Atmos Multi Installation & Servicing Instructions 24/80, 24/80 Plus, 32/80 Plus, 38/80 Plus Atmos Heating Systems West March Daventry Northants, NN11 4SA Tel: 01327 871990 Fax: 01327 871905 e-mail: sales@atmos.uk.com internet: www.atmos.uk.com MK2 Revised with 38/80 Plus 20.8.08 Amended 18.6.
© 2010 Atmos Heating Systems The information provided applies to the product in the standard model. Atmos Heating Systems can therefore not be held liable for any damage resulting from the product specifications that deviate from the standard model. The information provided has been compiled with the utmost care. However, Atmos Heating Systems cannot be held liable for any faults in the information nor for the consequences thereof.
Table of Contents Section Page Introduction 1. Installation Regulations 2. General Information 3. Technical Data 4. Schematic of Boiler 5. Operation and construction 4 5 5 6 7 9 9 10 11 12 12 12 12 13 13 15 15 5.1 Appliance construction 5.2 Operating principle 5.3 Controls and function 5.4 User's program 6. Installation Requirements 6.1 Gas supply 6.2 Electrical supply 6.3 Flue terminal clearances 6.4 Flue system 6.5 Condensate disposal 6.6 Combined safety discharge & condensate pipe 6.
Introduction The Atmos Multi gas fired storage combination boiler meets the requirements of Statutory Instrument 'The Boiler (Efficiency) Regulations' and is deemed to meet the requirements of: Gas Appliance Directive 90/396 EEC Efficiency Directive 92/42/ EEC Low Tension Directive 73/23 EEC (modified from 93/68) and; Electromagnetic Compatibility Directive 89/396 EEC (modified from 93/68) Atmos Heating Systems declare that the materials used in the manufacturer of this appliance are non-hazardous
1. Installation Regulations. 2. General Information. 1.1 The appliance must be installed by a qualified registered installer in accordance with the Gas Safety (Installation and Use) Regulations; October 1994. Failure to install appliances correctly could lead to prosecution. 2.1 The Atmos Multi is a wall mounted, fully automatic gas fired condensing combination boiler designed to provide 'unvented' domestic hot water at mains pressure via an integral hot water storage cylinder. 1.2.
Natural Gas & Propane (Propane in brackets where different) 24/80 24/80 Plus 32/80 Plus 38/80 Plus 7.5 – 25.0 7.5 – 25.0 10.0 – 32.7 11.3 – 37.8 3.
4.
Key Components Type 1 FAN MVL RG 148/1200-3612, 325 Vdc 2 GAS/AIR MIXING CHAMBER ATMOS 3 CATCHMENT PLATE ATMOS 4 GAS INJECTION NOZZLE ATMOS 5 GAS VALVE HONEYWELL VK 4115 V 220/240 VAC 6 AUTOMATIC AIR VENT TACO 3/8” 7 CASING ATMOS 8 HIGH LIMIT THERMOSTAT THERM-O-DISC 36TX E31 L 1050C 9 IONISATION PROBE ATMOS 10 INLET CASTING ATMOS 11 IGNITION ELECTRODE ATMOS 12 IGNITION TRANSFORMER HONEYWELL RAC1 13 AIR SEPARATOR ATMOS 14 BURNER FURIGAS PREMIX 15 WATER HEATER VES
5. Operation and Construction The Atmos Multi is a fully automatic, gas fired, high efficiency central heating boiler providing unvented domestic hot water at mains pressure via an integral 80 litre copper hot water storage tank. 5.1 Appliance construction A heat exchanger consisting of three concentric channels is positioned in the centre of the boiler's integral hot water tank. (Fig.1).
5.2 Operating principle No heat demand The appliance will carry out a self-test when the electrical supply is switched on and then once every 24 hours (if there has been no heat demand). For this test, the boiler's integral central heating pump will run for 3 minutes and the three-way valve will switch to central heating in order to prevent the pump from seizing.
5.3 Controls and function. The function mode of the appliance and the central heating water pressure are indicated on the electronic control unit's front fascia (fig 2), located at the bottom centre of the appliance. Table 1 : Status Reports Central Heating Display (fig 2 (4)) The central heating display may be set to indicate either the central heating water pressure (factory setting) or central heating water temperature. (See 'User's program').
Reset button. (fig 2 (3)) Operational parameters accessible via the Users' program are given in Table 2, the factory settings being underlined. A lockout situation following a malfunction is cancelled using the reset button. The button is also used to exit the 'User's program' or 'Installer program'. Hot water temperature control 5.
6.3 Flue terminal clearances. The flue terminal must be sited with minimum clearance distances as specified in figure 3. A terminal guard must be fitted if the terminal is sited less than 2m above ground level. Where the flue terminates within 1m of a plastic or painted gutter or within 500mm of painted eaves then protection should be provided in the form of an aluminium shield at least 1m in length, fitted to the underside of the gutter or painted surface.
Figure 4: Examples of flue installation options The equivalent length of the required flue system's configuration can be calculated from the resistance factors given for the individual flue components in Table 3. In the worked example (Fig 7), the maximum permitted combined length for a 80mm dia. twin flue is 64metres at a pressure of 100 Pa. Account has already been taken of the resistance of the balanced flue terminal. This can therefore be ignored in the calculation.
Note regarding internal air-flue systems It is recommended that the boiler is sited on or next to an external wall so as to negate the need to use a void or enclosure as a route for the flue system. Where this is not possible the following applies: CORGI have issued a Guidance Document on the safe installation of flue systems within a dwelling. This is a Technical Bulletin reference TB200, and can be downloaded from the CORGI web site www.trustcorgi.com by registered installers.
6.5 Condensate disposal. Provisions must be made for the safe disposal of condensate. The condensate drainage pipework must be run in an acid resistant material such as plastic waste pipe. Copper or steel pipe must not be used. The pipework must incorporate a minimum 1:20 downward slope towards its point of termination, which ideally should be an internal soil or waste pipe to avoid the possible risk of freezing.
Worked example: The example below is for a G ½ temperature relief valve with a discharge pipe (D2) having 4 No. 22mm elbows and length of 7m from the tundish to the point of discharge. From Table 1 Maximum resistance allowed for a straight length of 22mm copper discharge pipe (D2) from a G ½ temperature relief valve is: 9.0m. Subtract the resistance for 4 No. 22mm elbows at 0.8m each =3.2m Maximum resistance allowed for a straight length of 28mm-pipe (D2) from a G ½ temperature relief valve is: 18m.
6.8 Existing systems. Figure 8: Unpacking boiler All re-circulatory water systems are subject to corrosion unless an appropriate water treatment is applied. To prevent the risk of accumulated corrosion sludge, within an existing system, causing boiler noise and circulation problems along with possible pump and valve damage, the existing heating systems must be thoroughly flushed to ensure that all sludge and debris are removed prior to installation of the boiler.
Warning : When removing the red caps from the boiler pipes, dead water will come out, which can cause stains. Take care! Figure 11: Dimensions & minimum clearances Note The T & P valve discharge pipe is not shown (on LHS). 7.2. Minimum clearances.
The appliance must be installed on a flat vertical wall that is capable of taking the weight of the boiler. Do not fix directly on to low load bearing or plasterboard walls. In such cases, a sheet of 18mm plywood, reaching to the floor, can be used to overcome the problem. On a lightweight block wall, heavy duty Rawplugs must be used in place of the supplied wall plugs and bolts.
7.5. Connecting the flue system. Prior to connection of the boiler's flue system, please refer to sections 6.3 & 6.4 of these instructions. The flue and air duct are an integral part of the boiler and care must be taken on their installation to ensure that all joints are airtight and correctly made. The flue and fittings are push fitted together being sealed by the fittings integral 'O' ring.
7.6.Connecting the central heating circuit. Important Note! The Atmos Multi is suitable for use on a sealed heating system only. It must not be connected to an open vented heating system. The 22mm diameter connections for the central heating circuit flow and return pipes are located on the underside of the appliance. (Fig 14). The flow pipe (A) is colour coded red and the return pipe (B) is colour coded blue. Figure 14: Boiler flow & return connections.
Where required, the boiler offers the facility for an independent towel rail circuit to be installed via the extra central heating connection (Connection O in Fig 11). This allows for the separate heating of a radiator when the boiler is operating in either central heating or hot water mode, with a maximum power of 5kW.
7.7.Connecting the mains water. The following components are for the cold water supply to the boiler and the hot water outlet from the boiler: 1. UV3 cold water inlet manifold c/w pressure reducing valve pre-set at 3.5 bar and safety relief valve set at 6bar. 2. 5 litre potable expansion vessel (hot water). 3. Expansion vessel mounting bracket. 4. 22mm x 15mm compression reducing set. 5. Black plastic tundish. 6. 15mm Thermostatic mixing valve 7. ¼" BSPM drain cock. 8. 22mm butterfly isolating valve blue 9.
7.8 Assembly Instructions using loose components. Note: Atmos supply the components listed under 7.7 and also the following:1. Central Heating Y pattern filter. 2. Gas Union Valve 3. Multifit connector for condensate 4. Robokit (not pictured). The Robokit consists of: x 12 ltr expansion vessel x Expansion vessel mounting bracket x Filling loop complete with isolating valves x Pressure relief valve x Pressure gauge fig 2.
Now connect the complete block to the cold water inlet pipe and the hot water outlet pipe on the boiler as shown in fig 5. Bring the cold mains water to the boiler in 22mm pipe. Fit the 22mm butterfly isolation valve and connect to the 3.5 bar pressure reducing valve. Connect the hot water in 15mm pipe to the mixed outlet (M) on the thermostatic mixer valve. Fig 5.
Heating system flow and return connection The heating flow and return are connected in 22mm copper to the boiler connections (flow and return). The following connections must be made to the return pipe:1) Cold filler loop connection. 2) Heating system 12 ltr expansion vessel and pressure relief valve (part of the Robokit) 3) Towel rail return (if used) must be the last return connection on the system. The 22mm Y pattern filter (item 1 in fig 2) must be fitted in the CH return pipe to protect the boiler.
Central heating system cold fill valve Use the filler loop provided with the Robokit expansion vessel. Connect this according to the instructions between the cold supply and the heating system. Ensure that the double check valve is connected to the heating side. One of the connections on the 4-way connector manifold supplied with the Robokit can be used for the filler loop connection. If this connection is not used it needs to be blanked off.
The white condensate trap must be connected to the condensate outlet on the boiler. A 1” grey plastic flexible pipe is supplied with the white trap and must be connected to the outlet on the trap. The flexible pipe can be inserted into the open end of a vertical piece of waste pipe. Finally Tighten all joints, check over, fill system with water, and test for water tightness. Test for gas tightness.
7.9.Connecting the domestic hot water supply. Figure 20a Hot water secondary circulation The cold water inlet and hot water outlet connection points for supplying domestic hot water are located on the underside of the appliance (Fig 20). The cold water inlet (K) is colour coded blue, the hot water outlet (W) colour coded red, and both are 15mm. Figure 20: Mains-side hot & cold water connections. The cold water inlet to the boiler must be made via the UV3 manifold.
The ¼ turn gas tap provided must be fitted in the supply immediately before the boiler to enable complete gas isolation to the boiler during maintenance and servicing work. To prevent the ingress of foreign matter and possible damage to the gas-regulating block, the gas supply pipe must be checked for contaminants prior to connection to the boiler.
Figure 24: Atmos Multi wiring diagram.
7.14 Boiler with Pre-Assembled Pipework kit. Assembly As an option, Atmos can suply the boiler with preassembled pipework kit. This includes the following: UV3 manifold including pressure reducing valve pre-set at 3.5 bar. 1. Cold water safety relief valve set at 6 bar. 3. Central heating safety relief valve set at 3 bar. 5 litre potable expansion vessel. 12 litre central heating expansion vessel. Central heating pressure gauge. Central heating filler loop and bypass valve.
Figure 18b: Dimensions Figure 18c: Isometric Arrangement Figure 18d:Alternative Mounting An alternative mounting is shown with the pipework kit on a left hand return wall. In this case extra pipework must be fitted by the installer NOTE: The pipework kit cannot be used on the right hand side of the appliance.
8. Commissioning. Figure26: Venting the pump Note: The appliance must be installed and commissioned in accordance with the manufacturer’s instructions in order to comply with the Building Regs. To demonstrate compliance, the Benchmark Checklist (located at the back of this Manual) should be completed and signed at the time of commissioning, and left with the customer. Failure to flush and add a suitable inhibitor to the system will invalidate the Appliance Warranty. 8.1 Filling the heating system.
As stated at the beginning of 8.1, a suitable inhibitor must be added to the system water. Note! For existing central heating systems, the final system water must have a pH value of between 6.5 and 8. 8.2 Filling the domestic hot water system. Switch off the domestic hot water heating by pressing the 'Hot water' button on the operating panel. The 'On' indication light will go out.
If the boiler's burner fails to ignite after 3 reset attempts, re-purge the gas supply, using the inlet pressure measurement nipple. Otherwise consult the Atmos Heating Systems. Ensure that the appliance is functioning correctly by undertaking the following inspections and noting the results and work carried out on the Service Card (located on the front of the boilers storage tank insulation shells):- 1. Visual inspection of the combustion flame. 2.
9. System shutdown. Central heating circuit. 9.1 Central heating circuit. Leave the appliance connected to the main electrical supply. Turn the room thermostat to its minimum setting. The domestic water heater will remain at its set temperature setting. Note! On shutting down the central heating system, it is recommended not to set the room thermostat lower than 10ºC during the winter months.
The annual inspection of the boiler comprises the following:1. Visual inspection of the flame 2. Measuring the gas rate. 3. 4. Measuring the O2 or CO2 concentration in the flue gas. Measuring the CO/CO2 ratio. 5. Inspecting the ionisation flow. 6. Inspecting the siphon. Note! The inspection results and any servicing work undertaken should be noted on the Service card located on the front of the hot water storage tank insulation shells. 1.
4. Carbon monoxide : carbon dioxide ratio Atmos recommends that a carbon dioxide : carbon monoxide ratio test is carried out each time the boiler is serviced. This is best done after the O2 and the CO2 content of the flue gasses has been measured and the gas valve regulator adjusted. Measure the CO/CO2 ratio first with the burner set at the low rate (LL) and then again with the burner set at the high rate (HH). The CO/CO2 ratio at low or high burner rate should be no higher than 0.004.
5. Inspecting the Ionisation flow. The ionisation flow of the burner can be read off via the Installer Programme of the control unit. The ionisation flow should be greater than 40 for both the low and high positions. If there are differences the ionisation probe must be examined and replaced as necessary (see Section 11.4). Press and hold the 'Set' button on the controller for 10 secs until a capital 'A' appears on the central heating display. Press the 'Hot water' button once.
Figure 33: Removing burner assembly. 1. Cleaning the appliance outlet casting Using a 10mm socket, release the 3 fixing nuts securing the outlet casting to the base of the heat exchanger and remove the casting by gently separating it from the push fit connection with the condensate trap and the flue gas discharge pipe. (Fig 31). Remove the flue baffle and take care of the ceramic core. Inspect the outlet casting and baffle, cleaning where necessary. Replace in reverse order.
Inspect the fan and the inner grating of the burner and clean where necessary using a soft brush or compressed air. Inspect the inlet casting sealing gasket and change if necessary. Replace in reverse order. 3. Cleaning the heat exchanger. Inspect the heat exchanger from the topside of the appliance and remove any deposits from the heat exchanger and fins using a soft brush. 10.4. Completion of inspection and servicing.
Gas Valve. Detach the ignition transformer as described above. Disconnect the gas injector nozzle tube between the gas valve and the mixing chamber via the union (Fig 36). Detach the valve from the fixing bracket by releasing the two retaining bolts, disconnect the union and remove the gas valve. Fit replacement gas valve in reverse order. Reinstate boiler operation and check the gas valve settings (Refer to section 10.1). 11.
11.4 High limit thermostat. 11.6 Control Unit. Isolate the electrical supply to the boiler. Disconnect the thermostat's 'push' on electrical connections and unscrew the thermostat from its fitting using a 17mm socket (Fig 42). Isolate the electrical supply to the boiler. Unplug all leads from the control panel. Press the control panel in, twist anticlockwise, and gently pull forwards and away (Fig 44). Fit replacement thermostat in reverse order, using heat sink paste to ensure good conductivity.
11.8 Pump head. Figure 47 Isolate the electrical supply to the boiler. Disconnect the electrical connections from the pump terminal block (Fig 46). Release the two bolts securing the pump head using a 5mm-hexagon key, and remove the pump head from the pump body. Fit replacement pump head in reverse order. The pump must be vented via its vent plug on refilling of the boiler (venting shown in Fig 46) . Figure 46 11.10 Central heating water temperature sensor. 11.9a. Three way valve.
Figure 51 Figure 49 Multi Plus Model only In addition, disconnect the connections to the fast recovery coil (Fig 51). 1 1.12. Hot water tank. Disconnect and remove the following boiler components: Gas valve Fan/burner assembly High limit thermostat Temperature & pressure relief valve Boiler control unit Pump Front section of insulation shell. Disconnect the top water connection (Fig 50) and bottom water connections at the rear of the tank.
12. Malfunctions. The Atmos Multi has three types of malfunctions that can be reported via the diagnostic display, as follows : Warning report Block report Malfunction report Malfunction report. A malfunction is a fault that causes the appliance to be shut down by the control unit and locked. The appliance can only be unlocked by pressing the 'Reset' button. A flashing number or letter on the status display indicates a malfunction (Table 9). Table 9: Malfunction report Warning report.
