Atlantic Boilers VF Series Installation & Maintenance Manual
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Atlantic Boilers VF Series Installation & Maintenance Manual

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VF SERIES
GAS CONDENSING BOILER
INSTALLATION & MAINTENANCE MANUAL
MODELS 40 - 60 - 80 - 100
ATLANTIC 2000 - boilerplant sales ACM ATLANTIC - commissioning and maintenance ATLANTIC 4422 – spares
Atlantic 2000 Registered in England Company No: 1477687 Vat Reg No: 306 0653 89
PO BOX 11, ASHTON UNDER LYNE, OL6 7TR T: 0161 621 5960 E: technical@atlanticboilers.com www.atlanticboilers.com

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  • Page 1 VF SERIES GAS CONDENSING BOILER INSTALLATION & MAINTENANCE MANUAL MODELS 40 - 60 - 80 - 100 ATLANTIC 2000 - boilerplant sales ACM ATLANTIC - commissioning and maintenance ATLANTIC 4422 – spares Atlantic 2000 Registered in England Company No: 1477687 Vat Reg No: 306 0653 89...

  • Page 2: Table Of Contents

    CONTENTS 1. WARNINGS AND RECOMMENDATIONS ................5 1.1. Transport and storage ........................... 5 1.2. Symbols used in this document........................5 1.3. Qualifi cation of personnel for installing, adjusting, using and maintaining the equipment ......5 1.4. Safety instructions ............................6 1.5.

  • Page 3: Warnings And Recommendations

    1. WARNINGS AND RECOMMENDATIONS PLEASE READ THIS MANUAL CAREFULLY BEFORE INSTALLING, CARRYING OUT MAINTENANCE AND USING THE BOILER. IT CONTAINS IMPORTANT SAFETY INFORMATION. 1.1. Transport and storage 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%;...

  • Page 4: Safety Instructions

    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. If you smell gas: •...
  • Page 5 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). 1.5.2.
  • Page 6 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...

  • Page 7: Approvals

    2. APPROVALS 2.1. Compliance with European Directives - Low voltage (2006/95/EC) 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...

  • Page 8: Gas Supply Pressures

    1.7. Gas supply pressures The pressures given below should be measured at the input to the INFORMATION: gas valve. H G20 natural gas propane Nominal pressure (mbar) Minimum pressure (mbar) Maximum pressure (mbar) Page 10 / 130 00RNO0182-#...

  • Page 9: Technical Specifications

    3. TECHNICAL SPECIFICATIONS 3.1. Dimensions Ø Q Ø R Ø S Ø T Ø V Ø U Ø W U0561520-# fi gure 1 - Dimensional characteristics 18.03.2016 Page 11 / 130...
  • Page 10 MODELS 40 kW 60 kW 80 kW 100 kW 120 kW (mm) (mm) (mm) (mm) (mm) 66,5 (mm) 12,3 (mm) 103,5 (mm) 85,5 (mm) (mm) (mm) (mm) (mm) 242,5 (mm) 143,5 (mm) Ø Q G 1"1/4 Heating return connection Ø R G 1"...

  • Page 11: Boiler Components

    3.2. Boiler components Gas valve Ionisation electrode Ignition electrode Ignition transformer Fume temperature sensor Bleed valve Water return temperature sensor Flowmeter Water outlet temperature sensor Pressure sensor Anti-return fl ap Condensate siphon (supplied unmounted) User interface control panel NAVISTEM B3000 unit Air pressure switch Safety thermostat U0561578-#...
  • Page 12 Gas valve Ionisation electrode Ignition electrode Ignition transformer Fume temperature sensor Bleed valve Water return temperature sensor Flowmeter Water outlet temperature sensor Pressure sensor Anti-return fl ap Condensate siphon (supplied unmounted) User interface control panel NAVISTEM B3000 unit Air pressure switch Safety thermostat CEM fi...

  • Page 13: Combustion At 15°C And 1013 Mbar

    3.3. Combustion at 15°C and 1013 mbar 3.3.1. G20 natural gas MODELS 40 kW 60 kW 80 kW 100 kW 120 kW Nominal power Pn (80/60°C) 40,0 56,4 79,8 95,7 119,5 Nominal power when condensing P (50/30°C) 43,0 61,0 87,5 104,5 129,5 Minimal power Pn (80/60°C)
  • Page 14 3.3.2. G31 Propane Gas (for relevant models) MODELS 40 kW 60 kW 80 kW 100 kW Nominal power Pn (80/60°C) 40,0 56,4 79,8 95,7 Nominal power when condensing P (50/30°C) 42,1 59,7 85,6 102,3 Minimal power Pn (80/60°C) 11,5 31,9 33,5 Nominal heat input Qn 41,2...

  • Page 15: Conditions Of Use

    3.4. Conditions of use MODELS 40 kW 60 kW 80 kW 100 kW 120 kW Maximum start setting temperature °C Safety temperature °C 4000 Maximum service pressure (bar) 1000 Minimum cold pressure (bar) Nominal water fl ow rate Minimal water fl ow rate Water content 10,2 12,8...

  • Page 16: Installation

    4. INSTALLATION The boiler must not bear the weight of the accessories and connections IMPORTANT: (hydraulics, gas, exhaust system, etc.). 4.1. Installing the boiler VARFREE boilers must not be mounted on a wall covered with an infl ammable material: plastic, wood, etc.

  • Page 17: Removing / Installing The Front Panels

    4.2. Removing / installing the front panels  Pull the bottom of the panel forwards to release.  Pull the top of the panel forwards to release.  Remove the panel.  Do the opposite to install the panel.  ...
  • Page 18 4.3.1. Connection to a B23 chimney B23 type connection: Air from the installation premises, gas evacuation through the roof via a natural draft pipe. Check that the boiler installation premises have high and low IMPORTANT: ventilation, that it conforms to current regulations and that it is not obstructed.
  • Page 19   Filtering cloth A indicates the minimum upper position of the chimney adapter when fully inserted relative to the ground. B indicates the height of the of the chimney adapter when fully inserted relative to the upper panel of the boiler. U0561516-# fi...
  • Page 20 The combustion product extraction duct must be dimensioned by using the parameters set out in the table in chapter 3.3. Depending on the actual confi guration of the duct, a calculation is IMPORTANT: required to check that the pressures at the boiler outlet at Qmin, Qall and Qn do not exceed the maximum allowable values in this table.
  • Page 21 4.3.3. Connection to a C13 or C33 suction pipe C13 type connection: Air inlet and gas evacuation through concentric ducts connected to a horizontal concentric terminal (suction pipe). C33 type connection: Air inlet and gas evacuation through concentric ducts connected to a vertical concentric terminal.
  • Page 22 VARFREE 40 kW 60 kW 80 kW 100 kW 120 kW Terminal C13 040946 040987 Suction Ø Concentric 80/125 Concentric 100/150 duct pipe A min (mm) 1948 1995 horizontal type C13 Lmax (m) Terminal C33 black 040947 040988 Suction Terminal C33 ochre 040948 pipe Ø...
  • Page 23 fi gure 9 - C53 type connection VARFREE 40 kW 60 kW 80 kW 100 kW 120 kW Ø Separeted 80/80 Separeted 100/100 duct A min (mm) 2194 2240 Gas (L1) Air (L2) lengths Gas (L1) Air (L2) In calculating the duct length take the following rules into account: - 90°...

  • Page 24: Gas Connection

    4.3.5. 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 acid and thus aggressive (pH between 3 and 5). Use a suffi cient slope of the order of 3% to ensure correct fl ow of the condensates.

  • Page 25: Gas Change (G20 To G31, Only 40 Kw To 100 Kw)

    4.5. Gas change (G20 to G31, only 40 kW to 100 kW) This VARFREE boiler has been adjusted in the factory to work with group H (type G20) natural gas with a supply pressure of 20 mbar. Any operations involving changing the type of gas used must be IMPORTANT: performed by a qualifi...
  • Page 26 Scew (x4) Propane injector ø Vanne gaz 80 kW : ø 100 kW : Ecrou fi gure 10 - Installing the propane injector Always replace the washers on the two nuts. IMPORTANT: Check the seals. 4.5.2. Changing the ignition, pre-ventilation, minimum and maximum speeds Place the boiler in standby mode (see §...
  • Page 27 4.5.3. Adjustment of the gas valve - Before starting the burner, on the gas valve, preset the gas fl ow rate, using the gas fl ow rate adjustment screw R1, to the appropriate value given in the table below. - Start the burner at maximum power. - Using a combustion analyser, measure the CO ratio in the exhaust gases: on the gas duct, remove the plug from the opening and insert the...

  • Page 28: Hydraulic Connection

    Door open Checking the door pre-setting closed settings Model Pre-adjustment of the gas fl ow Indicative Indicative adjusting screw R1 Pmax Pmin Pmax Pmin 9,0 - 9,2 8,6 - 8,8 9,1 - 9,3 8,7 - 8,9 60 kW Screw R1 3 turns 3/4 10,2 - 10,4 9,8 - 10,0 10,3 - 10,5 9,9 - 10,1 Screw R2 1/4 turn 9,0 - 9,2...
  • Page 29 VARFREE - Installation, Commisioning and Servicing Instructions The boilers are equipped with the following elements: • an anti-return fl ap, • a manual drain tap, • a fl ow rate controller. It is imperative to fi t the boiler and its installation with the following components: •...

  • Page 30: Electrical Connection

    4.7. Electrical connection Always check that the electric power supply is switched off before WARNING: working on the boiler. It is mandatory to connect this boiler correctly to earth and to comply with standard for low-voltage electrical installations. Provide a two-pole circuit breaker upstream of the boiler (distance IMPORTANT: between contacts: 3.5 mm minimum).
  • Page 31 4.7.2. Cable ways Use the packing glands beneath the boiler to pass the cables to the various terminals of the NAVISTEM B3000. View from inside the control panel Rear of the boiler Three packing glands for the signal connections (sensors, communications bus, etc.). Eight packing glands for the power connections (alarm reports, heating circuit circulation pumps, domestic hot water circulation pump, mixer valves, etc.).
  • Page 32 VARFREE - Installation, Commisioning and Servicing Instructions 4.7.3. Wiring diagram Ionisation electrode Ignition Ignition electrode Air pressure transformer switch Gas valve Body 80 to 120 Body 40 and 60 Rear thermal fuse Thermal fuse Flow sensor Return sensor Front protective cover Flue-gas sensor Safety thermostat...
  • Page 33 4.7.4. Connection to the terminals of the NAVISTEM B3000 boiler controller To connect the NAVISTEM B3000 boiler controller, please refer to the installation and user manual. 4.7.5. Connection of the boiler circulation pump (compulsory accessory) 4.7.5.1. Accessory supplied by YGNIS If the accessory is supplied by YGNIS, please refer to the installation manual for the connection of the boiler circulation pump.

  • Page 34: First Use

    5. FIRST USE 5.1. Checks before fi rst use Check that the cold pressure is a minimum of 1 bar. If this is a boiler house renovation, ensure that fl ushing and if necessary silt removal from the installation have been correctly done (see chapter 1.5, page 5 of this manual).

  • Page 35: Checks After Commissioning

    6. CHECKS AFTER COMMISSIONING 6.1. Condensate removal Check that the removal of condensates is not obstructed on either the boiler side or 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.

  • Page 36: Maintenance Operations

    7. MAINTENANCE OPERATIONS These operations must be carried out by a qualifi ed professional. Before performing the following operations: • Switch off the main circuit breaker. • Close the gas supply isolation valve. • Isolate the boiler hydraulically. Clean the exchanger (see details in the next chapter) Check tube sooting visually.

  • Page 37: Annual Checks

    7.2. Annual checks • Switch off the electric power supply of the boiler, • Close the gas supply, • Remove the front panel (see § 4.2, page 16). Protect all the electric connectors inside the control panel when WARNING: working on the boiler hydraulics (risk of splashing). •...
  • Page 38 • Check the geometry of the electrodes, alumina deposits and the appearance of the ceramic and the seals. Replace the electrodes and the seals if they are damaged. • Clean the siphon and check that the condensate fl ows freely through it. The siphon must be fi lled after maintenance.

  • Page 39: End-Of-Life Cycle Of The Apparatus

    8. END-OF-LIFE CYCLE 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...

This manual is also suitable for:

Varfree 40Varfree 60Varfree 80Varfree 100Varfree 120

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