Groupe Atlantic Varmax 120 Installation, Use And Maintenance Instructions Download Page 43

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18.04.16

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VARMAX -

Installation, Use and Maintenance

7. MAINTENANCE

OPERATIONS

There are two types of maintenance operations:

• yearly maintenance
• 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 quali

professional.

Before carrying out the following operations:

• Switch off the main power
• Close the gas supply shut-off valve.

DANGER:

This boiler's earth bonding is ensured with connecting cables (green/
yellow) and speci

c attachment screws. During any dismantling work,

make sure you reconnect the cables concerned; it is IMPERATIVE to
reuse the original attachment screws.

No. of

paragraph to

consult

Maintenance

every

year

every

three

years

7.2

Veri

cation of the boiler's environment

7.3

Replacing the air

lter matting

7.4

Veri

cation of ignition and ionisation electrodes

7.5

Siphon cleaning

7.6

Checking the combustion circuit's gas-tightness

7.7

Checking combustion quality

7.9

Gas

lter cleaning

7.10

Cleaning exchangers and changing of seals on service doors

7.11

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

Summary of Contents for Varmax 120

Page 1: ... VAUX SITE DE PONT DE VAUX Installation use and maintenance instructions C O L L E C TIVE PROD U C T VARMAX GAS CONDENSING BOILER 120 to 450 kW with modulating burner for natural gas and propane gas Document No 00BNO9061 L 18 04 16 FR EN DE ES IT NL 00BNO3000 ...

Page 2: ......

Page 3: ...s 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 filter and filter 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 refitting the casing doors...

Page 4: ...g 44 7 4 Verification 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 filter 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 9 HYDRAULIC DIAGRAMS AND SETTI...

Page 5: ...18 04 16 Page 5 146 VARMAX Installation Use and Maintenance ...

Page 6: ...g these instructions may cause electrocution 1 3 Qualification of personnel for installing adjusting using and maintaining the equipment Boiler installation adjustment and maintenance operations must be conducted by a qualified 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 ...

Page 7: ...e 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 sludg...

Page 8: ...g by operating at a low power with high primary water flow When the tap water lacks the desired qualities e g high level of hardness water treatment is required The fill 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 calc...

Page 9: ...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 sufficient to check the amount of make up water fill water volume make up w...

Page 10: ...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 benefit through someone responsible for their safety from supervision or prior instruction concerning the use of the appliance Children must...

Page 11: ...2 4 Gas supply pressures INFORMATION The pressures given below must be read at the gas valve inlet Natural gas H G20 G31 Propane gas for relevant models and countries only 20 mbar Nominal pressure mbar 20 37 Minimum pressure mbar 17 25 Maximum pressure mbar 25 45 ...

Page 12: ...tion Use and Maintenance 3 TECHNICAL SPECIFICATIONS 3 1 Dimensions figure 1 Dimensions Condensate removal U0501956 ø X A B 45 mini 60 maxi 3 C D E F G H I J K L M N O P Q ø V ø W ø X ø X ø X ø T ø U ø U B23 B23P L R R S Y Z øAA K AB AC ø 25 ...

Page 13: ...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 Mail thread 2 Flange PN16 DN 65 Flange PN16 DN 80 Flange PN...

Page 14: ...wo 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 fit through doors 800 mm wide without the casing on which means that the following parts must be removed the two fr...

Page 15: ...75 9 19 5 93 0 19 5 108 7 17 1 126 3 27 1 159 6 36 7 191 33 4 Flue gas temperature at Qn Qmin 80 60 C C 60 8 56 9 62 1 57 3 61 0 56 6 62 3 57 7 61 7 58 3 63 4 57 2 62 5 57 4 64 8 57 1 Flue gas temperature at Qn Qmin 50 30 C C 35 7 28 8 37 7 30 2 33 7 30 0 36 9 30 2 36 3 29 8 36 2 28 3 36 7 30 41 7 30 2 Appliance pressure at nominal Qcal B23 Pa 88 108 103 147 132 162 152 203 Inside diameter of flue...

Page 16: ...22 42 142 42 Flue gas mass flow rate at Qn Qmin 50 30 C g s 50 2 17 3 58 7 17 3 80 28 96 28 117 39 136 40 Flue gas temperature at Qn Qmin 80 60 C C 60 3 56 7 62 6 56 7 60 3 57 1 62 2 57 6 63 58 65 4 58 4 Flue gas temperature at Qn Qmin 50 30 C C 34 6 30 6 37 1 28 9 37 1 31 37 29 4 40 29 41 4 31 3 Appliance pressure at nominal Qcal B23 Pa 68 95 102 140 123 165 Inside diameter of flue gas output mm ...

Page 17: ...ithout water kg 340 340 393 393 502 502 592 592 Sound power at Pmax Lw dB A 80 76 77 84 Sound pressure at 1 m at Pmax Lp dB A 65 61 61 68 Temperature of installation room min max C 5 45 Relative humidity of installation room between 5 and 95 Protection level IP20 Maximum altitude of installation m 2000 The sound power level is a laboratory measurement of the emitted sound power but contrary to the...

Page 18: ...d with the boiler Remove the protective air intake label Insert the air filter and attach it to the boiler using the 4 screws supplied with the filter All models Insert the rectangular filter matting between the filter 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 filter clo...

Page 19: ... 180 450 500 320 225 450 500 320 275 450 600 500 263 320 450 600 500 263 390 450 700 500 427 450 450 700 500 427 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 specific regulatory requi...

Page 20: ...and door followed by the right hand door Press the door s lever Put the handle locking system in a vertical position mark 1 4 4 Removing the control panel MMI 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 a...

Page 21: ...control panel 4 5 Removing refitting the casing doors With the doors open remove the pin on the top of the door to be removed Support the door during this operation because once the pin has been removed the door is no longer attached to the boiler When refitting firstly position the bottom of the door on the lug and then the top making sure to fully insert the pin into its housing U0502515 pin lug...

Page 22: ...itting the panels Note It may be necessary to remove the rear side panels in order to fit through doors To do this unscrew the fixing screws which hold the panel onto the boiler s structure and remove the panel 4 7 Removing refitting the top 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 c...

Page 23: ...eps on models 180 and above On models 180 to 320 Open the doors Unfold the step On models 390 and 450 Open the doors Remove the blocking element of the step Unfold the step Pull the lower step figure 11 Installing the step figure 12 Installing the step on models 180 320 U0502519 figure 13 Installing the step on models 390 and 450 U0502519 blocking element of the step ...

Page 24: ...G 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 minimu...

Page 25: ... on the model see opposite Install the diaphragm provided Screw the 4 nuts back in place Check the CO2 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 flange located at the entrance to the gas line on the side nearest the network connection ma...

Page 26: ...e gas line on the side nearest the network connection may require unscrewing 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 VARMAX boilers are approved to be connected to a B23 chimney all models a B23P chimney all models a C13 air ...

Page 27: ...ed so as not to cause condensate retention Check that the fuel gas is extracted via a gas tight duct VARMAXboilersareefficientboilerswithverylowflue gastemperatures as a result to maintain favourable ventilation the ducts must run upwards from the boiler outlet IMPORTANT If several boilers are connected to a single flue check 1 that the flue is not under pressure when all the boilers are in operat...

Page 28: ... to a B23P chimney Type B23P connection Air coming from the boiler premises extraction of gases through the roof via a pressurised duct IMPORTANT For the B23P type connection it is MANDATORY to use ducts which have pressurised duct certification such as CONDENSOR Poujoulat or rigid or flexible CHEMILUX CONDENSATION Ubbink IMPORTANT The duct extracting combustion products must be sized using the pa...

Page 29: ...s of a POUJOULAT system Condensor type figure 18 B23P Poujoulat sizing recommendations ø connection ø duct H 3 m Height of flue gas duct H in linear metres lm operating at 50 30 C ø connection 150 mm 180 mm 200 mm ø duct 130 mm 150 mm 180 mm 200 mm Type of gas G20 G31 G20 G31 G20 G31 G20 G31 MODELS 120 79 60 140 87 39 180 74 23 225 69 20 275 100 73 320 100 64 390 100 450 100 IMPORTANT The above va...

Page 30: ...e weight of flue gas ducts must not be supported by the boiler 4 10 3 Rules for installing air vent terminals Please refer to national standards and regulations Height of flue gas duct H in linear metres lm operating at 50 30 C duct ø 160 mm rigid flexible Type of gas G20 G31 G20 G31 MODELS 120 100 100 100 86 140 100 100 86 65 180 64 32 30 225 58 40 28 IMPORTANT The above values are provided for i...

Page 31: ... C13 or C33 configuration requires use of the Terminal kit comprising a terminal a dual flow adaptor and a male adaptor ø150 female adaptor ø160 reference 041421 figure 20 Type C13 connection figure 21 Type C33 connection The table below shows the maximum straight lengths authorised for air and flue gas ducts MODELS 120 140 180 225 L1 air 16 5 lm 13 5 lm L2 flue gases 17 5 lm 14 5 lm The lengths i...

Page 32: ...ths given include the lengths of the flue 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 el...

Page 33: ... avoid the risk of rainwater in the boiler To facilitate mounting flue gas ducts for models 120 to 225 coat the joints in liquid soap or a suitable grease provided in the terminal kit figure 22 Type C53 connection VARMAX models 120 to 225 figure 23 Type C53 connection VARMAX models 275 to 450 IMPORTANT The weight of flue gas ducts must not be supported by the boiler U0501496 U0501350 L2 L1 L1 L2 ø...

Page 34: ...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 fit the boiler and its installation with the f...

Page 35: ...VARMAX boilers are fitted with 2 internal water circuits allowing separation of high temperature returns coming from DHW preparation circuits radiators etc from low temperature circuits underfloor heating circuits low temperature radiator circuits etc In some installations additional improvement may be obtained using 4 tappings This separates the condenser low temperatures from the main exchanger ...

Page 36: ...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 WARNING The boiler s gas line connection must not be subject to any mechanical stress risk of loss of gas tightness of the gas val...

Page 37: ...the boiler The control panel is on the upper front left of the boiler Unscrew the turn screw at the bottom of the cover Lift up the cover and pull backwards 4 13 2 Cable bushing 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 t...

Page 38: ...tructions provided with the accessory reference 059751 figure 29 AVS75 location U0501963 AVS75 location behind side door 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 7...

Page 39: ... L2 N L3 N L3 L1 N L N L N 1 2 1 2 1 2 3 1 2 0 10V HMI B8 AVS75 x 3 B2 B7 00BET9008_C X50 AVS75 X11 OCI 345 X30 L2A L2B N1A N1B OCI 345 230 V M AVS75 x 3 X50 QAC 34 QAZ 36 QAD 36 QAD 36 QAA 75 x 3 NAVISTEM B3000 X11 OCI 345 QAA 75 x 3 DB MB G CL CL L N 0 10V QAC 34 QAZ 36 QAD 36 QAD 36 230 V M L N ...

Page 40: ...ter 9529 the boiler power locking function is therefore no longer active MODELS Parameter 9529 value 120 140 180 225 275 320 390 450 power locked 4610 5300 3180 3870 3360 3930 3440 3900 power unlocked 6490 7460 4410 5400 4620 5450 4810 5480 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...

Page 41: ...lisateur 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 flue gas analyser via a sample taken from the flue outlet see diagram opposite CO2 value range G20 at Qmin 8 3 CO2 8 7 at Qmax 8 8 CO2 9 2 G31 at Qmin 9 8 CO2 10 2 at Qmax 10 4 CO2 10 8 4 Adjust the boiler s...

Page 42: ...upply 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...

Page 43: ...sured with connecting cables green yellow and specific attachment screws During any dismantling work make sure you reconnect the cables concerned it is IMPERATIVE to reuse the original attachment screws No of paragraph to consult Maintenance every year every three years 7 2 Verification of the boiler s environment X 7 3 Replacing the air filter matting X 7 4 Verification of ignition and ionisation...

Page 44: ...e air filter matting DANGER To make sure this task is performed in safety switch off the boiler and cut off the upstream power Main exchanger drain valve front of boiler Condenser drain valve rear of boiler U0502206 figure 32 Drain valves 7 1 Boiler draining Close the shut off valves of the flow and return tappings Connect the drain valves main exchanger and condenser to the drain with a suitable ...

Page 45: ...link between both ends of the matting is under one of the mountings For models 390 and 450 insert the square filter cloth on the back gate of the filter 7 4 Verification of ignition and ionisation electrodes 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 wi...

Page 46: ...ovement of the float ball Also check that the seal is not damaged 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 speed obtained by disconnecting the PWM signal connector...

Page 47: ...cumstances 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 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 exchange...

Page 48: ...aximum power Using the combustion analyser measure the rate of CO2 in the flue gases in the flue outlet see figure 39 Check the CO2 value at Maximum power and if necessary manipulate the valve s gas throughput adjustment screw to obtain CO2 values between 8 8 and 9 2 or between 10 4 and 10 8 G31 Move to Minimum power and check that the CO2 value is between 8 3 and 8 7 G20 or between 9 8 and 10 2 G...

Page 49: ...lve must be taken using the pressures indicated Pvalve and Pupstream see diagram opposite figure 41 Gas valve setting Cover Offset regulator Hexagonal 3 mm wrench Pvalve Pupstream 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 ...

Page 50: ...een 8 8 and 9 2 G20 or between 10 4 and 10 8 G31 Then switch to minimum power Adjust the offset regulator see figure 41 to get a CO2 rate at minimum power between 8 3 and 8 7 G20 or between 9 8 and 10 2 G31 Use a flat 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 CO2 rate in the flue gas...

Page 51: ...lose the 2 flue gas baffle strappings mark 2 Remove the 2 strappings mark them in some way so that you can refit them in the same order and then remove the flue gas baffles marks 3 Mark these too so that you can refit them in the same position Cleaning baffles and exchangers Brush the flue gas baffles with a stainless steel or plastic brush so as not to geometrically deform them Clean by brushing ...

Page 52: ...e strappings Tighten the fastenings and ensure the baffles are correctly fitted to the exchanger tubes and check that each of the baffles are correctly fitted on the exchanger tubes at their lower and upper ends Note It is normal that the baffles are not fitted tightly in the area between the 2 strappings Checking gas tightness After refitting the 3 service doors tightening torque of screws 15 N m...

Page 53: ...hapter 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 flange and compress on it by pressing down removable part spool piece cover figure 48 Removable upper door figure 49 Removal of spool piece co...

Page 54: ... 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 refitting WARNING When removing the burner tube be careful not to rub metal mesh against the spool piece Cleaning the burner tube Suck out the entire surface in metal mesh using a vacuum cleaner U0502459 gas tube figure 51 Positions of the fastening clamps P...

Page 55: ...on the clamp the word UP must be visible and the inner lug must be positioned on the rear axis of the boiler see figure 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 figure 47 Check the seal on the spool piece s cover and replace if necessary Position the cover over the s...

Page 56: ...roduct 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 ...

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