Atag XL140 Release note

8G.51.19.08 / 05.18 Changes reserved.
Installation & Servicing
Instructions
These instructions are to be retained by the user.
XL70
XL110
XL140

Installation & Servicing instructions ATAG XL
2
Version:
from sv 4.1
05-2013

Installation & Servicing instructions ATAG XL
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Content
1 Introduction.............................................................................................................................................4
2 Regulations ............................................................................................................................................7
3 Scope of delivery....................................................................................................................................9
4 Description ...........................................................................................................................................10
5 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
6 Hydraulic and gas line system..............................................................................................................16
6.1 Heating system ............................................................................................................................16
6.2 Expansion vessel .........................................................................................................................17
6.3 Water quality ................................................................................................................................17
6.4 Gas line ........................................................................................................................................19
6.5 Condensate drain.........................................................................................................................20
6.6 Hot water supply ..........................................................................................................................22
7 Flue gas system ...................................................................................................................................23
7.1 Parallel boiler connection .............................................................................................................24
7.2 Concentric boiler connection........................................................................................................24
7.3 Connectingtheuegasoutlet/airsupplysystem.........................................................................25
7.4 Individualuegasoutlet...............................................................................................................25
7.5 Collectiveuegasoutlet ..............................................................................................................28
7.6 Condensateventcollectiveuegassystem ................................................................................31
8 Electrical connections...........................................................................................................................32
8.1 External controls ..........................................................................................................................34
8.2 Wiring diagram .............................................................................................................................36
9 Boiler control ........................................................................................................................................38
9.1 Operational status ........................................................................................................................39
9.2 Operation .....................................................................................................................................39
9.3 Commissioning.............................................................................................................................40
9.4 Filling heating system...................................................................................................................43
10 Basic settings .......................................................................................................................................45
11 Parameters...........................................................................................................................................47
11.1 Activate factory settings ...............................................................................................................50
12 Put out of operation .............................................................................................................................50
13 Inspection and maintenance ................................................................................................................51
13.1 Maintenance intervals ..................................................................................................................51
13.2 Checks prior to commissioning ....................................................................................................51
13.2.1 Pollution check..................................................................................................................52
13.2.2 Control O2 .........................................................................................................................53
13.3 Maintenance activities..................................................................................................................54
13.4 Counter running hours .................................................................................................................57
13.5 Warranty.......................................................................................................................................57
14 Error report ...........................................................................................................................................58
AnnexATechnicalspecications................................................................................................................59
Annex B System water additives................................................................................................................60
Annex C Dimensions..................................................................................................................................61
Annex D Resistance table sensors.............................................................................................................66
Annex E Declaration of conformity .............................................................................................................67
Annex Benchmark commissioning checklist and service record.............................................................68

Installation & Servicing instructions ATAG XL
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1 Introduction
These instructions describe the functioning, installation, use and primary maintenance of
ATAG central heating boilers for the United Kingdom and Ireland. Where necessary the
di󰀨erentregulationsforeachcountryareseparatelydescribed.
These instructions are intended for the use of Gas Safe registered installers or registered
Bord Gais installers in connection with the installation and putting into operation of ATAG
boilers. It is advisable to read these instructions thoroughly, well in advance of installation.
Separate instructions for use are supplied with the boiler for users ofATAG 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. Further, ATAG reserves
therighttoalteritsproductswithoutpriornotication.
When delivering the boiler, give the customer clear instructions concerning its
use; present the customer with the user’s manual and card.
With regard to installing ue systems and/or external controls, we refer you to
the supplier involved.
Eachboileristtedwithanidenticationplate.Consultthedetailsonthisplatetoverify
whether the boiler is compliant with its intended location, e.g.: gas type, power source
andexhaustclassication.
Oncompletionoftheinstallation,theinstallerorcommissioningengineermustllout
and complete the Commercial Commissioning/Service Sheet supplied with the boiler
and hand this to the customer for future record keeping. The Service Sheet must also
be completed by the service agent following each service call, and returned to the
customer. A copy of the Commercial Commissioning/Service Sheet must be returned to
ATAG Heating along with the warranty registration card to register the appliance for the
standardwarrantybenets.

Installation & Servicing instructions ATAG XL
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description components gure 1.a
1 heat exchanger 1 (All types OSS4)
2 heat exchanger 2 (XL110: OSS2, XL140:OSS4)
3 ignition unit
4 fan unit
5 damper
6 gas valve
7 automatic air vent
8 main switch 230V
9 boiler control unit
10 control unit MMI
11 connection terminal
12 connection terminal cascade bus communication
13 siphon
14 circulation pump
15 gas isolation valve (in optional boiler connections set)
16 servicevalvesow/return(inoptionalboilerconnectionsset)
17 llanddrainvalve(inoptionalboilerconnectionsset)
18 safety valve (in optional boiler connections set)
19 ueconnection(concentric)
20 airsupply(forparallelueconnection)
21 collectiveuepipe
22 information plate
T1 owsensor
T1a secondaryowsensor(onlyOSS4)
T2 return sensor
P1 water pressure sensor
G gas pipe
A owpipeCH
R return pipe CH
C condensate drain pipe
1
2
3
4
5
6
7
8
10
9
11
12 13
14
3
4
5
6
7
G C A R
15 16
18
17
22
21
20 19
T1a
T2
P1
T1

Installation & Servicing instructions ATAG XL
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description components gure 1.b
1 Airsupply(forparallelueconnection)
2 Flue/Air supply (concentric)
3 Gas isolation valve
4 Servicevalvesowandreturn
5 Non-return valve
6 Flow/return header
7 Gas line
8 Low velocity header
9 Safety valve 4 bar
10 Fill and drain valve
11 Automatic air vent low velocity header
12 Pocket for temperature sensor T10
13 Cascade manager
14 Frame
12
3 4 5 6 78 10 9
11
12
13
14

Installation & Servicing instructions ATAG XL
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2 Regulations
The following regulations apply to the installation of ATAG central heating boilers:
Legislation and Regulations.
Gas Safety (Installation and Use) Regulations. All gas appliances must by law, be installed by
a competent person, eg. Members of Gas Safe Register and in accordance with the current
Gas Safety (Installation and Use) Regulations. Failure to install the appliance correctly could
lead to prosecution.
All Gas Safe registered installers carry a Gas Safe ID card and have a registration number.
You can call Gas Safe Register directly on 0800 408 5577.
In addition to the above regulations this appliance must be installed in compliance with the
current IEE Regulations, the Building Standards (Scotland Consolidation) Regulations.
Regulations and byelaws of the Local Water Authority and the Current Health and Safety
Regulation.
Installers are required to carry out installation, commissioning and servicing work in
accordance with the Benchmark Code of Practice which is available from the Heating
and Hot water Industry Council who manage and promote the Scheme.
Visit www.centralheating.co.uk for more information.
Ireland:
- Irish standard 813
The current Electricity at Work Regulation must be complied with and also be in
accordance with the relevant and current editions of the British Standards.
TheATAGXLboilerisacertiedapplianceandmustnotbemodiedorinstalledinany
way contrary to this Installation Manual. Manufacturers instructions must not be taken,
in any way, as overriding statutory obligations.
TheATAG 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.
The device may be operated only by authorized persons who have been in-
structed on the operation and use of the device. Improper use may cause dam-
age to the device and / or to the connected installation.
The appliance is not to be used by children or persons with reduced physical,
sensory or mental capabilities, or lack of experience and knowledge, unless
they have been given supervision or instructions.
Children being supervised are not to play with the appliance.
Observe the following rules of safety:
- All work on the boiler must take place in a dry environment.
- ATAG boilers may never be in operation without their housing, except in connection
with maintenance or adjustments (see Chapter 13).
- Never allow electrical or electronic components to come into contact with water.
Carry out the following tasks in connection with maintenance, etc. to an already-installed
boiler:
- Shut down all programs
- Close the gas isolation valve
- Turno󰀨theboilerselectricalisolatorswitch.

Installation & Servicing instructions ATAG XL
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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; always check the connections of all
parts through which gas ows using leak detection uid (LDF).
The following (safety) symbols may be encountered in these installation instructions and
on the boiler:
This symbol indicates that the boiler must be stored away from frost.
This symbol indicates that the packaging and/or contents can be damaged as a
result of insu󰀩cient care taken during transport.
This symbol indicates that, whilst still in its packaging, the boiler must be
protected from weather conditions during transport and storage.
KEY-symbol. This symbol indicates that assembly or dismantling, must be
carried out.
ATTENTION symbol. This symbol indicates that extra attention must be paid in
connection with a particular operation.
Useful tip or advice.

Installation & Servicing instructions ATAG XL
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3 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);
• PG cable glands;
• Suspension bracket;
• Mounting material consisting of plugs and screws;
• Installation manual;
• Instruction manual;
• Warranty card.
Depending on the selected cascade systems, the following parts are supplied:
1.Pipeworkheadersforow/returnandgas
• DN65orDN100ow/returnpipeworkheadersfor2or3boilerswith:
• Flanges, M12/16 bolts, nuts, spring washers and gaskets
• 35 mm blind covers for unused boiler connections
• DN50 or DN65 gas pipe work header for 2 or 3 boilers with:
• Flanges, M12 bolts, nuts, spring washers and gaskets
• 1¼" blind covers for unused boiler connections
• M6x8x16 close tolerance bolts for fastening gas pipeline
• Adjustable feet M8x35
2. Boiler connection set
• Couplings and pipe branches
• Isolation valves
• Supply and drainage tap with T-piece;
3. Boiler connection set for connecting external boiler
• Three-way valve (only when boiler supplies hot water)
4. Low velocity header
• DN65 or DN100 Low velocity header with:
• Adjustable feet, bolts, nuts, spring washers and gaskets
• Automatic air vent, sensor pocket for T10 and drain valve
5. Frame (if stand-alone)
• Assembly frame (for 1 boiler in line or 2 boilers back to back)
• I-column(s)
• L-column(s) (for back- to- back positioning)
• Adjustable feet, bolts, spring washers and nuts
6. Parts such as: Bus communication cable, insulation.

Installation & Servicing instructions ATAG XL
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4 Description
The ATAG XL is a condensing and modulating CH-boiler.
The boiler has one or two stainless steel heat exchangers with smooth pipes. A high-
tecprinciplewithdurablematerialssuitableforroomsealedopenueoroverpressure
cascadeuesystems
The CH-boiler uses (natural) gas to supply heat. This heat is transferred in the heat
exchanger to the water contained in the CH-installation. Severe cooling down of the
ue-gasescauses condensation.That isthe reasonwhythey areso highlye󰀩cient.
Theinternalsiphondrainso󰀨theresultingcondensate,whichdoesnothaveanegative
impact on the heat exchanger or its functioning.
Theboilerisequipedwithitsowncontrollerperheatexchangerandisttedwithanin-
tegrated cascade manager. The control unit (MMI) allows central read-outs of settings.
Each boiler anticipates the heat demands of the CH-installation or the hot water supply.
Consequently, the boiler modulates its capacity to the installation. As a result, the boiler
will be operational longer at a lower level. The cascade manager controls the boiler order
and even allocation of burning hours.
Connected to an external sensor, the control can operate weather dependent. This means
thatthecontrolsystemmeasuresoutsidetemperaturesandwaterowtemperatures.
Usingthisdata,thecontrolsystemworksouttheoptimumwaterowtemperaturere-
quired for the installation.
StandardconnectionfacilitiesforexternalcontrolsviaOpenTherm,on/o󰀨-contactor0-10
volt control are available, including built in time program.
ATAG XL CH-boilers are high-powered wall-mounted gas boilers for instances where
a lot of power is required. Cascading the XL CH-boilers provides ample room to con-
nect up to a maximum of 8 boilers and an output capacity of 1.1 MW. The XL-series is
structured as follows:
- XL70 Nominal capacity (80/60°C) 60.0kW
- XL110 Nominal capacity (80/60°C) 95.0kW
- XL140 Nominal capacity (80/60°C) 120.0kW
Explanation of type indication: ATAG XL 140
XL = Type
140 = Indication of input load in kW
In principle any combination is possible. Based on the requested capacity, ATAG’s online
cascadeconguratoro󰀨ersvariousoptions.
Youcanchooseeitherthemoste󰀩cientorthemostcompactsolutionyourself.
The capacity of the hydraulic pipes, gas line and low velocity header are adjusted to the
selected overall demand.
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.
If changes are made to the boiler construction the boiler no longer complies with
the CE requirements.

Installation & Servicing instructions ATAG XL
11
5 Installation and mounting
Install the boiler in a well-ventilated boiler room in accordance to the actual lo-
cal regulations BS6644:2005.
The installation location of the CH-boiler(s) has to be, and remain, frost-free.
It is NOT necessary to have a purpose provided air vent providing a twin pipe or
concentricroomsealeduesystemisusedintheroomorinternalspaceinwhichthe
boiler is installed. Neither is it necessary to ventilate the compartment in which the boiler
is installed, due to the extremely low surface temperature of the boiler casing during
operation. Therefore the requirements of BS 6798, Clause 12, and BS5440:2 may be
disregarded.
Theoorhastobeatandlevelandhavesu󰀩cientdeadweightcapacityforthecomplete
(lled)installation.
The ATAG XL cascade can be mounted in 3 ways:
- Wall-mounted in line All boilers alongside one another on the wall
Refer to chapter 5.1 and 5.4
- free-standing in line All boilers hanging alongside one another on a free-
standing frame. Refer to chapter 5.2 and 5.4
- free-standing back-to-back. All boilers hanging back-to-back on a free-standing
frame. Refer to chapter 5.3 and 5.4
General guidelines:
Pay attention to the minimum distance required between the boilers, walls and
ceiling for installing and removing the housing (refer to g. 5.a.) for commis-
sioning and servicing and installing the ue system (refer to chapter 7).
Figure 5.a measurements in mm
wall or frame
ceiling
*
460 400 600
50 50
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tting
-Gasline   ø28mmcompressiontting
*
Individualue:min.400mm
Collectiveue:dependantontheselected
uesystem.Pleasecontactthesupplier

Installation & Servicing instructions ATAG XL
12
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.
B. Determinethepositionofthesuspensionbracketsbasedongure5.1.c.Theboil-
erscanbettedonthewallusingthesuppliedsuspensionbracketsandmounting
material(minimumof3screwsforeachboiler).Thewallhastobeatandstrong
enough to carry the weight of all boilers including their water contents.
Figure 5.1.a
Figure 5.1.c measurements in mm
Figure 5.1.b
C. Hang the boilers on the suspension brackets.
Lift the boiler only by the special grips on the bottom panel (1) and support
the boiler by its rear panel (2). Refer to gure 5.1.d.
D. Place the gas line in its intended recess. When using several pipe work headers:
couple the gas lines using the supplied DN50/DN65 gaskets, M12 bolts, spring
washersandnuts.Refertogure5.1.e.
Fasten the gas line with the 2 special close tolerance bolts M6x8x16 on each
ange of the pipe work header(s). Refer to gure 5.1.f.
Continue with chapter 5.4
Figure 5.1.d
Figure 5.1.e
Figure 5.1.f
1
1
22
Lifting and carrying precautions:
- Lift only a manageable weight, or ask for help.
- When lifting the boiler, bend the knees, and keep the back straight and feet apart.
- Do not lift and twist at the same time.
- Lift and carry the boiler close to the body.
- Wear protective clothing and gloves to protect from any sharp edges.

Installation & Servicing instructions ATAG XL
13
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.
B. Place the gas line in its intended recess. When using several pipe work headers:
couple the gas lines using the supplied DN50/DN65 gaskets, M12 bolts, spring wash-
ersandnuts.Refertogure5.2.b.
Fasten the gas line with the 2 special close tolerance bolts M6x8x16 on each
ange of the pipe work header(s). Refer to gure 5.2.c.
C. FittheI-columnsontheangeplateusing2xboltsM8x40x70mm.
Attention: Use the correct holes in the column!
When using a left ange plate: use the right-hand holes in the column.
When using a right-hand ange plate: use the left-hand holes in the column.
D. FitamountingframeontheI-columnusing3-xboltM8x50mm.Refertogure5.2.e.
Attention: mounting rail at the top.
E. FitamountingframeontheotherI-columnusing3-xboltM8x50mm.Refertogure
5.2.f.
 IfboilersalsohavetobettedontheothersideoftheI-column,thenthenextmount-
ingframealsohastobettedstraightonit.
F. Fit the remaining I-column(s) between the mounting frames using 3x M8x50mm.
Refertogure5.2.f.
G. Hang the boilers on the mounting rail.
Lift the boiler only by the special grips on the bottom panel (1) and support
the boiler by its rear panel (2). Refer to gure 5.2.g.
Continue with chapter 5.4
Figure 5.2.a
Figure 5.2.b
Figure 5.2.c
Figure 5.2.d
OK
Figure 5.2.e
Figure 5.2.f
Figure 5.2.g
1
1
22
Lifting and carrying precautions:
- Lift only a manageable weight, or ask for help.
- When lifting the boiler, bend the knees, and keep the back straight and feet apart.
- Do not lift and twist at the same time.
- Lift and carry the boiler close to the body.
- Wear protective clothing and gloves to protect from any sharp edges.

Installation & Servicing instructions ATAG XL
14
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
using the adjustable feet.
B. Place the gas line in its intended recess. When using several pipe work headers:
Couple the gas lines using the supplied DN50/DN65 gaskets, M12 bolts, spring
washersandnuts.Refertogure5.3.b.
Fasten the gas line with the 2 special close tolerance bolts M6x8x16 on each
ange of the pipe work header(s). Refer to gure 5.3.c.
C. FittheL-columnsontheangeplateusing2xboltsM8x40x70mm.
Attention: Use the correct holes in the column!
When using a left ange plate: use the right-hand holes in the column.
When using a right-hand ange plate: use the left-hand holes in the column.
D. FitamountingframeontheL-columnusing3xboltM8x50mm.Refertogure5.3.e.
Attention: mounting rail at the top.
E. FitamountingframeontheotherL-columnusing3-xboltM8x50mm.Refertogure
5.3.f.
 IfboilersalsohavetobettedontheothersideoftheL-columnthenthenextmount-
ingframealsohastobettedstraightonit.
F. Fit the remaining L-column(s) between the mounting frames using 3x M8x50mm.
Refertogure5.3.f.
G. Hang the boilers on the front and rear of the frame on the mounting rail.
Lift the boiler only by the special grips on the bottom panel (1) and support
the boiler by its rear panel (2). Refer to gure 5.3.g.
Continue with chapter 5.4
Figure 5.3.a
Figure 5.3.b
Figure 5.3.c
Figure 5.3.d
OK
Figure 5.3.e
Figure 5.3.f
1
1
22
Figure 5.3.g
Lifting and carrying precautions:
- Lift only a manageable weight, or ask for help.
- When lifting the boiler, bend the knees, and keep the back straight and feet apart.
- Do not lift and twist at the same time.
- Lift and carry the boiler close to the body.
- Wear protective clothing and gloves to protect from any sharp edges.

Installation & Servicing instructions ATAG XL
15
5.4 Connecting the boiler
A. Remove the remaining packaging part from the bottom of the boiler.
Note: this packaging part is provided with boiler parts which are needed for
mounting the boiler.
B. Cap the connections that are not used on the pipe work headers:
 Flowandreturn: ø35mmblindcompressiontting (2items/boiler)
Gas: 1 ¼" blind cap with gasket (1 item/boiler)
For connections, use the supplied gaskets. Check all connections for leak-
age and gas-tightness.
C. Connecting the isolation valves to the boiler:
 Flow: 1½"atcouplingx35mmcompressionisolationvalvewithredhandle
 Return:1½"atcouplingx35mmcompressionttingcrossunionwith
  ll/drainvalveandisolationvalvewithbluehandle
The boiler is supplied with a 3 and 4 bar safety valve.
 ATAGUKrecommendttingthe4barsafetyvalveduetothecontrolsettingsshutting
theboilero󰀨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 ow and return.
For connections, use the supplied gaskets. Check all connections for leak-
age and gas-tightness.
D. Connect the valves to the pipe work headers:
 Flow: 35mmpipepieceswith35mmcompressionttings(elbowandsocket)
 Return:35mmpipepieceswith35mmcompressionttings(elbowandsocket)
 Gas: 28mmpipepiecewith1¼"atand28mmcompressiontting
Back-to-back installation:
 Flow: 35mmpipepieceswith35mmcompressionttings(bendandsocket)
 Return:35mmpipepieceswith35mmcompressionttings(bendandsocket)
 Gas: 28mmpipepiecewith1¼"atand28mmcompressiontting
For connections, use the supplied gaskets. Check all connections for leak-
age and gas-tightness.
E. Fillthesiphonwithtapwaterandtthesiphoncupunderneaththeboiler.
The siphon cup is supplied separately and can be found behind the housing.
Figure 5.4.b
Figure 5.4.c
Figure 5.4.d
Figure 5.4.a

Installation & Servicing instructions ATAG XL
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6 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ange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.
Low velocity header
There are 3 low velocity headers available:
AX00470U Lowvelocityheaderfor1or2XLboilerstomax.200kW(g.6.1.a)
supplied with automatic air vent, drain valve and pocket for temperature sensor T10
Boiler connections are 4x 1 ½”, installation connections are 2x 2”. The low velocity
header MUST be connected between the boiler[s] and the system pumps.
AX00120U LowvelocityheadersDN65to452kW(g.6.1.b)
AX00130U Low velocity headers DN100 to 960kW
The low velocity headers comes standard with adjustable feet, automatic air vent,
drain valve, pocket for temperature sensor T10, M12 or M16x55 bolts, spring washers
and nuts. The low velocity header can be positioned on either the left or right hand
side of the pipe work headers.
AX00630U FlowtemperaturesensorT10(g.6.1.c)
Every system with 1 or more XL-boilers must be provided with a ow tempera-
ture sensor T10 and must be connected on the master boiler (address 01) to
terminal 3, position 5 and 6. The ow sensor must be placed in the pocket of the
low velocity header.
Set of bends
The low velocity header can be positioned at a 90° angle. A set of bends may be used
for that purpose.
AX00300U BendssetDN65ow/return(g.6.1.d)
AX00310U BendssetDN100ow/return
Blanking anges
Theendsofthepipeworkheadershavetobettedwithblankinganges.Theblanking
angescomestandardwithafullycongureddelivery,includingbolts,springwashers
and gaskets.
AX00320U BlankingangesetDN65ow/return2items(g.6.1.e)
AX00330U BlankingangesetDN100ow/return2items
Welded-on anges
Uponrequest,welded-onangesareavailabletoconnectCH-pipelinestothesecondary
side of the low velocity header and to connect the gas line.
AX00680U Welded-onangesetDN65ow/return2items+DN50gas1item(g.6.1.f)
AX00690U Welded-onangesetDN100ow/return2items+DN65gas1item
Figure 6.1.b
Figure 6.1.d
Figure 6.1.e
Figure 6.1.f
Figure 6.1.c
Figure 6.1.a

Installation & Servicing instructions ATAG XL
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Required components that are not supplied by ATAG:
- The installation pump; - The condensate discharge system.
- Theinstallationwaterlter; -Airanddirtseparator
- Gaslter;   -Hotwatersupply
- Regulation valve; - Flue system
- Expansion vessel(s);
6.2 Expansion vessel
TheCH-installationhastobettedwithanexpansionvessel.Theexpansionvesselused
has to comply with the water contents of the installation.
It is not necessary to install an expansion vessel to each boiler. One single, central in-
stalledexpansionvesselissu󰀩cient.Whenusingasingleexpansionvesselthehandles
ofthevalvesontheowandreturnpipesbelowtheboilerhavetoberemovedwhilstopen.
A boiler expansion vessel can be connected on the cross union inside the return pipe
toeachboiler,ifrequired.Theconnectionisttedwitha3/4"outerthreadblankingcap.
Expansion DHW cylinder circuit
When applying a DHW cylinder connected directly to the boiler (ATAG cylinder connec-
tion with use of 3-way valve) the circuit between the three-way valve and the separation
of the DHW cylinder should be provided of an expansion tank.
6.3 Water quality
Fill the installation with drinking water.
Inmostcases,aheatingsystemcanbelledwithwateraccordingtonationalstandards
for water and treatment of this water is not necessary.
InordertoavoidproblemswiththeCH-installations,thequalityofthellingwaterhasto
meetthespecicationsmentionedintable6.3.a:
Ifthellingwaterdoesnotmeettherequiredspecications,youareadvisedtotreatthe
watertosuchanextentthatitdoesmeettherequiredspecications.
The warranty becomes invalid, if the installation is not being ushed and/or the
quality of the lling water does not meet the specications 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.
Installation:
- The use of groundwater, demi-water and distilled water is prohibited. (on the next
pageyouwillndanexplanationofthesedenitions)
- Ifthedrinkingwaterqualitymeetsthespecicationsmentionedintable1,youcan
startushingtheinstallationbeforeinstallingtheboiler(s).
- Whilstushing,corrosionproducts(magnetite),ttingproducts,cuttingoilandother
undesirable products have to be removed.
- Anotherpossibilityistoremovethepollutionbyinstallingalter.Theltertypehas
totthetypeandgrainsizeofthepollution.ATAGrecommendslterusage.
- In this case, the whole piping system should be taken into consideration.
- The CH-installation has to be properly vented before using the system. For that pur-
pose, we refer to the commissioning chapter.
- If a regular water top up is required (>5% on an annual basis), then there is a structural
problem and an installer has to solve the problem. Regularly adding fresh water to the
system also adds additional calcium and oxygen implying that magnetite and calcium
residues can continue. The result may be blockages and/or leakages.
- The use of anti-freeze and other additives requires periodical quality checks of the
llingwaterinaccordancewiththeperiodlaiddownbytheadditivessupplier.

Installation & Servicing instructions ATAG XL
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- 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specicationsorthechemicalad-
ditives have not been approved by ATAG.
- On installation and during additions or changes at a later stage, ATAG recommends
to keep a record of the type of water used, its quality at the time, and if applicable,
which additives and quantities were added.
Parameter Value
Water type Potable water
Softened water
pH 6.0-8.5
Conductivity (at 20°C in µS/cm) Max. 2500
Iron (ppm) Max. 0.2
Hardness (°dH):
Installation volume/capacity
<20 l/kW
1-12
Installation volume/capacity
>=20 l/kW
1-7
Oxygen No oxygen di󰀨usion allowed during
operation.
Max.5%llingwateradditionannually
Corrosion inhibitors Refer to Additives Attachment
pH increasing or lowering agents Refer to Additives Attachment
Anti-freeze additives Refer to Additives Attachment
Other chemical additives Refer to Additives Attachment
Solid substances Not allowed
Residues of processing water not for-
ming part of the drinking water
Not allowed
table 6.3.a
Water type denition:
Potable water: Tap water compliant with the European drinking water guideline:
98/83/EG dated 3 November 1998.
Softened water: Water with partly de-ionised calcium and magnesium.
Demi-water: Virtually completely demineralised water (very low conductivity)
Distilled water: Water no longer containing minerals.

Installation & Servicing instructions ATAG XL
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6.4 Gas line
Mount the gas line in accordance with present legislation.
If required, mark the gas line in accordance with present legislation.
United Kingdom:
The gas supply must comply to the current Gas Safety, Installation & Use Regulations.
Ireland:
- Irish standard 813
- Domestic gas installations
The gas line leading to the installation has to be calculated to the maximum capacity to
determine the diameter of the supply pipe.
Thegaslinehastobeplacedontheallocatedopeningsoftheangeplatesofthepipe
workheadersow/returnandsecuredonallangeplatesbythespecialM6x8x16close
tolerance bolts.
Pressure loss for a newly installed natural gas line may be 1.7 mbar max. In the case of
an extension, this may be 2.5 mbar max. This value is to be measured in between the
operational gas meter and the CH-boilers.
For correct functioning of the boilers, it is necessary that the gas dynamic inlet pressure
must be at least 19 mbars.
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.
Following maintenance tasks always check all gas carrying components for
leakages by using of leakage detection uid (LDF).
Figuur 6.4.a
LPG

Installation & Servicing instructions ATAG XL
20
6.5 Condensate drain
AllATAGwallhunggasred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(g.6.5.a).Connectthetubetothemaincondensatedrain(minimumdiameter=
40mm) by means of an open connection to avoid sewage gasses coming into the boiler.
Fit a pipe work header for the condensate drain behind the hydraulic system. For that
purpose,theangeplateshaveholesallowingtheinstallationofaPVCdrainofø40mm
max. Use this drain to connect the individual condensate drains of each boiler.
Thesiphonofauegassystemcanalsobeconnected,ifrequired,bymeansofan
open connection.
Routing of the pipework,
Wherever possible, the condensate pipework should be routed internally to prevent
freezing.
The condensate pipework must fall at least 50mm per metre towards the outlet and take
the shortest possible route
Support the pipe at least every 50 cm for near horizontal sections and 1 metre for vertical
sections
External pipework
The pipework should be kept to a minimum and the route as vertical as possible.
Do not exceed 3 metres outside the dwelling.
The condensate pipe must be run using suitable corrosion resistant materials (eg. plastic).
Terminate as close to the ground or drain as possible (below the grating and above the
water level) while still allowing for safe dispersal of the condensate.
Connection of a condensate drainage pipe to a drain may be subject to local building
controls.
Pipework subjected to extreme cold or wind chill conditions should be in a 40mm diameter
pipe.
Protect all external pipework with weather resistant insulation and, if necessary, box in,
to reduce the risk of freezing.
Making it safe.
Condensate pipework must not leak, freeze or block up.
Condensatetrapsmustbelledbeforeringtheboilertopreventthepossibilityofpotential
harmfulueproductsevacuatingviathecondensateroute.
Do not dispose condensate into a water recovery system where it is reclaimed for reuse.
Condensate can be discharged into a rainwater hopper which is part of a sewer carrying
both rain water and foul water.
Figuur 6.5.a
Figuur 6.5.b