Atag XL140 Installation & Servicing Instructions Manual
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Atag XL140 Installation & Servicing Instructions Manual

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I n s t a l l a t i o n & S e r v i c i n g
Instructions
XL70
XL110
XL140
These instructions are to be retained by the user.

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  • Page 1 I n s t a l l a t i o n & S e r v i c i n g Instructions XL70 XL110 XL140 These instructions are to be retained by the user.
  • Page 2 Version: from sv 4.1 05-2013...

  • Page 3: Table Of Contents

    Content Introduction .............................4 Regulations ............................7 Scope of delivery ............................9 Description ............................10 Installation and mounting ........................11 5.1 Wall-mounted in line ..........................12 5.2 Free-standing in line ........................13 5.3 Free-standing back to back ......................14 5.4 Connecting the boiler ........................15 Hydraulic and gas line system ......................16 6.1 Heating system ..........................16 6.2 Expansion vessel .........................17 6.3 Water quality ..........................17...

  • Page 4: Introduction

    It is advisable to read these instructions thoroughly, well in advance of installation. Separate instructions for use are supplied with the boiler for users of ATAG central heating boilers. ATAG is not liable for the consequences of mistakes or shortcomings which have found their way into the installation instructions or user’s manual.
  • Page 5 20 19 description components figure 1.a heat exchanger 1 (All types OSS4) service valves flow/return (in optional boiler connections set) heat exchanger 2 (XL110: OSS2, XL140:OSS4) fill and drain valve (in optional boiler connections set) ignition unit safety valve (in optional boiler connections set) fan unit flue connection (concentric) damper air supply (for parallel flue connection) gas valve collective flue pipe automatic air vent...
  • Page 6 description components figure 1.b Air supply (for parallel flue connection) Low velocity header Flue/Air supply (concentric) Safety valve 4 bar Gas isolation valve Fill and drain valve Service valves flow and return Automatic air vent low velocity header Non-return valve Pocket for temperature sensor T10 Flow/return header Cascade manager Gas line Frame...

  • Page 7: Regulations

    Installation Manual. Manufacturers instructions must not be taken, in any way, as overriding statutory obligations. The ATAG XL is a central heating boiler for individual or multiple cascade purposes. These boilers must be connected according to these instructions and all installation norms in respect of the part of the boiler to be connected.
  • Page 8 Take note of the following when maintenance or adjustments are needed: The boiler must be able to function during these activities; for this reason, the boiler’s supply voltage, gas pressure and water pressure must be maintained. Ensure that there is not a source of potential danger during these activities. Following maintenance or other activities;...

  • Page 9: Scope Of Delivery

    Scope of delivery The boiler will be delivered ready for use. The delivery package includes the following: • Boiler and housing: • Boiler pump(s); • Cascade control system; • Automatic air vent(s); • Siphon; • Lid ø100 air supply (with screw); •...

  • Page 10: Description

    When installing a single XL boiler or cascaded XL boilers, you should always use a low velocity header adjusted to the set demand. ATAG supplies 2 low ve- locity header versions, which are suitable for a maximum demand of either 452 kW or 960kW (80/60°C) respectively.

  • Page 11: Installation And Mounting

    Figure 5.a measurements in mm If you have opted to build the hydraulic part yourself, then ATAG recommends using a boiler connection set AX00480U (Connection set XL as single boiler) for each boiler. In that case, the connection measurements are: - Flow and return line ø35mm compression fitting...

  • Page 12: Wall-Mounted In Line

    5.1 Wall-mounted in line A . Position the pipe work header against the wall. When using several pipe work head- ers: couple the pipe work headers and supplied gaskets, M12 (DN65) or M16 (DN100) bolts, spring washers and nuts. Align the pipe work header(s) horizontally using the adjustable feet.

  • Page 13: Free-Standing In Line

    5.2 Free-standing in line A . Position the pipe work header in the required location. When using several pipe work headers: couple the pipe work headers using the supplied gaskets, M12 (DN65) or M16 (DN100) bolts, spring washers and nuts. Align the pipe work header(s) horizon- tally using the adjustable feet.

  • Page 14: Free-Standing Back To Back

    5.3 Free-standing back-to-back A. Position the pipe work header in the required location. When using several pipe work headers: couple the pipe work headers with the supplied gaskets, M12 (DN65) or M16 (DN100) bolts, spring washers and nuts. Align the pipe work header(s) horizontally Figure 5.3.a using the adjustable feet.

  • Page 15: Connecting The Boiler

    Flow: 1½" flat coupling x 35mm compression isolation valve with red handle Return: 1½" flat coupling x 35mm compression fitting cross union with Figure 5.4.b fill/drain valve and isolation valve with blue handle The boiler is supplied with a 3 and 4 bar safety valve. ATAG UK recommend fitting the 4 bar safety valve due to the control settings shutting the boiler off at 3.8 bar. Gas: 1¼" x 28mm gas isolation valve Polluted test water may be released when removing the plastic caps on the boiler flow and return.

  • Page 16: Hydraulic And Gas Line System

    Hydraulic and gas pipe line system 6.1 Heating system Install the CH-system in accordance with present legislation. The pipe work headers are available in 2 dimensions, i.e. DN65 and DN100 and are connected to one another by the flange couplings and gaskets, M12 or M16x55 bolts, spring washers and nuts. The low velocity header and the complete installation can then be connected to it.

  • Page 17: Expansion Vessel

    The warranty becomes invalid, if the installation is not being flushed and/or the quality of the filling water does not meet the specifications recommended by ATAG. Always contact ATAG in advance, if things are not clear or you wish to discuss any deviations. Without approval, the warranty becomes invalid.
  • Page 18 Chemical additions are to be avoided and should only be used after ATAG HEATING has approved their corresponding use. Should you wish to achieve the required water quality by using chemical additives, then this is your own responsibility. The warranty on the product delivered by ATAG expires, if the water quality does not meet ATAG´s specifications or the chemical ad-...

  • Page 19: Gas Line

    With regard to new lines in particular, ensure that the gas line does not contain any residual pollution. When the boiler has to be converted from natural gas to LPG, ATAG provides special kits for this purpose. Special instructions are supplied with the kit.

  • Page 20: Condensate Drain

    6.5 Condensate drain All ATAG wall hung gas fired condensing boilers contain a siphonic condensate trap to collect and release condensate. The amount of condensate formed is determined by the type of boilers and the water temperature produced by the boiler. Condensate pipework. Press the supplied plastic ribbon tube onto the condensate drain at the bottom of the boiler (fig. 6.5.a). Connect the tube to the main condensate drain (minimum diameter=...
  • Page 21 Final discharge options. The condensate pipe can only terminate into any one of the five areas as shown in the diagrams on this page. Draining of the condensation water to the external rain guttering is not permitted in view of the danger of freezing. Before putting the boiler into operation fill the siphon with 600 ml of water. A -Condensate from boiler siphon/trap B -Sink with internal overflow C -25mm dia.

  • Page 22: Hot Water Supply

    6.6 Hot water supply The hot water supply control can be connected to the ATAG XL. For connection and settings refer to the Boiler Control chapter. Expansion DHW cylinder circuit When connecting a DHW cylinder to the boiler before the low velocity header an ATAG three way valve is recommended.

  • Page 23: Flue Gas System

    Boiler Class indicated on the boiler’s type plate (Flue category) Locally applicable rules. The supplier’s installation instructions When in doubt or if you have any questions, always contact ATAG HEATING. The boiler can be fitted with a parallel connected flue gas outlet and air supply system (the connection diameter for both channels is ø100mm) or a concentric flue gas outlet and air supply system. In that case, the connection diameter is ø100/150mm. Refer to...

  • Page 24: Parallel Boiler Connection

    7.1 Parallel boiler connection The boiler comes as standard with a parallel connection for the flue gas outlet and air supply system. The air supply opening (1) has a diameter of ø100mm. The air supply channel can be connected to it, or, if it involves an “open device” (Drain- age category B), an air filter must be fitted. The air supply (3) of the concentric part is closed by a lid ø150mm. Figure 7.1.a The flue gas outlet connection (2) has a diameter of ø100mm.

  • Page 25: Connecting The Flue Gas Outlet/Air Supply System

    RV15RPS0 Roof terminal Ø100 - 150 PP - MZ RV15WPS0 Wall terminal Ø100 - 150 PP - MW The flue gas systems described in this document are solely suited for ATAG central heating boilers. For this purpose the CE Certificate has been supplemented under the Gastec nr: 0063BQ3021, 0063BT3195 and 0063CM3648. The flue gas system should be built up using only ATAG Duopass program products. Combinations with other brands or systems, without permission in writing from ATAG Heating UK, are not allowed.
  • Page 26 Possible warranty claims will not be honoured if incorrect changes result in non compliance with the installation manual or local rules and regulations. The terminal should be located where dispersal of combustion products is not unimpeded and with due regard for the damage or discolouration that might occur to parts of the building in the vicinity (see fig 7.4.a).
  • Page 27 87° bend resistance length -2,1 in there are 2 x 45° bends, so 45° bend resistance length the maximum flue gas length XL140 Maximum straight lenth 100 87° bend resistance length -2,1 25 – ( 2 x -1.3) = 22.4 meters.

  • Page 28: Collective Flue Gas Outlet

    In the case of collective venting of flue gases, the flue gas-venting outlet always has to end up in the open area (outlet area 1). ATAG Heating UK can supply a collective flue gas outlet system for the ATAG XL. Re- fer to the following chapters with regard to the various possibilities and maximum pipe lengths that can be used.
  • Page 29 7.5.1 Collective flue gas outlet under-pressure Diameter and venting lengths of the flue gas outlet/air supply: Open system, with under-pressure Dimensions cascade flue ATAG XL Open system, underpressure (calculated with thermal draft) Output (P) under atmospheric circumstances. kW at 80/60°C Type XL d = minimum diameter Ø in mm...
  • Page 30 An installation with a collective flue gas outlet over-pressure in combination with individually controlled boilers (e.g. 0-10 V control), where no bus cable AX00600U is connected, is NOT allowed. Diameter and venting lengths of the flue gas outlet/air supply: Open system with over-pressure. Dimensions cascade flue ATAG XL Open system, overpressure, parallel Output (P) kW at 80/60°C Type XL d = minimum diameter Ø...

  • Page 31: Condensate Vent Collective Flue Gas System

    7.6 Condensate vent collective flue gas outlet system Flue gases condensate inside the outlet system. Anticipate approx. 1 litre of con- densate per m3 of natural gas spent on heating. The resulting condensate has to be drained. Therefore, collective flue gas outlet systems have to be fitted with a condensate drain- age facility. Using a plastic siphon, the drainage is connected to the sewage system by means of an open connection.

  • Page 32: Electrical Connections

    Electrical connections The appliance complies with the CE Machinery Directive 89/392/EEC. The EC Low Voltage Directive 72/23/EEC and the EC EMC Directive 89/336/EEC. A 230V -50Hz mains electrical supply is required fused externally at 5A. - A deviation on the grid of 230V (+10% or -15%) and 50Hz The installation must continue to comply with: United Kingdom: the national rules for electrical installations, IEE regulations.
  • Page 33 1. High voltage supply: 16 Connections Position Connection Application Max. On/Off Error General 230V~ 230V Open- signal purpose Therm On/Off 1, 2, 3 Live Neutral Earth Power for boiler. Power cable not supplied 13,5* 230V 230V~ 230V Heat 0-10Volt LWCO demand signal 4, 5, 6...

  • Page 34: External Controls

    When this is achieved the boiler modulates back to maintain the desired temperature and prevents over shoot. If an OpenTherm controller of another brand than ATAG is used, it must be ensured that for certain error messages the heat demand is not omitted. This can result in complete loss of heat production.
  • Page 35 At a heat demand of the 0-10 Volt controller a signal is sent out and varies from 0-10 Volt. On/Off This signal is translated by the ATAG XL to a set value (desired flow water temperature General or load) which is send via the ATAG data bus to the boiler(s). Depending on the Voltage Open- purpose Therm the set value becomes higher or lower.

  • Page 36: Wiring Diagram

    8.2 Wiring diagram T1a (OSS4) 6,3A T 6,3A T 20 10 20 10 6,3A T 6,3A T 10 1 10 1 10 1 18 9 18 9 18 9 figure 8.1.a...
  • Page 37 Connections Item Art.nr. Description Main components Control unit with screen Burner A Control unit Circulation pump Ignition unit on gas block Ignition electrode Ignition cables Flow sensor T1 Water pressure sensor P1 Return sensor T2 Flow sensor T1a Burner B Control unit Circulation pump Ignition unit on gas block...

  • Page 38: Boiler Control

    Boiler control The boiler has a pilot-control. This control takes care of most of the manual settings but also provides numerous settings to adjust the control exactly to the installation and user requirements. Display The LCD screen is backlit. The light is activated by pushing one of the buttons. There are 3 light colours available.

  • Page 39: Operational Status

    9.1 Operational status - Standby Standby. Boiler is ready for operation. - Vent.Phase Ventilation stage Standby - Ignition phase Ignition stage - Burner lit CH Burner active for heating - Burner lit DHW Burner active for hot water - CH T > Tset Burner off on account of too high flow temperature CH - Overrun CH Overrun time pump over CH...

  • Page 40: Commissioning

    9.3 Commissioning Turn the electrical supply on (heating system does not have to be filled); During start-up, a blue screen is displayed: -- NC -- NC Power Up (= start-up screen) Power Up Please wait (under certain circumstances) Address Then you see: Address (= allocation of boiler address) In the case of a cascade installation: Select the correct address and press OK Select for the first boiler 01 (=Master), for the next 02, 03 etc (=Slave) The address can be changed by pushing the + button (increase value) and the – button (decrease value). Once the + or – buttons has been pushed, the value starts flashing.
  • Page 41 The standard read-out offers 3 information screens. Switching to different screen scan be found using the + or - button 1. "Good"- read-out Good with actual day and time (see above) Good we 10:17 2. Operational status Refer to chapter 9.1 for explanation of texts Standby 3. Technical read-out Actual water flow temperature. (T1 in °C) 20.0 °C and water pressure (P in bar). 1.65 bar For XL boilers in cascade For XL boilers in cascade, the bus communication cables between the boilers must be...
  • Page 42 9.4 Setting the maximum flow water temperature with On/Off-control P101 = 0 Setting the maximum flow water temperature with connected outdoor sensor T4 (starting with illuminated display): 1. Press the right arrow button: The display shows: Basic Settings; Basic Settings 2.

  • Page 43: Filling Heating System

    9.5 Filling the heating system When all boilers have been electrically commissioned as described above, then the heating system can be filled. Each boiler is fitted with a filling and drain valve. The filling hose from the water tap is then connected to it. Fill the heating system only with drinking water. Refer to the Water Quality chap- ter for quality requirements of the filling water.

  • Page 44: Basic Settings

    Basic settings Menu structure There are 2 setting levels 1. Basic level (manager/user) Blue screen 2. Setting level (Installer): Green screen With the illumination switched off, first press on one of the buttons to switch the illumination on and then continue with the setting. Having pressed the last but- ton, the blue illumination will switch off after 2 min.
  • Page 45 Menu structure at Setting level With the illumination switched off, first press on one of the buttons to switch the illumination on and then continue with the setting. Having pressed the last button, the green illumination will switch off after 2 min. From the standard read-out, keep both arrow buttons pushed down simultaneously for 2 sec.

  • Page 46: Parameters

    Parameters For operation and menu overview, refer to chapter Boiler control and Basic settings. Basic settings Basic settings factory PARA Description Range setting CH prog CH-program on/off DHW prog DHW-program on/off Pump prg Pump program (frost protection) on/off Timerpr CH Clock program CH on/off Timerp DHW...
  • Page 47 Param Mode Parameter chapter factory PARA Description Range setting Cascade param. Cascade parameters P100 Domestic hot water facility NOTE: 0: no DHW Option 6 and 8 not for Low Temerature 1: Solo boiler with 3-way valve systems, unless separately controlled 2: n.a.
  • Page 48 Boiler param Boiler parameters P100 Domestic hot water facility (visible when boiler address is 2 - 8) 0: no DHW 1: Solo boiler with 3-way valve 2: n.a. 3: Solo boiler with cylinder loading pump P4 and 3-way valve 4: n.a. P102 Cascade flue gas system 0: Flue gas system individual or collective under pressure...
  • Page 49 Number of running hours to go for maintenance interval Ignition Number of times ignition Faults Number of times in error Safety 02017005 Regul. 01017016 03017017 OEM par. 00017xxx xxx: 020 = XL70, 080 = XL110, 140 = XL140...

  • Page 50: Activate Factory Settings

    5. Repeat procedure from point 3 onward. This switches off the functions DHW prog and Pump prog respectively. 6. Press the return button to return to the standard display. ATAG recommends leaving the power switch switched on to ensure that the boiler pump(s) and three-way valve (if fitted) are automatically activated to prevent them from sticking. The frost protection remains active. Leave gas supply open.

  • Page 51: Inspection And Maintenance

    Boiler maintenance is only to be carried out by qualified staff with calibrated equipment. When replacing spare parts only original ATAG Service parts are to be used. For this purpose, please refer to the Service parts list to find article numbers and exploded views.

  • Page 52: Pollution Check

    Press OK; - Press the right arrow button until Airflush is displayed; Press OK; The screen displays Airflush off; Only for XL110 and XL140: Press the right arrow button to select burner A. The exchanger symbol displays the selected burner (AB, A or B) - Open the top test nipple (fig. 13.2.1.a); Measuring point air flow figure 13.2.1.a Connect the hose of the digital pressure meter to the top test nipple of the gas valve.

  • Page 53: Control O

    CO/CO ratio less than 0.004% adjusting screw figure 13.2.2.b Contact ATAG Heating when the measured values is outside this range. End of measuring: - Press the – button until off is displayed (keep pushed down). This ends the procedure for burner A. Only for XL110 and XL140: Press the return button 1x Press the right arrow button to select burner B.

  • Page 54: Maintenance Activities

    Required tools: Cross head screwdriver ATAG T-handle key set with 3 bits (hex key 4mm, hex key 5mm and cross head PZ2) Open end wrench 8mm The following actions have to be taken in order to be able to carry out maintenance: - Switch the device off using the mains switch, Close the gas tap;...
  • Page 55 Pull the complete ventilator unit and heat exchanger’s gas valve forward; Remove the burner cassette (18) from the ventilator unit; Check the burner cassette for wear and tear, pollution and any breakages. Clean the burner cassette with a soft brush and vacuum cleaner. In the case of breakages, always replace the complete burner cassette (18);...
  • Page 56 Ignition electrode Replace the ignition electrode when necessary, but certainly every 4 years. This can be checked by reading out the ionization current. The minimum ionization cur- rent has be greater than 2,0 µA at full capacity. To read out the ionization current follow the instructions: From the standard blue screen display: 1.

  • Page 57: Counter Running Hours

    Siphon (refer to fig. 13.3.j) Place a collector (i.e. a bucket) under the siphon to collect the dirty and aggres- sive condensate water. Wear protective clothing like latex gloves and safety glasses. Dismantle the siphon by unscrewing the siphon cup (H). Check the siphon cup (H), siphon adapter (G) and siphon pipe (I) for pollution.

  • Page 58: Error Report

    Error report On the display, errors found are shown in the form of a message or blocking on a blue screen or an error on a red screen. Blocking This is a temporary error that will sort itself out, or it will block the boiler after several attempts (error) (Except: Bx01sc01 = reset) Error Error implies a blocking of the boiler and can only be solved by a...

  • Page 59: Annex A Technical Specifications

    Annex A Technical specifications Technical specifications Natural gas ATAG XL-Series Boiler type XL70 XL110 XL140 Type heat exchanger OSS4 OSS4 OSS4 OSS2 OSS4 Input Hs CH 68,5 107,9 136,4 Input Hi CH 61,8 97,3 Efficiency class according BED  ...

  • Page 60: Annex B System Water Additives

    ATAG support the use of inhibitors suitable for mixed metal applications that keep the pH level between 6 and 8. Dosage levels as per manufacturers instructions. Preferred inhibitor suppliers are Fernox and Sentinel.

  • Page 61: Annex C Dimensions

    Annex C Dimensions ø150 ø100 ø100 Individual flue: min. 400mm Collective flue: depen- dant on the selected flue sytem. Please contact the supplier ATAG XL-Series Boiler type XL70 XL110 XL140 Concentric flue connection 100/150 100/150 100/150 Parallel flue connection 2x 100 2x 100 2x 100 Gas pipe - g 1 1/4"...
  • Page 62 ATAG XL 2 boilers free-standing in line ATAG XL 3 boilers free-standing back-to-back 1430 1430 1000 ATAG XL 4 boilers free-standing in line 2830 ATAG XL 8 boilers free-standing in line 5630...
  • Page 63 Dimensions flue connections 1430 1000...
  • Page 64 Dimensions low velocity header DN65 until 452kW Dimensions main header G1/2” DN65 / DN100 G3/8” DN65 G1” DN65 DN65 L 2/4 places = 1398mm (DN65/DN100) L 3/6 places = 2098mm (DN65/DN100) DN65 Dimensions low velocity header DN100 until 960kW Dimensions bend DN65 and DN100 G1/2”...
  • Page 65 1 XL boiler, wall hung 2 XL boilers, wall hung, max. 200kW 3/8” 1/2” 1 XL boiler, free-standing 2 XL boilers, free-standing, max. 200kW 1/2” wall hung free standing Number of XL‐boilers (XL70, XL110, XL140) Necessary articles: AX00010U L‐shape frame for back to back alignment AX00020U I‐shape frame for line alignment AX00030U Boiler frame AX00470U Low velocity header for 1 or 2 boilers (max. 200kW) AX00480U Boiler connection set for single boiler AX00600U Bus communication cable...

  • Page 66: Annex D Resistance Table Sensors

    Annex D Resistance table sensors Resistance table sensors Flow sensor T1(a) Return sensor T2 DHW sensor T3 Outside sensor T4 Common flow sensor T10 NTC1k (25°C) NTC10k (25°C) Temperature Resistance Temperature Resistance [°C] [Ohm] [°C] [Ohm] 4.574 55.047 4.358 32.555 4.152 19.873 3.958...

  • Page 67: Annex E Declaration Of Conformity

    Annex E Declaration of conformity CE DECLARATION OF CONFORMITY Hereby declares ATAG Verwarming Nederland BV that, the condensing boiler types: ATAG XL70 XL110 XL140 are in conformity with the following standards: EU Gas Appliance Regulation 2016/426/EU EN 15502-1: 2012 EN 15502-2-1:...

  • Page 68: Annex Benchmark Commissioning Checklist And Service Record

    GAS BOILER SYSTEM COMMISSIONING CHECKLIST This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference. Failuretoinstallandcommissionaccordingtothemanufacturer’sinstructionsandcompletethisBenchmarkCommissioningChecklistwillinvalidatethe warranty.Thisdoesnotaffectthecustomer’sstatutoryrights.
  • Page 69 SERVICE RECORD It is recommended that your heating system is serviced regularly and that the appropriate Service Interval Record is completed. Service Provider BeforecompletingtheappropriateServiceRecordbelow,pleaseensureyouhavecarriedouttheserviceasdescribedinthemanufacturer’sinstructions. Alwaysusethemanufacturer’sspecifiedsparepartwhenreplacingcontrols. SERVICE 01 SERVICE 02 Date: Date: Engineername: Engineername: Companyname: Companyname: TelephoneNo: TelephoneNo: GassaferegisterNo: GassaferegisterNo: Atmax.rate: COppm AND CO ²...
  • Page 72 ATA G H e a t i n g U K L t d . • U n i t 3 • B e a v e r T r a d e P a r k • Q u a r r y L a n e C h i c h e s t e r W e s t S u s s e x P O 1 9 8 N Y Phone: 01243 815 770 •...

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