Atmos InterCombi HE32 Installation And Servicing Instructions
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- Page 1 Atmos InterCombi Installation & Servicing Instructions for HE32 (GC 47-249-01) 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 © 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.
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Page 3: Table Of Contents
TABLE OF CONTENTS 1. Safety Regulations General ..................................7 CH system...................................7 Gas system .................................7 Electrical system .................................7 Domestic water system ...............................7 Flue discharge and air supply .............................7 2. Description of the Appliance General ..................................8 Operation ..................................8 Operating conditions ..............................8 PC interface ................................10 Test programmes ..............................11 3. - Page 4 Burner resonates...............................46 No heating (CH) ................................46 Reduced output.................................47 CH does not reach the correct temperature......................47 No hot water (HW) ..............................47 Hot water does not reach the correct temperature....................48 9. SERVICING THE BOILER AND COMPONENT REPLACEMENT SERVICING THE BOILER ............................49 COMPONENT REPLACEMENT..........................51 10.
- Page 5 This manual Using this manual you can safely install and maintain this appliance. Carefully follow the instructions. In case of doubt, contact Atmos Heating Systems. Keep these instructions near the appliance. Abbreviations and names used Description To be referred to as High Efficiency Atmos InterCombi wall-mounted gas heater Appliance...
- Page 6 Atmos Warranty – Short version 1. Atmos Warranty is against any material, construction or operation faults that are found to be of original manufacturing origin. A full statement of the Atmos Warranty is available (www.atmos.uk.com or 01327 871990). 2. Atmos boiler warranty is, subject to conditions; two years from date of invoice, or 12 months from date of installation;...
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Page 7: Safety Regulations
SAFETY REGULATIONS The appliance must be installed in accordance with the Gas Safety (Installation and Use) Regulations; October 1994. Failure to install appliances correctly could lead to prosecution. Atmos Heating Systems does not accept any liability for damage or injury caused by not (strictly) observing the current safety regulations and instructions, nor by negligence while installing the Atmos InterCombi wall- mounted gas heater and any accompanying accessories. -
Page 8: Description Of The Appliance
DESCRIPTION OF THE APPLIANCE General The Atmos InterCombi wall-mounted gas boiler is designed for delivering heat to the water of a CH system and the domestic hot water. The air supply and flue discharge can be connected to the appliance by means of two separate pipes or a concentric connection. - Page 9 Waiting position The LED of the on/off button and if necessary one of the LED’s of the domestic hot water Keep hot function are on. The appliance is ready for responding to the demand for CH or domestic hot water. 0 Pump overrun After the operation of the CH, the pump has an overrun.
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Page 10: Pc Interface
determined by the weather dependent control programmed in the controller. During CH operation, the demanded CH supply temperature is displayed on the operating panel. During CH operation, the actual CH supply temperature can be read by pressing the service button. Note: Instead of an on/off thermostat, an OpenTherm thermostat can be connected to the controller as described in §5.4.1. -
Page 11: Test Programmes
Test programmes In the controller, there is provision for putting the appliance into a test status. By activating a test programme, the appliance will become active with a fixed fan speed without intervention of the control functions. The safety functions remain active though. Simultaneously press + and –... -
Page 12: Main Components
MAIN COMPONENTS CH pump Flue discharge (or concentric connection) Gas valve Connecting block / terminal list X Clamping plate Condensate discharge Supply sensor S1 Hot water sensor S3 Return sensor S2 Condensate trap Heat exchanger Hot water flow switch Controller operating panel and display Pressure gauge Ionisation/ignition probe 1m connecting cable 230 V ~... -
Page 13: Accessories
Accessories Description Part Ref Pipe mounting bracket 092.537 Connection supply and return 22 mm diameter • Connection cold and hot water 15 mm diameter • Connection gas ½" female thread • Mounting strip boiler • Bag with fixings • Rear mounting frame for top pipe connection 092507 Bottom Pipework cover 092527... -
Page 14: Installation
INSTALLATION Overall dimensions CH flow 22 mm diameter 670mm InterCombi HE 32 CH return 22 mm diameter 15 mm diameter 810mm InterCombi HE 32 Cold water 15 mm diameter Domestic hot water 15 mm diameter Flue gas outlet 80 mm diameter Condensate 32 mm dia (after trap 25 mm dia flexible) Air supply inlet... -
Page 15: Unpacking The Appliance
Unpacking the appliance 1. Unpack the appliance. 2. Check the content of the packaging. This consists of:- • Appliance (A) • Mounting strip (B) • Condensate trap (C) • Installation Instructions • User Operating Instructions • Warranty card 3. Valve set (supplied separately with boiler) comprising 2 x 22mm isolation valves, 1 x 15mm isolation valve with blue lever (for cold water), 1 x gas valve. -
Page 16: Boiler Location
Boiler location Clearances Above casing 200mm min Below casing 230mm min 30mm min 30mm min (in operation) 140mm min (servicing) Front 30mm min (in operation) Front 450mm min (servicing) Keep 50 mm free space above the front panel in order to be able to remove the front panel from the casing. -
Page 17: Mounting And General Information
Mounting and General Information Depending on the mounting option ordered, the following mounting methods are available:- Mounting strip (A) alone, OR mounting strip (A) and optional pipe mounting bracket (B), OR rear mounting frame (C) and pipe mounting bracket (B), which are both optional items. -
Page 18: Mount The Appliance
4.5.4 Installation connections 1. Make the various connections to the valves (see diagram). 2. Install a filling loop (not supplied) between the cold water inlet pipe and the CH return connection. 3. For most installations, the flexible tube for the safety discharge will be long enough to fit into the condensate discharge waste pipe (see below). -
Page 19: Condensate Disposal
Condensate disposal The appliance is provided with a 25 mm flexible pipe from its condensate trap. As given in §4.6, this should be inserted into an open waste pipe of not less than 32 mm diameter, together with the safety discharge pipe. -
Page 20: Connections
CONNECTIONS Connect the CH system 1. Flush the CH system thoroughly. 2. Mount the flow and return pipes to the mounting bracket. All pipes must be mounted tension-free in order to avoid ticking of the pipes. Existing connections must not be twisted in order to avoid leaks at the connections with the external pipes. -
Page 21: Hot Water System
5.1.4 Underfloor heating For a good operation of the domestic hot water supply, there must be no undesired circulation through the appliance caused by a second pump of the CH circuit. Connect underfloor heating with an electric shut-off valve (two-way valve) to prevent circulation through the appliance when there is no demand for central heating. -
Page 22: Connecting The Gas Supply
Connecting the gas supply 1. Connect the appliance gas valve to the gas pipe. 2. Check the boiler's data plate to ensure that the appliance has been set for the correct gas supply. The boiler is supplied for Natural Gas (G20). - Page 23 Controller Label and Associated Terminals Note: Terminals X4/11 & 12 are available for OpenTherm modulating stat. 5.4.1 24V dc Electrical connections dc Terminals X4 Description Connector X4 Remarks Room stat 6 - 7 6= +24Vdc Outside temp 8 - 9 sensor OpenTherm 11 - 12...
- Page 24 5.4.3 Outside temperature sensor (Weather compensation option) The appliance has a connection for an outside temperature sensor. The outside temperature sensor can be applied in combination with an on/off room thermostat or time clock. If not using either of these, a wire link must be made across X4/6 &...
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Page 25: General Flue Requirements
General Flue Requirements 5.5.1 Flue terminal clearances The flue terminal must be sited with minimum clearance distances as shown in the diagram. A terminal guard must be fitted if the terminal is sited less than 2m above ground level, or above a balcony, or accessible flat roof. -
Page 26: Flue Discharge And Air Supply
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. - Page 27 Mounting 60/100mm horizontal concentric terminal 1. Drill hole of diameter 110 mm or larger hole. 2. Cut the terminal to the length required. 3. Slide the terminal into the opening and fit rosettes to cover the opening. 4. Ensure the pipes slope back to the appliance. An alternative telescopic 60/100 horizontal concentric terminal is available from Atmos.
- Page 28 5.6.3 Vertical Concentric connection Straight adapters are available for either 60/100mm or 80/125mm systems. IMPORTANT! Using the concentric adapter set (see photo), the standard two-pipe connection can be changed into a concentric connection. 1. Seal the open air supply connections in the appliance with the sealing cap delivered with the set (item C in photo).
- Page 29 80/125mm Concentric extension for balcony outlet When the free outlet is hindered by an eave, balcony, gallery or anything else, the concentric terminal must be extended to at least the front side of the overhanging part (see diagram). Table of Atmos 80/125mm concentric flue equivalent lengths Maximum equivalent concentric length allowed is 27 metres (Note: Includes an allowance for the terminal;...
- Page 30 5.6.6 80mm twin pipe flue system Refer to the Atmos Price List for the full list of flue components. Terminal The flue discharge at the terminal must be at least 75mm in front of the air intake and the distance between the two pipes at least 75mm.
- Page 31 5.6.7 Plastic twin pipe flue systems NOTE Consult Atmos for these systems. Use of non-approved flue systems will invalidate the guarantee. For special applications, the appliance can be used with plastic flue pipes, which are available from Atmos as follows: PPS.
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Page 32: Roof Outlet Prefabricated Chimney
Roof outlet prefabricated chimney Appliance category: C33 When there is little space in a shaft, a roof outlet through a prefabricated chimney may be necessary. The prefabricated chimney must comply with the minimum lengths shown. The supplier must guarantee the proper operation of the prefabricated chimney with respect to wind attack, ice formation, rain ingress, etc. -
Page 33: Atmos Ms System
Atmos MS System Appliance category: C53 (individual vertical flue and separate horizontal air inlet). CAUTION The air supply (A) in the outside wall must be provided with an Atmos inlet grid. Flue terminals (B) can be individual, or common terminals can be provided for groups of up to 6 flues. -
Page 34: Atmos Communal Flue System (Cfs)
Atmos Communal Flue System (CFS) A design service is provided for each application. There are different configurations possible and the main ones are illustrated. CFS-NV Naturally ventilated, working under negative pressure CFS-FA Fan assisted, working under positive pressure – smaller diameter pipes are used 5.9.1 Atmos CFS... -
Page 35: Commissioning
COMMISSIONING Note The appliance must be installed and commissioned in accordance with the Fill and de-aerate the appliance and the system manufacturer’s instructions in order to comply with the Building Regs. To demonstrate WARNING compliance, the Benchmark Checklist (located at the back of this Manual) should be Connect the appliance to the mains voltage only after completed and signed at the time of filling and de-aerating! -
Page 36: Commissioning Of The Appliance
Commissioning of the appliance After having carried out the above operations, the appliance can be commissioned. 1. Switch on the electrical supply to the appliance. The appliance may carry out a self-test as determined by the controller: 2 (on service display). After completing the self-test, a horizontal mark will appear in the service display: - . -
Page 37: System Shutdown
System Shutdown CAUTION Drain the appliance and the system when the mains voltage has been disconnected and there is a chance of freezing. 1. Drain the appliance using the drain tap. 2. Drain the system at the lowest point. 3. Close the main valve for the cold water supply to the boiler. 4. -
Page 38: Setting And Adjustment
SETTING AND ADJUSTMENT The functioning of the appliance is mainly determined by the (parameter) setting in the appliance controller. A part of this can be set directly via the operating panel, while another part requires an Installer code to be entered before settings can be changed. -
Page 39: Parameters
Parameters Parameter Setting Factory Description setting InterCombi Note: Appliances produced before Nov 07 had earlier version of HE 32 s/w (c not included, and d = minimum speed). Service code [15] Access to installer settings. The service code must be entered (=15). -
Page 40: Setting Maximum Ch Power
Setting maximum CH power The maximum CH power is set to 50% in the factory. When the CH system requires more or less power, the maximum CH power can be changed by adjusting the fan speed. See table: Setting CH power. This table gives the relation between the fan speed and the appliance power. -
Page 41: Weather-Dependent Control
Weather-dependent control T supply °C When the outside sensor is connected, the supply temperature is automatically controlled dependent on the outside temperature in accordance with the set control line. The T set CH (= CH supply temperature) is set via the temperature display. -
Page 42: Setting Gas-Air Control
In case of any alterations, replacement of the gas valve or conversion to another gas type, the control must be checked and reset if necessary according to the table below:- Gas type Natural gas H Propane P Gas category 2H G20 3P G31 (propane) % at low position (L) 8.8 –... -
Page 43: Carbon Monoxide : Carbon Dioxide Ratio
13. Exit the test mode by simultaneously pressing the “+” and “–“ buttons on the operating panel. Replace the dust cap (A) and close the flue gas measuring nipple. 14. Remount the front cover of the appliance. Caution: Check the measuring nipples used for gas tightness. Caution: On windy days or on installations with a long flue run it is necessary to replace the front cover of the boiler in order to obtain an accurate CO measurement... -
Page 44: Faults
FAULTS When the controller detects a fault, the red fault LED flashes (above the Reset button) and a fault code is shown on the Temperature display. After the fault has been remedied, the controller can be restarted by pressing the Reset button for 5 secs. The following faults are detected and displayed:- Temperature Description... -
Page 45: Burner Does Not Ignite
Burner does not ignite Possible causes Remedies Gas tap is closed 1. Open the gas tap. Air in th e gas pipe. 1. De-aerate the gas pipe. Inlet pressure too low. 1. Contact the gas company. No ignition 1. Replace the ignition probe. No spark. -
Page 46: Burner Resonates
Burner resonates Possible causes Remedies Inlet pressure too low. 1. The house gas meter may be faulty. Contact the gas company. Re-circulation of the flue gases. 1. Check the flue gases and air supply. Gas-air mixture not adjusted properly. 1. Check the adjustment, see Gas-air control. -
Page 47: Reduced Output
Reduced output Possible causes Remedies At high speed, the power has decreased 1. Check appliance and flue system by not more than 5%. for pollution. 2. Clean appliance and flue system. CH does not reach the correct temperature Possible causes Remedies Room thermostat settings not correct. -
Page 48: Hot Water Does Not Reach The Correct Temperature
Hot water does not reach the correct temperature Possible causes Remedies Tap flow higher than 9 l/min. 1. Adjust the inlet combination. Temperature setting water circuit too low. 1. Set the hot water circuit to 60ºC, dependent on the required temperature. No heat transfer due to scaling or pollution 1. -
Page 49: Servicing The Boiler And Component Replacement
SERVICING THE BOILER AND COMPONENT REPLACEMENT SERVICING THE BOILER The appliance and the system should be serviced annually by a qualified service engineer. For appliances connected to propane gas, a six monthly service in the first two years to simply clean the condensate trap and pipe may be neccessary. - Page 50 Open the gas tap and check the gas couplings below the gas valve and on the mounting bracket for leaks. Switch on the electrical supply to the appliance Switch on the appliance, using the On/Off button on the operating panel. Check the front cover and the connection of the fan to the front cover for leaks.
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Page 51: Component Replacement
COMPONENT REPLACEMENT 9.2.1 Preparation Switch off the appliance using the On/Off button on the operating panel. Switch off the electrical supply to the appliance. Close the gas tap. Unscrew the two recessed screws left and right at the front underneath the appliance and lift/remove the front panel. - Page 52 9.2.5 Burner/ spark ignition probe Remove the front cover of the heat exchanger as described in § 9.1.2. Unscrew the 4 screws shown on the photo to allow the stainless steel burner mesh to be removed. These screws are Torx 20 (RVS A2 4,2x25”) or Allen bolt M4x20 (units before 2006).
- Page 53 9.2.11 Pump head Disconnect the pump wires from the controller (see note in § 9.2.1). Undo two Allen bolts on the Wilo pump head (alternative pump Grundfos has 4 Allen bolts) to remove the pump head from the body. Fit replacement pump head in reverse order. The pump must be vented via its vent plug after refilling the appliance.
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Page 54: Technical Specifications
TECHNICAL SPECIFICATIONS Appliance category B13; B33; C13; C 33; C 43; C53; C63; C83 Gas inlet pressure 20 mbar Suitable for gas Technical data InterCombi HE 32 Domestic hot water Heat power input (gross) 8.0 – 36.3 Heat power input (net) 7.2 –... -
Page 55: Electrical Diagram
10.1 Electrical diagram Notes 1. F1: 5x20mm anti-surge fuse 2A. 2. 230Vac stat circuit: 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). -
Page 56: Ce Declaration
CE DECLARATION Declaration of conformity according to ISO IEC GUIDE 22. Manufacturer: Atmos Heating Systems Address: West March, DAVENTRY, Northants, NN11 4SA Hereby declares that the application: Atmos, Type InterCombi HE32 Meets the stipulations of the following directives: • Machine directive (89/392/EC) as amended in directive (93/68/EC) •... - Page 57 881617_Inst_InterCombiHE32...
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