Atlantic CONDENSINOX 40 Quick start guide

CONDENSINOX
GAS CONDENSING BOILER
40, 60, 80 or 100 kW
with modulating burners
for natural gas and propane gas
FR EN DE ES IT NL
Installation,
use and
maintenance
instructions
Document No. 00CNO0183-C / 02/09/15
C
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SITE DE PONT-DE-VAUX
1 route de Fleurville - BP 55
FR - 01190 PONT-DE-VAUX

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CONDENSINOX - Installation, Use and Maintenance
CONTENTS
1. WARNINGS AND RECOMMENDATIONS..............................................................................5
1.1. Transport and storage................................................................................................................................... 5
1.2. Symbols used in this document .................................................................................................................... 5
1.3. Staff qualification for installation, adjustment, use and maintenance............................................................ 5
1.4. Safety instructions......................................................................................................................................... 5
1.5. Water characteristics..................................................................................................................................... 6
2. CERTIFICATION ...................................................................................................................10
2.1. Compliance with European Directives ........................................................................................................ 10
2.2. Regulatory installation conditions................................................................................................................ 10
2.3. Gas category............................................................................................................................................... 10
2.4. Gas supply pressures ................................................................................................................................. 11
3. TECHNICAL SPECIFICATIONS...........................................................................................12
3.1. Dimensions ................................................................................................................................................. 12
3.2. Combustion at 15°C and 1013 mbar........................................................................................................... 13
3.3. Conditions of use ........................................................................................................................................ 14
3.4. Electrical connection ................................................................................................................................... 14
4. INSTALLATION.....................................................................................................................15
4.1. Boiler location.............................................................................................................................................. 15
4.2. Exhaust connection..................................................................................................................................... 16
4.3. Hydraulic connection................................................................................................................................... 25
4.4. Connecting the gas supply.......................................................................................................................... 27
4.5. Changing the gas ........................................................................................................................................ 27
4.6. Electrical connection ................................................................................................................................... 31
5. COMMISSIONING.................................................................................................................35
5.1. Checks before commissioning .................................................................................................................... 35
5.2. Commissioning............................................................................................................................................ 35
6. CHECKS AFTER COMMISSIONING....................................................................................36
6.1. Condensate removal ................................................................................................................................... 36
6.2. Gas supply .................................................................................................................................................. 36
7. MAINTENANCE OPERATIONS ...........................................................................................37
7.1. Draining the boiler ....................................................................................................................................... 37
7.2. Checks on the boiler environment............................................................................................................... 38
7.3. Cleaning the combustion chamber/exchanger............................................................................................ 38
7.4. Checking the ignition and ionisation electrodes .......................................................................................... 39
8. END-OF-LIFE CYCLE OF THE APPARATUS......................................................................40

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9. HYDRAULIC DIAGRAMS AND CONFIGURATIONS...........................................................41
9.1. Selection diagrams...................................................................................................................................... 41
9.2. Symbols used in the diagrams .................................................................................................................... 43
9.3. List of diagrams........................................................................................................................................... 43
10. SPARE PARTS LIST.............................................................................................................90
11. CUSTOMER PARAMETERS TABLE ...................................................................................98
12. ANNEX A.............................................................................................................................115

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CONDENSINOX - Installation, Use and Maintenance
1. WARNINGS AND RECOMMENDATIONS
PLEASE READ THIS MANUAL CAREFULLY BEFORE INSTALLING,
MAINTAINING OR USING THE BOILER. IT CONTAINS IMPORTANT
INFORMATION ABOUT SAFETY.
1.1. Transport and storage
The boiler:
- must be stored vertically in a place where the temperature is between
-20°C and +55°C and the relative humidity is between 5% and 95%.
- must not be stacked,
- must be protected against humidity.
1.2. Symbols used in this document
INFORMATION: This symbol draws attention to comments.
!ATTENTION:
Failure to comply with these instructions may
cause damage to the installation or to other
objects.
!DANGER: Failure to comply with these instructions may
cause injury and serious material damage.
DANGER: Failure to comply with these instructions may
cause electrocution.
1.3. Staff qualification for installation, adjustment, use and maintenance
The appliance must be installed, configured and maintained by a qualified,
approved professional in accordance with the local and national regulations
in force. These operations may require work to be done with the machine
powered up and the door panels (on the front of the boiler) open.
The basic operations of use should be performed with the door panels closed.
1.4. Safety instructions
• Always switch off the boiler and close the general gas supply before
working on the boiler.
• After all operations on the boiler (maintenance or repair), check the
installation for gas leaks.

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!DANGER:
If you smell gas:
• Do not use naked flames, do not smoke and do not activate
electrical contacts or switches.
• Cut the gas supply.
• Ventilate the room.
• Trace the leak and repair it.
!DANGER:
If smoke is released:
• Switch off the boiler.
• Ventilate the room.
• Trace the leak and repair it.
DANGER:
The boiler is earthed via connecting cables (green/yellow) and special
fixing screws. If the boiler is disassembled, make sure the cables are
reconnected properly and ALWAYS reuse the original fixing screws.
1.5. Water characteristics
The following rules apply once the boiler is put into service and remain valid
until the end of life of the product.
1.5.1. Preparing the water system before putting the boiler into service
For any installation (new or renovation), the water system pipes must be
thoroughly cleaned. The purpose of this initial cleaning is to eliminate germs
and residue that can cause deposits to form.
In new installations in particular, any residues of grease, oxidised metal or
copper micro-deposits must be removed.
In renovated installations, cleaning should focus on removing sludge and the
products of corrosion formed when the unit was last in operation.
There are two types of methods for cleaning and removing sludge: a high-
intensity approach that takes a few hours and a slower, more gradual
approach that takes several weeks. This first type of cleaning must be done
before connecting the new boiler, and with the second type, a filter should be
installed on the boiler return circuit to capture loosened deposits.
The cleaning performed prior to installation improves performance, reduces
energy consumption, and resists scaling and corrosion on the unit. A water
treatment professional should carry out the cleaning.

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CONDENSINOX - Installation, Use and Maintenance
1.5.2. Protecting the unit against scaling
Water naturally contains dissolved calcium ions and carbonates that cause
scaling (calcium carbonate) to form. To prevent excessive deposits, take
precautions with regard to the water used to fill the unit: hardness < 100 ppm
Water must be added during the life of the boiler. The new water adds scaling
to the water system. The amount of fill water plus the amount of make-up
water added during the life of the unit should not be more than three times
the water capacity of the heating system. Also, the hardness of the make-up
water must be controlled. Make-up water: hardness < 50 ppm
Adding a large amount of untreated water always contributes a significant
amount of scaling. To monitor this and to detect problems, a system water
meter must be installed.
Failure to comply with these guidelines (such that the fill water plus the make-
up water is more than three times the water capacity of the heating system)
requires a full cleaning (to remove sludge and scaling) to be performed.
Additional precautions are required for operation:
- If a softener is present in the installation, the equipment must be
checked frequently to ensure it is not discharging chloride-rich water into
the system: the chloride concentration must always remain below
50 mg/litre.
- To prevent the build-up of calcium deposits (such as on exchange
surfaces), the unit should be brought into service slowly, starting by
operating at a low power with high primary water flow.
- If the water in the system does not have the required qualities (e.g.
high hardness), it must be treated. The fill water must be treated, and
whenever new water is added, the make-up water must also be treated.
- Installations with multiple boilers require all of the boilers to be brought
up simultaneously at minimal power. Doing this prevents the calcium in
the water from depositing on the exchange surfaces of the first boiler.
- When working on the unit, avoid draining it completely; only the required
parts of the system are to be drained.
The rules listed above are designed to minimise scaling on the exchange
surfaces and thus to increase the life of the boilers.
To optimise how the equipment operates, calcium deposits can be removed.
This must be done by a specialised company. Also, before putting the unit into
service, verify that the heating system is not damaged (e.g. leaks). If it has
excessive scaling, the unit's settings for operation and for water treatment
must be adjusted.

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1.5.3. Protecting steel and stainless steel boilers against corrosion
Corrosion can affect the iron components used in boilers and heating
systems, which is directly related to the presence of oxygen in the water
heater's water. Dissolved oxygen that enters the unit when it is being filled for
the first time reacts with the equipment materials and quickly disappears. If
the oxygen is not renewed through significant 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 flowing into the heating water.
These rules include:
- Give preference to an expansion vessel with a membrane rather than an
open expansion vessel that allows direct passage.
- Ensure the pressure in the installation is greater than 1 bar when cold.
- Remove leaky (permeable to gas) components and replace with sealed
components.
If the guidelines above are followed, the unit's system water has the proper
characteristics to last a long time: 8.2 < pH < 9.5 with a dissolved oxygen
concentration of < 0.1 mg/l.
If there is a chance that oxygen could enter the unit, you must take additional
precautions. Adding an oxygen scavenger (e.g. sodium sulphite) is highly
recommended. We recommend directing any water treatment questions to
specialists, who can provide:
- The appropriate treatment based on the characteristics of the unit,
- A monitoring agreement with a guarantee as to the results.
In the case of an installation in which the water comes into contact with
a variety of materials, e.g. copper and aluminium, appropriate treatment is
recommended to ensure the long-term operation of the installation. In most
cases, this treatment will involve adding corrosion inhibitors in the form of
chemical solutions. We recommend contacting a water treatment specialist.
1.5.4. Unit monitoring
If the recommendations listed above (new installation or renovation) have
been followed, the unit monitoring is limited to:
- Checking the amount of make-up water (fill water volume + make-up
water volume < 3 times the unit volume).
- Checking the pH (stable or rising slightly).
- Checking the water hardness (stable or falling slightly).
We recommend monitoring these parameters two to three times a year. Note
that monitoring the quantity of make-up water is vital to ensure the long-term
operation of the installation.
If any of these parameters deviates from the above recommendations, refer
to a water treatment specialist to correct the problem.

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CONDENSINOX - Installation, Use and Maintenance
1.5.5. Setting up a plate exchanger
If the recommendations listed above cannot be met, you can set up a plate
exchanger to separate the primary system from the secondary system, which
protects the boiler from undesirable effects.
1.5.6. Setting up a filtration system
A filtration system on the boiler return circuit is recommended in order to
remove suspended particles from the unit (filter, dirt separator etc.).

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2. CERTIFICATION
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
benefit, through someone responsible for their safety, from supervision
or prior instruction concerning the use of the appliance.
Children must be supervised to ensure they do not play with the
appliance.
- Electromagnetic compatibility (2004/108/CEE)
- Gas appliances (2009/142/CE)
- Efficiency (92/42/CEE) until 26/09/2015
- Energy labelling (2010/30/EU): from 26/09/2015
In application of the directive and according to the requirements of the
EU regulation No. 811/2013 of 18 February 2013, the information on
condensation boilers with a power of less than or equal to 70 kW is
available in appendix A.
- Eco-design (2009/125/EC): from 26/09/2015
In application of the directive and according to the requirements of
the EU regulation No. 813/2013 of 02 August 2013, the technical
parameters of condensation boilers with a power of less than or equal
to 400 kW are available in appendix A.
2.2. Regulatory installation conditions
The appliance must be installed by an approved professional in accordance
with regulations and current professional practices.
2.3. Gas category
This boiler has been adjusted in the factory to work with group H natural
gas (type G20) with a supply pressure of 20 mbar.
For an installation on a 300 mbar gas network, place a gas filter and
gas pressure regulator upstream of the boiler in accordance with current
regulations.
See chapter 4.8 for how to change the gas, and use a qualified professional.
INFORMATION: Any work on a sealed component will lead to loss of the guarantee.

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CONDENSINOX - Installation, Use and Maintenance
Categories
BE LU CH ES FR GB IE IT PT
CONDENSINOX
40-60
B23 - B23 P I2E(S) I2E (G20) II2H3P II2H3P II2ESI3P II2H3P II2H3P II2H3P II2H3P
C13 - C33 -
C53 C43 - C83 I2E(S) I2E (G20) I2H I2H I2ESI I2H I2H I2H I2H
CONDENSINOX
80-100
B23 - B23 P I2E(R) I2E (G20) II2H3P II2H3P II2ESI3P II2H3P II2H3P II2H3P II2H3P
C13 - C33 -
C53 C43 - C83 I2E(R) I2E (G20) I2H I2H I2ESI I2H I2H I2H I2H
2.4. Gas supply pressures
INFORMATION: The pressures given below should be measured at the input to the
gas valve.
H G20
natural gas
L G25
natural gas
G31 propane
(only with B23 and B23P)
Nominal pressure (mbar) 20 25 37
Minimum pressure (mbar) 17 20 25
Maximum pressure (mbar) 25 30 45

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3. TECHNICAL SPECIFICATIONS
3.1. Dimensions
figure 1 - Dimensional characteristics
MODEL ABCDEFGH I J
Ø K LM Ø N O
(mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm)
40 - 60 1475 595 670 1449 58 100 336 400 406 76 1"1/4 1354 205 G1/2" 114
80 - 100 1708 695 779 1626 102 110 336 400 550 85 1"1/4 1529 131 G3/4" 114
B
A
20 min 40 max
C
E
O
GHI
øN
øK
U0510468-#
M F
J
øK
øK
ø25
D
L
Gas
(cylindrical male)
Flow
(conical male)
Hot return
Cold return
Condensate
discharge

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CONDENSINOX - Installation, Use and Maintenance
MODEL
40 60 80 100
Nominal power Pn (80/60°C) G20
G25 set up for G20 ** kW 40.0
33.2
60.0
49.8
80.0
65.6
97.0
80.5
Nominal power when condensing
Pn (50/30°C)
G20
G25 set up for G20 ** kW 43.8
36.3
65.5
54.4
87.5
71.8
105.5
87.5
Rated heat input Qn G20
G25 set up for G20 ** kW 41.6
34.5
62.1
51.5
82.7
67.8
100.0
83.0
Min heat input Qmin
G20 / G25
G25 set up for G20 **
G31
kW
8.3
6.9
19.5
12.4
10.3
20
16.5
13.5
20.7
19.5
16.2
19.5
Gas flow rate at Pn (15°C)
G20
G25
G25 set up for G20 **
G31 ***
m3/h
4.4
5.1
2.2
3.2
6.6
7.6
6.3
4.8
8.8
10.2
8.4
6.4
10.6
12.3
10.2
7.8
Value range of CO2% See paragraph 4.5
Exhaust mass flow rate at Qn / Qmin (80/60°C) * g/s 19 /
4.0
28.3 /
5.9
38.5 /
7.9
46.5 /
9.6
Exhaust mass flow rate at Qn / Qmin (50/30°C) * g/s 17.8 /
3.5
25.3 /
5.5
35.9 /
7.3
43.5 /
8.9
Exhaust temperature at Qn / Qmin (80/60°C) * °C 74 / 56 85 / 55 76 / 57 82 / 57
Exhaust temperature at Qn / Qmin (50/30°C) * °C 48 / 29 58 / 30 56 / 30 56 / 30
Exhaust circuit pressure loss at Qn * Pa 135 162 145 140
Exhaust outlet diameter mm 80 80 100 100
Maximum allowable nozzle pressure (B23P)
at Qn / Qmin (80/60°C)* Pa 160 / 6 160 / 5 120 / 7 120 / 5
Maximum allowable nozzle pressure (B23P)
at Qn / Qmin (50/30°C)* Pa 129 / 5 129 / 5 101 / 5 105 / 5
Combustion air flow rate at Qn * m3/h 53 80 108 131
NOx class 5
Exhaust removal and air inlet type classifications
B23, B23P
C13, C33, C43,
C53, C83
B23, B23P,
C13, C33, C53
* values corresponding to a G20 set-up.
** G25 set up for G20: gas category I2E(S) or I2E(R)
*** only for B23 and B23P exhaust evacuation
3.2. Combustion at 15°C and 1013 mbar

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3.3. Conditions of use
MODEL
40 60 80 100
Maximum starting temperature setpoint °C 80
Max starting temperature °C 85
Safe temperature °C 106
Max service pressure hPa
(bar)
4000
(4)
Minimum cold pressure hPa
(bar)
1000
(1)
Hydraulic pressure loss at ∆T 20 daPa 160 350 210 300
Nominal water flow rate (P/20) m3/h 1.7 2.6 3.4 4.2
Maximum water flow rate (P/7) m3/h 4.9 7.4 9.8 11.9
Water capacity L 94 88 136 130
Weight without water kg 134 140 215 225
Room temperature (min/max) °C 5 / 45
Room relative humidity 5% to 95%
Level of protection IP20
Maximum installation altitude m 2000
3.4. Electrical connection
MODEL
40 60 80 100
Electrical power supply V 230 V AC (+10% -15%), 50Hz
Electrical power consumption
at Qn (excluding accessories) W 120 160 210 280
Electrical power consumption
in standby mode W5
Maximum length of sensor cables m
Hot water sensor: 10
Outdoor sensor: 40 at 0.5 mm² (120 at 1.5 mm²)
Room thermostat: 200 at 1.5 mm²
Room sensor: 200 at 1.5 mm²
Terminal output power
V 230 V AC (+10%, -15%)
A 5 mA at 2 A

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4. INSTALLATION
4.1. Boiler location
CONDENSINOX boilers must not be installed on an inflammable surface
(wooden floor, plastic floor covering etc.).
Recommended clearance from walls and ceiling:
Sufficient clearances must be provided to permit easy maintenance
operations on the boilers.
The minimum values (in mm) are indicated in figure 2 and the table below.
A (mm) B (mm) C (mm) H (mm)
MODEL
40 - 60 200 150 200 1750
80 - 100 500 365 500 1980
figure 2 - Clearance around the boiler
H
A
Zone that must
remain clear to
allow opening of
the combustion
chamber door
(note: the
combustion
chamber door can
only be opened to
the right)
U0510471-#
U0510507-#
AA B B
C
800

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These values cannot be substituted for the specific regulatory
requirements.
!ATTENTION:
The boiler must be positioned horizontally using a spirit level to
promote effective ventilation of the heat exchanger body (use the
plinth as a reference surface).
To adjust the level, screw or unscrew the 4 adjustable feet as required using
a 13 mm wrench.
4.2. Exhaust connection
It is essential to comply with the regulations and codes of practice in force in
the country where the boiler is installed, i.e.
For France, DTU 65.4, DTU chimney, DTU 24.1 (exhaust system) and NF P
51-201 of February 2006.
For Belgium, the NBN D51.003, NBN D51.004 and NBN D61.001 standards.
An exhaust temperature sensor guarantees protection for type B and C
combustion product evacuation flues.
4.2.1. Connection to a B23 chimney
B23 type connection:
Air from the installation room, gas evacuation through the roof via a natural
draft duct.
!ATTENTION:
Ensure that the room where the boiler is installed has high and low
ventilation outlets in accordance with the regulations in force and
that they are not obstructed.
For the CONDENSINOX 40-60, the use of the ø125 Chimney Adaptor
accessory (code 040940) is mandatory to connect a CONDENSINOX boiler to a
B23 chimney duct. This kit is suitable for Ø 125 exterior ducts.
For the CONDENSINOX 80-100, the use of the ø160 Chimney Adaptor
accessory (code 041050) is mandatory to connect a CONDENSINOX boiler to a
B23 chimney duct. This kit is suitable for Ø 160 exterior ducts.
!ATTENTION:
Under no circumstances is use of these mandatory accessories a
substitute for checking the dimensioning of the chimney ducts (given
a combustion gas pressure at the boiler outlet equal to 0 Pa).
DTU 24-1 authorises the use of a draft stabiliser to give a pressure of 0
Pa at the nozzle. This will enable the boiler to operate without disruption
due to excessive draft.
The exhaust extraction ducts must be made in a material resistant to the
condensate that can form when the boiler is operating. These materials
must also be capable of supporting exhaust temperatures up to 120°C.

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CONDENSINOX boilers are high-performance boilers with very low exhaust
temperatures; consequently to retain a favourable draft the ducts must run
upwards from the boiler outlet.
Horizontal duct runs must be avoided so as not to cause condensate retention.
Use a minimum slope of 3% towards the boiler in the horizontal parts.
!IMPORTANT:
If several boilers are connected to the same flue, make sure:
1. By calculation, that the flue is not under pressure when all the
boilers are operating.
2. If one of the boilers is operating at minimum power, that the
others do not discharge into it.
CONDENSINOX
40 60 80 100
Code 040940 041050
Ø duct Ø 125 Ø 160
A (mm) 1690 1925
figure 3 - Connection to a chimney
The dimension A indicates the
upper position of the completely
inserted chimney adapter
Filter sheet


A
U0510509-#

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4.2.2. Connection to a B23P chimney
B23P type connection:
Air from the installation room, gas evacuation through the roof via a
pressurised duct.
!ATTENTION:
The use of the “Chimney Adaptor” accessory is mandatory to connect
a CONDENSINOX boiler to a B23P chimney duct. The table below
represents the accessories available for each boiler type.
Ø duct CONDENSINOX
40 60 80 100
Ø 80 Code 040945
(contains part ) * --
Ø 110 -- Code 041052
(contains part ) *
Ø 125 Code 040940
(contains part +) *
Code 041051
(contains part +) *
Ø 160 -- Code 041050
(contains part +) *
* See figure 3 on the previous page.
!ATTENTION: For this type of configuration, it is imperative to use an exhaust
system with technical evaluation document (ducts under pressure).
The Ø 80 Chimney Adaptor accessory (code 040945) has an 80 diameter
500 mm long straight component that can be cut to the desired dimension
(195 mm min).
The Ø 125 Chimney Adaptor accessory (code 040940) has a 125 diameter
outlet that cannot be recut.
Height A (in mm)
Ø duct CONDENSINOX
40 60 80 100
Ø 80 1605 min / 1910 max --
Ø 110 -- 1795
Ø 125 1690 1910
Ø 160 -- 1925
A purge tee is not necessary, because condensate recovery is incorporated in
the boiler. Use a minimum slope of 3% towards the boiler in the horizontal parts.
To ease fitting coat the joints with liquid soap or an appropriate grease.
!ATTENTION:
Ensure that the room where the boiler is installed has high and low
ventilation outlets in accordance with the regulations in force and
that they are not obstructed.

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4.2.2.1. Single boiler installation case
!ATTENTION:
The combustion product extraction duct must be dimensioned by
using the parameters set out in the table in chapter 3.2.
Depending on the actual configuration of the duct, a calculation is
required to check that the pressures at the boiler outlet do not exceed
the maximum allowable values in this table.
Values corresponding to the 50/30°C regime are to be used for this
calculation.
4.2.2.2. Cascade installation case
!ATTENTION:
The combustion product extraction duct must be dimensioned by
using the parameters set out in the table in chapter 3.2.
Depending on the actual configuration of the duct, a calculation is
required to check that the pressures at the boiler outlet do not exceed
the maximum allowable values in this table.
Values corresponding to the 50/30°C regime are to be used for this
calculation.
The installation must be done so that if one of the boilers is stopped or
operating at minimum, the others do not discharge into it. Depending on the
installation configuration, it may be necessary to install a valve at the boiler
outlet.
For this type of connection, the manufacturer offers exhaust connection
accessories with duct diameter A = 160 mm for the 40 and 60 kW models
and A = 200 mm for the 80 and 100 kW models. These accessories contain
a valve for each boiler.
If boilers of different power ratings are being connected, the most powerful
models should be closest to the chimney.
NOTE: The manufacturer's accessories do not allow 40/60 kW models
to be combined with 80/100 kW models.
4.2.3. Rules for installing air vent terminals
Please refer to national standards and regulations.

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4.2.4. Connection to a C13 or C33 vent (G20 and G25 only)
C13 type connection:
Air intake and gas evacuation via separate ducts connected to a horizontal
concentric terminal (vent).
C33 type connection:
Air intake and gas evacuation via separate ducts connected to a vertical
concentric terminal.
!IMPORTANT:
The use of the “Horizontal air vent” accessory is mandatory to connect
a CONDENSINOX boiler with a concentric C13 vent.
The use of the “Black vertical air vent” or "Ochre vertical air vent"
accessory is mandatory to connect a CONDENSINOX boiler with a
concentric C33 vent.
figure 4 - C13 type connection
figure 5 - C13 type connection
The dimension A indicates the upper
position of the boiler exhaust outlet
A min
L
A L