Atmos InterSystem HE26 Installation And Servicing Instructions Download

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Summary of Contents for InterSystem HE26

Page 1: ...ation Servicing Instructions for HE26 GC 41 249 05 Atmos Heating Systems West March Daventry Northants NN11 4SA Tel 01327 871990 Fax 01327 871905 e mail sales atmos uk com internet www atmos uk com Issue 22 01 10 Main revision ...

Page 2: ...tly Similar arrangements apply in Scotland and Northern Ireland Atmos Heating Systems is a member of the Benchmark Scheme and the Benchmark Checklist is included at the back of these Instructions The Benchmark Checklist provides a Commissioning Checklist and Service Record to be completed by the Installer Service Engineer Benchmark places responsibilities on both manufacturers and installers The p...

Page 3: ... gas supply 20 5 3 Electrical connection 20 5 4 General Flue Requirements 23 5 5 Flue discharge and air supply 24 5 6 Roof outlet prefabricated chimney 30 5 7 Atmos MS System 31 5 8 Atmos Communal Flue System CFS 32 6 Commissioning 33 6 1 Fill and de aerate the appliance and the system 33 6 2 Commissioning of the appliance 34 6 3 System Shutdown 35 7 Setting and Adjustment 36 7 1 Directly via oper...

Page 4: ... THE BOILER AND COMPONENT REPLACEMENT 46 9 1 SERVICING THE BOILER 46 9 2 COMPONENT REPLACEMENT 48 10 Technical Specifications 50 10 1 Electrical diagram 51 11 CE Declaration 52 NOTE The Benchmark Checklist Service Record are included at the back of the Manual 4 ...

Page 5: ...os Heating Systems West March DAVENTRY Northants NNII 4SA Tel 01327 871990 fax 01327 871905 Email sales atmos uk com internet www atmos uk com Environment When the appliance needs replacement your installer may arrange for disposal Should this not be possible then make enquiries with your local council about the possibilities for re use or environmental friendly processing of the materials used or...

Page 6: ...ccordance with Building Regulations 6 Completion of the Benchmark Checklist Service Record is a condition of the boiler warranty Customer s statutory rights not affected which must be completed and supplied to Atmos if required The Warranty card must be completed and the signed Atmos copy received within 8 days of installation By signing the Warranty card the buyer agrees that the goods have been ...

Page 7: ...s or local Water byelaws 1 2 CH system The entire system should comply with the valid safety regulations as mentioned in BS 5449 Central Heating for Domestic Premises 1 3 Gas system The entire system should comply with the valid safety regulations as mentioned in BS 6798 Specification for installation of gas fired hot water boilers of rated input not exceeding 60 kW BS 6891 Installation of low pre...

Page 8: ...d gas heater is a modulating high efficiency boiler This implies that the power is adjusted to the heat demand In the aluminium heat exchanger is an integrated copper circuit The appliance has been provided with an electronic controller that controls the fan with the heat demand from the heating system or the hot water tank opens the gas valve and ignites the burner continuously monitors the flame...

Page 9: ...y means of electric spark ignition During ignition the code 4 appears If the burner is not ignited another ignition attempt is made after about 5 seconds If the burner has still not fired after the fourth ignition attempt the controller indicates a fault See 8 1 5 CH operation An on off thermostat can be connected to the controller if necessary in combination with an outside sensor See the Electri...

Page 10: ... 1x h Burner on with maximum power set by parameter 4 service and 2x H Switch off test programme and Current operating condition 2 5 1 Frost protection The boiler has provision for protecting its heat exchanger as described below NOTE However to avoid the condensate freezing the boiler must be installed in a FROST FREE room In order to avoid freezing of the appliance heat exchanger it has an appli...

Page 11: ...eturn sensor S2 R Heat exchanger F Fan S Controller operating panel and display H Pressure gauge T Ionisation ignition probe I 1m connecting cable 230 V U Position type plate J Manual air vent V Expansion vessel shown in broken lines K Sight glass and mirror W Pressure relief safety valve 3 bar L Air supply left or right Additional Components supplied Valve set supplied separately with boiler 11 ...

Page 12: ...iameter Connection gas female thread Mounting strip boiler Bag with fixings 092 537 Rear mounting frame for top pipe connection 092507 Bottom Pipework cover 092527 Outside sensor for weather compensation 203 207 Conversion set to Propane LPG or G31 075537 Interface cable for Installers 230677 12 ...

Page 13: ... flow 22 mm diameter h 670mm InterSystem HE 26 B CH return 22 mm diameter C Gas 15 mm diameter H 810mm InterSystem HE 26 Z Flue gas outlet 80 mm diameter F Condensate 32 mm dia after trap 25 mm dia flexib le Y Air supply inlet 80 mm diameter 13 ...

Page 14: ...prising 2 x 22mm isolation valves 1 x gas valve 4 Check the appliance for any damage report damage to the Supplier immediately CAUTION This appliance should be lifted and handled by 2 people Weight 39 kg 4 3 Additional dimensions The diagram shown below gives additional dimensions primarily for the mounting arrangement using the OPTIONAL mounting bracket Note The centre line of the hexagonal notch...

Page 15: ...all There must be an earthed electrical supply within a distance of 1 m from the appliance In order to avoid freezing of the condensate discharge the appliance should be installed in a frost free room 4 4 1 Installation in a kitchen cupboard Make sure there is sufficient ventilation above and below the appliance When the appliance is placed in a small cupboard ventilation openings of at least 50 c...

Page 16: ...the appliance A C B B A 4 5 1 Fitting the mounting strip 1 Fasten the mounting strip horizontally to the wall using the screws and plugs supplied 2 Mount the appliance 4 5 2 Fitting the mounting strip and the mounting bracket 1 Fasten the mounting strip and the pipe mounting bracket horizontally to the wall according to the drilling pattern using the screws and plugs supplied 4 5 3 Fitting the rea...

Page 17: ... sure that the pipes simultaneously slide into the compression fittings of the optional mounting bracket 3 The flexible tube from the condensate trap should be inserted into an open waste pipe of not less than 32 mm diameter If connected to a soil pipe or waste system the waste pipe must include a trap similar to arrangement for washing machine For more information on condensate disposal please re...

Page 18: ... made soakaway The pipework must incorporate a minimum fall of 2 5 degrees or 44mm metre towards its point of termination The condensate pipework external to the property or in an unheated part eg a garage must be suitably insulated to protect against freezing and the length of the external pipe restricted to a maximum of 3 metre If an external drain or gulley is used then the open end of the pipe...

Page 19: ...n vessel The appliance is fitted with a 6 litre expansion vessel which is adequate for a system with a water volume not exceeding 100 litres typically 8 radiators For larger volume systems an additional expansion vessel must be fitted Atmos can supply 12 litre or 18 litre Robokit 5 1 2 Thermostatic radiator valves Building regulations require a room thermostat to be fitted on all installations Do ...

Page 20: ...1 5 3 Electrical connection CAUTION The appliance requires a 230 V ac 50 Hz mains supply and must be earthed and connected via a double pole isolating switch fitted with a 3 amp fuse The switch must be readily accessible within 1m of the appliance and provide complete electrical isolation for the boiler and control system The appliance is supplied factory wired complete with 1 m of mains cable All...

Page 21: ...ust also be taken to avoid induced voltages caused by the running of the thermostat cables along side mains voltage cables 5 3 2 Volt free Room thermostat on off 1 Connect the room thermostat See 5 3 1 2 The terminal block for the connection for a volt free room thermostat or time clock is X4 on the control panel The terminals are wired to the input circuit of the control unit which has its own 24...

Page 22: ... relay This relay needs to be wired so that the outside sensor electrical circuit is opened whenever there is a call for heat for hot water 5 3 4 OpenTherm modulating thermostat The appliance is suitable for connecting an OpenTherm modulating thermostat as shown in 5 3 1 The most important function of the modulating thermostat is calculating the supply temperature at a required room temperature in...

Page 23: ...ainted surface Please Note Due to the low flue gas temperature pluming will occur at the flue terminal Care should be taken to ensure that the discharge plume will not cause annoyance to the customer or neighbours It is generally recommended that flues should discharge vertically at roof level In this position pluming is not normally a problem 5 4 2 Flue system The flue system must be installed in...

Page 24: ... different flue systems are available from Atmos for use with this appliance 60 100mm concentric system comprising a standard through the wall flue kit or an extended system 80 125mm concentric system 80mm twin pipe system which enables separate air intake and flue pipes to be fitted to the appliance 80mm PPS and 50mm Mupvc plastic twin pipe system for special applications Maximum lengths are spec...

Page 25: ...lable from Atmos The flue should be adjusted to length and the supplied sealing tape applied NOTE Atmos also provide anti plume kits for use with the telescopic flue system 5 5 2 60 100mm Concentric extended flue system Refer to the Atmos Price List for the full list of flue components Table of Atmos 60 100mm concentric flue equivalent lengths Maximum equivalent concentric length allowed is 10 met...

Page 26: ...tion 5 Seal the open air supply connections in the appliance with the sealing cap delivered with the set item C in photo 6 Remove the sealing ring around the flue discharge in the appliance as shown above 7 In its place fit the sealing ring ø 116 x 110 mm item B in photo 8 Fit the adapter item A in photo on the flue discharge 5 5 4 80 125mm Concentric flue system Refer to the Atmos Price List for ...

Page 27: ...tric length allowed is 27 metres Note Includes an allowance for the terminal ie the terminal can be ignored from the equivalent length 80 125mm concentric components Equivalent concentric length M Remarks 450 bend 1 5 870 bend 3 0 5 5 5 Twin pipe connection 9 When using the right hand air supply the sealing cap must be moved to the left hand air supply 10 Locate the pipes for the air supply and fl...

Page 28: ...rminal ie the terminal can be ignored from the equivalent length 80mm components Equivalent length M Remarks 450 bend 1 5 870 bend 3 0 80mm Twin pipe extensions for balcony outlet When the free outlet is hindered by an eave balcony gallery or anything else the air supply pipe and the flue discharge pipe must be extended to at least the front side of the overhanging part In this case the flue disch...

Page 29: ... runs Note that it must only be used vertically and MUST NOT be used for horizontal runs because the condensate will accumulate and could block the flue path Plastic combustion air inlet systems All plastic pipes can be used for air inlet The pipe does not need to slope since there is no condensate NOTE In longer runs of 80mm plastic flue pipe 3m long or longer it is advisable to fit a condensate ...

Page 30: ...himney with respect to wind attack ice formation rain ingress etc In view of the different models and requirements the prefabricated chimneys must be adjusted to the local situation a gas certificate is not required CAUTION The connection of the air supply and the flue discharge between the appliance and the prefab chimney must be made in pipes of diameter 80 mm Maximum pipe length See 5 5 5 Mount...

Page 31: ...ake an opening of diameter 90 mm at the place of the supply 2 Shorten the air supply pipe to the correct length out of the wall 3 Mount the Atmos inlet grid and attach this to the pipe 4 Slide the air supply pipe into the opening and cover the opening with a rosette if necessary Mounting flue terminal vertical 1 Mount a roof tile with shell in a pitched roof surface at the place of the outlet Moun...

Page 32: ...ply together is 75 metres 80mm pipes Common flue discharge The outlet of the flue discharge can be made at any place in the pitching roof surface provided that the outlet in the roof surface has the same orientation as the air supply in the outside wall With a flat roof the outlet of the flue discharge must be made in the free outlet area 5 8 2 Atmos CFS System Appliance category C43 CFS NV or CFS...

Page 33: ...ic and rubber A suitable product is Sentinel X100 following the manufacturer s instructions 1 Use the filling loop to fill the system to a maximum pressure of 1 to 2 bar with a cold system 2 De aerate the appliance with the manual air vent A in diagram Alternatively an automatic air vent can be mounted to the appliance instead of the manual air vent Note When the appliance is located at or near to...

Page 34: ... through is 200 l h at a set power of 7 0 kW 750 l h at a set power of 26 2 kW 7 Switch off the electrical supply to the appliance 8 De aerate the appliance and the system after cooling down fill up if necessary 9 Check the heating system for proper operation 10 Instruct the User about filling de aerating and the operation of the heating system Remarks The appliance has been provided with an elect...

Page 35: ... freezing of the appliance heat exchanger it has an appliance frost protection When the temperature of the heat exchanger drops to 5ºC the burner will be activated and the pump will start running until the temperature of the heat exchanger reaches10ºC When the system or a part thereof can freeze a frost thermostat should be installed in the area to be protected Connect this according to the wiring...

Page 36: ...e display Note On appliances produced before Nov 07 the red LED is lit and a flashing fault code is shown in the service display The appliance can be restarted by pressing the Reset button for 5 seconds Check the nature of the fault by means of the fault codes under 8 and solve the problem if possible before resetting the appliance 7 2 Settings through the service code The controller of the applia...

Page 37: ... output signal given for CH operation n a 1 output signal given for HW tank operation n a b n a C Step modulation 1 0 step modulation off during CH operation 1 step modulation on during CH operation c Min speed in CH operation 25 Setting range 25 to 50 of fan speed Note For propane or for appliances with flue non return valve set 40 d n a E Min supply temperature during OT demand 10 Setting range ...

Page 38: ... slowly increases while burning modulation by time and decreases as soon as the set supply temperature is reached 7 5 Setting pump position The switch for setting the pump position is located on the connecting box of the CH pump 1 Set the pump position on the basis of the set maximum power and the resistance of the system on the water side See diagram Pressure loss and pump lift type Ups 50 130 po...

Page 39: ... the gas tap 3 Remove the front cover of the appliance 4 Disconnect the coupling 1 above the gas valve and turn the gas mixing pipe 2 backwards 5 Replace the O ring 3 and the gas setting ring 4 by the rings of the conversion set 6 Reassemble in reverse order 7 Open the gas tap 8 Check the gas connections for tightness leaks 9 Switch on the electrical supply to the appliance 10 Change the parameter...

Page 40: ...put by simultaneously pressing the Service and buttons on the operating panel until an L appears on the service display 19 Measure the CO2 value If the CO2 value does not correspond with the value in the table proceed as follows for setting 20 Remove the front cover of the appliance 21 Remove the dust cap A with a torx T15 driver 22 Using a torx driver T15 adjust the setting screw B to the correct...

Page 41: ...ng and setting replace the cover cap A and close the measuring nipple C again 38 Remount the front cover of the appliance Caution Check the measuring nipples used for gas tightness 7 10 Carbon monoxide carbon dioxide ratio Atmos recommends that a carbon dioxide carbon monoxide ratio test is carried out when the boiler is commissioned This is best done when the CO2 content of the flue gasses is mea...

Page 42: ...place boiler sensor S1 and or S2 1 Temperature too high Air in system Pump does not run Too little circulation in system radiators closed pump setting too low 2 Exchange S1 and S2 Check the cable loom Replace S1 or S2 4 No flame signal Gas tap closed Incorrect ignition distance Gas inlet pressure too low or disappears Gas valve or ignition unit does not receive voltage 5 No flame signal Condensate...

Page 43: ...the gas pipe Air in the gas pipe Yes No Inlet pressure too low Yes No No ignition Yes No No spark Yes Ignition unit on gas unit faulty No Gas air control not Yes adjusted properly No Fan faulty Yes No Fan blockage Yes No Gas valve faulty Yes Possible causes 1 The house gas meter may be faulty Inlet pressure too high Yes Contact the gas company No 1 Check the adjustment See Gas air control 1 Replac...

Page 44: ...ermostat weather dependent control not closed or faulty 2 Replace the thermostat Yes 3 Replace the weather dependent control No 1 Check the voltage 2 Check the connector x4 3 Replace defective pump 4 Replace defective controller 1 Replace sensor S1 or S2 See Fault code display 1 or 2 1 See Burner does not ignite Burner does not ignite Yes No Burner does not operate on CH Sensor S1 or S2 faulty Yes...

Page 45: ... system Possible causes 1 Check the setting and adjust if Room thermostat settings not correct Yes necessary set to 0 1 A No 1 Raise the pump setting or replace the pump 1 Check for circulation at least 2 or 3 radiators must be open 1 Adjust the power see Setting maximum CH power 1 Descale or flush the heat exchanger on the CH side No heat transfer due to scaling or pollution in the heat exchanger...

Page 46: ...ate The burner does not need any maintenance Never clean the burner with a brush or compressed air This causes damage to the metal fibre Check the spark ignition probe and gently clean any deposits As the spark gap cannot be checked directly use a flat surface across the corner of the heat exchanger to measure the distance to the probe See the diagram in 8 2 The distance should be in the range 27 ...

Page 47: ...ply flue gas discharge system Inspect the air supply flue discharge system throughout its entirety ensuring that it is in sound condition with no damage to the pipes or joints Inspect the terminals ensuring that they are clear and unobstructed 9 1 6 Checking the gas air control Check the gas air control as given in 7 9 and adjust as necessary 9 1 7 Check the CO CO2 ratio The CO CO2 ratio should be...

Page 48: ... If replacing the ignition block then pull apart as above Remove the push fit cable to the probe and undo the X1 connections at the controller and earth Replace the ignition block and make the connections Note Appliances manufactured after 1st January 2009 have a Torx T10 screw holding the ignition block on the gas valve Remove this screw prior to pulling the ignition unit off 9 2 3 Fan Remove the...

Page 49: ...n tap and drain the system at the lowest point After replacement refill the appliance as given in 6 1 9 2 7 Pressure relief valve Remove the plastic pipe from the safety discharge Undo the pressure sensor capillary and undo the union at the connection with the CH flow pipe Remove the pressure relief valve and inlet pipe Remove the plastic fitting from the discharge and undo the pipe connection to ...

Page 50: ...1 CH operating pressure bar 1 2 see note 2 Max CH water temperature C 90 Other data Gas consumption m3 h 0 85 3 25 Electrical data Mains voltage V 230 Protection class IP44 B IP20 Consumed power full load W 105 Consumed power partial load W 40 Consumed power standby W 2 4 Overall dimensions and weight Height mm 810 Width mm 450 Depth mm 270 Weight kg 39 The maximum CH power is set to 50 of the hig...

Page 51: ...t Available for room stat etc The switched live can also be used for S plan or Y plan circuits note that the 230Vac live to the Wiring Centre must come from the same fused spur as the 230Vac supply to the boiler 3 OpenTherm When using an OpenTherm thermostat 6 7 must not be used 51 ...

Page 52: ...e stipulations of the following directives Machine directive 89 392 EC as amended in directive 93 68 EC Low voltage directive 73 23 EC as amended in directive 93 68 EC Directive concerning gas appliances 90 396 EEG Boilers Efficiency Directive for new oil and gas fired central heating boilers 92 42 EC EMC Directive 89 336 EC as most recently amended in directive 93 68 EC Daventry 5 January 2010 J ...

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