfort

Edition: 06 / 2015 Page 95 / 146

Comfort setting temperature (710) - - -

Heating curve slope (720) - - -

VARMAX - Installation, Use and Maintenance

Diagrams: VX210 / VX220

Diagram VX210 only:

• Domestic hot water menu

Set the comfort setting

• Activate DHW mode

Diagram VX220 only:

• Circulation circuit 1 menu

Set the starting value to use in the event of a demand from the circulation circuit

Line No. Value

Comfort setpoint (1610) - - -

Value of starting temperature for

circulation circuit demand (1859)

page 5 / 8

- - -

On boiler(s) No. 2 (and later): slave

• Conﬁ gure as slave in the cascade: LPB network menu

Appliance number

Segment number

Set the bus power supply.

Set the clock mode

• Connect the bus between the boilers (

• Turn off the slave boiler(s) and then turn on again. If communication is successful, the clock is correctly updated.

respect the polarity).

Appliance address (6600) 2 (or later for the

other slaves)

Segment address (6601) 0

Bus supply function (6604) Automatic

Clock function (6640) Slave without

adjustment

E. ELECTRICAL AND HYDRAULIC VALIDATION

On boiler No. 1: master

• Cascade diagnostic menu

Check that all boilers are present in the cascade

Status of generator 1 (8100) Released / not

released

Status of generator 2 (8101) Released / not

released

Page 96 / 146 00BNO9061-J

VARMAX - Installation, Use and Maintenance

Diagrams: VX210 / VX220

• Input/output test menu

Check the outputs

Alarm relay

DHW pump Q3 (diagram VX210)

Constant circuit pump Q15 (diagram VX220)

Opening V3V CC

Closing V3V CC

CC pump

Reset outputs

page 6 / 8

Line No. Value

Relay test (7700) Relay output QX1

Relay test (7700) Relay output QX2

Relay test (7700) Relay output QX21

module 1

Relay test (7700) Relay output QX22

module 1

Relay test (7700) Relay output QX23

module 1

Relay test (7700) No test

Check sensor values

External sensor B9 External T° B9 (7730) in °C

DHW sensor B3

Flow sensor B1

• Configuration menu

Check the hydraulic diagram

On boiler No. 2: slave

• Input/output test menu

Check the outputs

Temperature sensor BX21 module 1 (7830) in °C

Information on heating circuits 3, 2 and 1 (6217) 3

DHW temperature B3/B38 (7750) in °C

Generator 1 check (6212) 14

Generator 2 check (6213) 0

Information on DHW (6215) 4

(

Diagram VX210)

(

Diagram VX220)

Alarm relay

Insulating valve Q1.2

Reset outputs

Edition: 06 / 2015 Page 97 / 146

Relay test (7700) Relay output QX1

Relay test (7700) Relay output QX3

Relay test (7700) No test

VARMAX - Installation, Use and Maintenance

Diagrams: VX210 / VX220

• Configuration menu

Check the hydraulic diagram

F. OPTIMISATION OF SETTINGS

Optimisation of heating circuit:

• Heating circuit 1 menu

Set the reduced setting

• CC1 time programme menu

page 7 / 8

Line No. Value

Generator 1 check (6212) 14

Generator 2 check (6213) 0

Information on DHW (6215) 0

Information on heating circuits 3, 2 and 1 (6217) 0

Reduced temperature setting (712) - - -

Preselection

Adjust the time programme

• Circuit CC1 holiday menu

Preselection

Adjust the time programme

• Switch the heating mode to automatic

Optimisation of DHW:

• Domestic hot water menu

Set the comfort setting

Set the DHW release mode

Preselection (500) - - -

On / Off phases (501...506) - - -

Preselection (641) - - -

On / Off phases (642-643) - - -

AUTO

Reduced setting (1612) - - -

DHW release (1620) Time programme 4/

DHW

• Time programme 4 / DHW menu

Preselection

Adjust the time programme

• DHW storage tank menu

Adjust the boost

Page 98 / 146 00BNO9061-J

Starting value of boost temperature (5020) - - -

On / Off phases (561...566) - - -

Preselection (560) - - -

VARMAX - Installation, Use and Maintenance

Diagrams: VX210 / VX220

Diagram VX210 only:

• Domestic hot water menu

Conﬁ gure an anti-legionella function

Line No. Value

Anti-legionella function (1640) - - -

Periodic anti-legionella function

(1641)

Day week anti-legionella function (1642) - - -

Anti-legionella temperature setting (1645) - - -

Duration of anti-legionella function (1646) - - -

page 8 / 8

- - -

Optimisation of the cascade:

The cascade may be optimised as required with the parameters of the Cascade menu. Refer to the LMS boiler command table instructions for more details.

Maintenance optimisation:

It is possible to generate a maintenance message without harming the boiler. This maintenance message may appear when the 3 following meters have elapsed:

• Time since last maintenance (or commissioning): set parameter 7044 to 12 months

• Operating hours of the burner (parameter 7040)

• Number of start-ups (parameter 7042)

The last 2 parameters depend on the boiler room's hydraulic installation. It is recommended to use at least parameter 7044 for yearly maintenance.

Edition: 06 / 2015 Page 99 / 146

VARMAX - Installation, Use and Maintenance

BOILERS IN A CASCADE CONFIGURATION

Secondary networks regulated by external regulated

communicating by LPB bus or 0...10V

A. HYDRAULIC DIAGRAM

0/10 V SIGNAL TO NAVISTEM B3000

SIGNAL 0/10 V VERS LMS

or LPB BUS TO OCI345

ou bus LPB sur OCI 345

COMMUNICATING REGULATOR

REGULATEUR COMMUNICANT

B10

Diagram

VX211

page 1 / 6

Q1.1 Q1.2

B3000 B3000

ﬁ gure 65 - Diagram VX211

B. NECESSARY ADJUSTMENT ACCESSORIES

Quantity

Communication kit 2 OCI 345 059572 Network sensor kit 1 QAx 36

Appliance

reference

Order No.

059261 (QAZ 36)

059592 (QAD 36)

Page 100 / 146 00BNO9061-J

hamworthy Varmax 120 User guide

Specifications and Main Features

Frequently Asked Questions

User Manual