Atlantic Varmax Twin Parts list manual

MANUFACTURER:
1 route de Fleurville - BP 55
FR - 01190 PONT-DE-VAUX
PONT DE VAUX
(FRANCE) SITE
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Instructions
for installation,
use and main-
tenance
VARMAX TWIN
GAS CONDENSING BOILER
550 to 900 kW
with modulating burner for
natural gas
Document No. 00BNO9132-# / 23.02.2015
ENFR DE ES IT NL

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VARMAX TWIN - Installation, Use and Maintenance
SOMMAIRE
1. AVERTISSEMENTS ET RECOMMANDATIONS....................................................................4
1.1. Limite de fourniture de la VARMAX TWIN.....................................................................................................4
1.2. Transport et stockage....................................................................................................................................4
1.3. Symboles utilisés dans ce document............................................................................................................4
1.4. Qualification du personnel pour l'installation, le réglage, l'utilisation et l'entretien........................................5
1.5. Consignes de sécurité...................................................................................................................................5
1.6. Caractéristiques de l'eau...............................................................................................................................5
2. HOMOLOGATIONS ................................................................................................................6
2.1. Conformités aux Directives Européennes.....................................................................................................6
2.2. Conditions réglementaires d’installation pour la France ...............................................................................6
2.3. Conditions réglementaires d'installation pour la Belgique.............................................................................6
2.4. Conditions réglementaires d'installation autres pays....................................................................................7
2.5. Compatibilité environnementale....................................................................................................................7
2.6. Catégorie gaz................................................................................................................................................7
2.7. Pressions d'alimentation gaz.........................................................................................................................7
3. SPÉCIFICATIONS TECHNIQUES ..........................................................................................8
3.1. Dimensions ...................................................................................................................................................8
3.2. Passage de porte..........................................................................................................................................9
3.3. Combustion à 15°C et 1013 mbar.................................................................................................................9
3.4. Conditions d'utilisation.................................................................................................................................10
3.5. Raccordement électrique............................................................................................................................10
4. INSTALLATION.....................................................................................................................11
4.1. Mise en place des filtres à air et des nappes filtrantes ............................................................................... 11
4.2. Mise en place de la chaudière .................................................................................................................... 11
4.3. Mise en place des goulottes de passage câble bus LPB............................................................................13
4.4. Ouverture / fermeture des portes d'habillage..............................................................................................14
4.5. Démontage des panneaux de commande (IHM)........................................................................................14
4.6. Démontage / remontage des portes d'habillage..........................................................................................14
4.7. Démontage / remontage des panneaux latéraux........................................................................................14
4.8. Démontage / remontage des panneaux supérieurs....................................................................................14
4.9. Marchepied .................................................................................................................................................14
4.10.Changement de gaz (de G20 à G25).........................................................................................................14
4.11.Raccordement fumées ...............................................................................................................................15
4.12.Raccordement hydraulique ........................................................................................................................19
4.13.Raccordement gaz.....................................................................................................................................22
4.14.Raccordement électrique ...........................................................................................................................22
5. MISE EN SERVICE...............................................................................................................24
6. CONTRÔLES APRÈS LA MISE EN SERVICE.....................................................................24
7. OPÉRATIONS D'ENTRETIEN ..............................................................................................24
8. SCHÉMAS HYDRAULIQUES ET PARAMÉTRAGES..........................................................25
9. LISTE DES PIÈCES DÉTACHÉES.......................................................................................55

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1. WARNINGS AND RECOMMENDATIONS
PLEASE READ THIS MANUAL CAREFULLY BEFORE INSTALLING,
MAINTAINING AND USING THE BOILER. IT CONTAINS IMPORTANT
SAFETY INFORMATION.
1.1. VARMAX TWIN supply limits
The VARMAX TWIN boiler you have received is composed of:
•2 VARMAX type generators with the same power to be connected to each
other
•1 450 mm common exhaust flue between the generators
•4 Teflon plates (to help position the generators)
•2 LPB bus cable trays with holding screws
•1 LPB bus cable
•2 OCI 345 communication modules with holding screws
•1 QAZ 36 flow sensor
This manual describes the specific features of the assembly. Everything
which relates to one of the 2 generators (internal accessibility, settings,
maintenance, spare parts, etc.) is described in the particular generator's
manual. The following data must therefore be used:
- For the VARMAX TWIN 550, see the information for the VARMAX 275,
- For the VARMAX TWIN 640, see the information for the VARMAX 320,
- For the VARMAX TWIN 780, see the information for the VARMAX 390,
- For the VARMAX TWIN 900, see the information for the VARMAX 450.
1.2. Transport and storage
The generators:
-must bearrangedhorizontallyin aplacewherethetemperature isbetween
0 °C and +50 °C and whose relative humidity is between 5% and 95%.
-must not be stacked,
-must be protected from humidity.
1.3. Symbols used in this document
INFORMATION: This symbol draws attention to comments.
!IMPORTANT: Failure to comply with these instructions may
cause damage to the installation or to other
objects.
INFORMATION: The hydraulic connection elements to be added according to the
diagram are not supplied (refer to chapters 4.12 and 8).

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VARMAX TWIN - Installation, Use and Maintenance
!WARNING: Failure to comply with these instructions may
cause injury and serious material damage.
WARNING: Failure to comply with these instructions may
cause electrocution.
1.4. Qualification of personnel for installation, adjustment, use and mainte-
nance
The operations to install, adjust and maintain the boiler must be carried out
by qualified and approved professionals in accordance with current local
and national regulations. These operations may required intervention under
voltage, with the casing doors (located on the front of the generators) open.
The basic usage operations must be carried out with the casing doors closed.
1.5. Safety instructions
• Always remove the power supply to the boiler and shut off the overall gas
supply to it before carrying out any work on it.
• Check that there are no gas leaks on the installation after any intervention
on the boiler (maintenance or repair).
!WARNING:
If you smell gas:
• Do not use any naked flames, smoke or activate any contacts or
electric switches.
• Switch off the gas supply.
• Ventilate the premises.
• Look for the leak and correct it.
!WARNING:
If any smoke is released:
• Switch off the generators.
• Ventilate the premises.
• Look for the leak and correct it.
WARNING:
This boiler's earth continuity is provided by link cables (green/yellow)
and specific holding screws. During any disassembly operations,
make sure that the cables in question are reconnected; you MUST
also reuse the original holding screws.
1.6. Water characteristics
Refer to the VARMAX generator's installation, use and maintenance manual.

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2. APPROVALS
2.1. Compliance with European Directives
- Low voltage (2006/95/CE)
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)
- Efficiency (92/42/CEE)
- Gas appliances (2009/142/CE)
2.2. Regulatory installation conditions
The appliance must be installed and maintained by a qualified professional,
in accordance with the regulations and current regulatory practices in the
country where the boiler is installed.
2.3. Environmental compatibility
This appliance contains electrical and electronic elements which must not be
thrown away with household waste.
Local legislation must be complied with.
2.4. Gas category
This boiler has been adjusted in the factory to work with group H (type G20)
natural gas with a supply pressure of 20 mbar.
INFORMATION: Any work on a sealed component will lead to loss of the guarantee.
Category
CZ, DK, EE, FI, GB, GR, HU, IE, LT,
LV, NO, RO, SE, SI, SK, TR I2H

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VARMAX TWIN - Installation, Use and Maintenance
2.5. Gas supply pressures
INFORMATION: The pressures provided below must be taken at the input to the gas
valve (20 mbar).
Natural gas H G20
20 mbar
Nominal pressure (mbar) 20
Minimum pressure (mbar) 17
Maximum pressure (mbar) 25

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VARMAX TWIN - Installation, Use and Maintenance
A
B
D
3°
E
450
±
10
3. TECHNICAL SPECIFICATIONS
3.1. Dimensions
figure 1 - Dimensional characteristics
C
3°
øF
MODELS
550 640 780 900
A (mm) 2059 2259
B (mm) 1877 2023
C (mm) 2032 2114
D (mm) 2519 2749
E (mm) 1500 1590
Ø F (mm) 250 300
The diameter indicated is the interior
diameter.
!IMPORTANT:
The dimension of 450 mm between the 2 generators must be respected
to assemble the exhaust flue (it is not a minimum or maximum
dimension).
sleeve for safety valve on
each generator (F 1"1/4)
45 min 60 max

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VARMAX TWIN - Installation, Use and Maintenance
Refer to the VARMAX generator's installation, use and maintenance manual.
3.3. Combustion at 15°C and 1013 mbar
MODELS
550 640 780 900
Nominal power Pn (80/60°C) kW 536 624 762 878
Nominal power when condensing Pn
(50/30°C) kW 580 676 830 956
Rated heat input Qn kW 550 640 780 900
Min heat input Qmin kW 66 66 87 87
Gas flow rate at Pn (15 °C) * m3/h 58.2 67.72 82.6 95.2
CO2value range %at Qmin: 8.3 % < CO2< 8.7 %
at Qmax: 8.8 % < CO2< 9.2 %
Exhaust mass flow rate at Qn / Qmin
(80/60°C) * g/s 240.1 and
31 257.7 and 30.9 352 and 43 398 and 44
Exhaust mass flow rate at Qn / Qmin
(50/30°C) * g/s 225.9 and
26 239.5 and 26.6 327 and 41 378 and 42
Exhaust temperature at Qn / Qmin
(80/60°C) * °C 61 and 54.7 60.8 and
55.1 60.3 and 54.5 62.1 and 55.6
Exhaust temperature at Qn / Qmin
(50/30°C) * °C 35.4 and
30.7 37.1 and 31 36 and 29.3 36 and 30.4
Firebox pressure at nominal Qcal
(B23) Pa 132 162 152 203
Exhaust outlet interior diameter mm 250 250 300 300
Maximum allowable nozzle pressure
(B23P) at Qn / Qmin (80/60°C)* Pa 127 and 3 151 and 3 177 and 3 200 and 3
Maximum allowable nozzle pressure
(B23P) at Qn / Qmin (50/30°C)* Pa 104 and 3 123 and 3 149 and 3 178 and 3
Combustion air flow rate at Qn *
(15°C) m3/h 704.8 820.2 999.6 1153.4
NOx class 5
Smoke removal and air inlet type
classifications B23, B23P
* values corresponding to a G20 setting.
3.2. Doorway

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3.4. Operating conditions
MODELS
550 640 780 900
Max flow temperature setting °C 85
Max flow temperature °C 88
Maximum safe temperature °C 110
Max service pressure hPa
(bar) 6000 (6)
Min cold pressure hPa
(bar) 1000 (1)
Hydraulic pressure loss at ∆T 20 per generator
daPa
2 or 3 tapping version 820 1185 770 970
4 tapping version
Main exchanger
Condenser 790 50 1060 65 660 190 840 230
Nominal water flow rate (P/20) VARMAX TWIN m3/h 23 26.8 32.8 37.8
Nominal water flow rate (P/20) per generator m3/h 11.5 13.4 16.4 18.9
Maximum water flow rate (P/10) per generator m3/h 23.0 26.8 32.8 37.8
Total water content (2 generators) L 478 478 574 574
Total weight without water (2 generators) kg 1050 1050 1240 1240
Installation premises temperature (min / max) °C 5 and 45
Installation premises relative humidity between 5% and 95%
Protection level IP20
Maximum installation altitude m 2000
3.5. Electrical connection
MODELS
550 640 780 900
Electrical supply V 230 V AC (+10% -15%), 50Hz
Electrical power consumed at Qn (excluding
accessory) VARMAX TWIN W 476 704 960 1320
Electrical power consumed in standby mode
VARMAX TWIN W10
Maximum length of sensor cables m
DHW sensor: 10
Outdoor sensor: 40 in 0.5 mm² (120 in 1.5 mm²)
Ambient thermostat: 200 in 1.5 mm²
Room thermostat: 200 in 1.5 mm²
Power terminal output per generator V 230V AC (+10%, -15%)
A 5 mA at 1A

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VARMAX TWIN - Installation, Use and Maintenance
4. INSTALLATION
4.6. Positioning the air filters and the filtering layers
!IMPORTANT: The air filters provided with the generators MUST be installed.
The air filters must be installed before the gas lines are connected.
Refer to the VARMAX generator's installation, usage and maintenance
manual, paragraph "4-1 Positioning the air filter and the layer").
4.7. Installing the boiler
The VARMAX TWIN boilers must not be installed on an flammable surface
(wooden floor, plastic floor covering, etc.).
Recommended distances relative to 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 in the table below.
A* B* C H
MODELS
550 450 600 263
640 450 600 263
780 450 700 427
900 450 700 427
The greyed out zone above the boiler must remain free of any obstacles
to enable the burner to be inspected and cleaned.
These values cannot be substituted for the specific regulatory
requirements.
figure 2 - Peripheral clearance
H
A
B
C450±10

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!IMPORTANT:
• The 2 VARMAX generators must be positioned horizontally using a
spirit level to enable effective gas release for the exchanger body
(use the base as the reference surface).
• The space between the 2 VARMAX generators must be 450±10 mm.
• A 2 cm free space must also be left above the side panels to allow
for their disassembly and reassembly.
• The 2 generators must be in the same alignment and on the same
horizontal level.
figure 3 - Generator positioning
450±10
OK
OK
OK
To adjust the flush level, screw or unscrew the 4 adjustable feet, using a 17
mm wrench.

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4 Teflon plates are provided to facilitate the introduction of the 2 generators
in relation to each other:
• Put one plate under each of the 4 feet of the generator to be moved,
• Position the generator,
• Remove the Teflon plates.
figure 5 - cable trays
Teflon plates (x4)
4.8. Installing the LPB bus cable trays
Position the 2 trays for the LPB bus cable on the rear of the 2 generators and
secure them using the 4 self-tapping screws provided.
figure 4 - Teflon plate positioning
}
4 self-tapping screws provided
The roof of each generator must be drilled (Ø 4 bit); to do so, use the trays
as scale.

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4.9. Opening / closing the casing doors
Refer to the VARMAX generator's installation, use and maintenance manual.
4.10. Removing the control panels (MMI)
Refer to the VARMAX generator's installation, use and maintenance manual.
4.11. Installing / removing the casing doors
Refer to the VARMAX generator's installation, use and maintenance manual.
4.12. Installing / removing the side panels
Refer to the VARMAX generator's installation, use and maintenance manual.
4.13. Installing / removing the upper panels
Refer to the VARMAX generator's installation, use and maintenance manual.
4.14. Step
Refer to the VARMAX generator's installation, use and maintenance manual.

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VARMAX TWIN - Installation, Use and Maintenance
4.15. Exhaust connection
!IMPORTANT:
There is a specific connection for the exhausts to the VARMAX TWIN
boilers. Do not refer to the VARMAX generator's installation, use and
maintenance manual.
The size of the chimney pipes must be determined taking account of
combustion gas pressure on boiler output equal to 0 Pa (see table § 3.3).
You must comply with the regulatory texts and rules of the art that apply in
the country where the boiler will be installed, i.e.:
One exhaust temperature sensor per generator guarantees the
protection of the combustion product evacuation ducts.
The VARMAX TWIN boilers are approved to be connected to:
• a B23 chimney (all models)
• a B23P chimney (all models)
4.15.1. Installing the exhaust flue
Theflueprovidedmaybeinstalledeither to the right orthe left ofthe VARMAX
TWIN boiler.
INFORMATION: The duct lengths provided below are in linear metres (ml). The total length of all the ducts is rounded to a straight-line length (the curves have a
straight-line equivalent).
figure 6 - Flue orientation
Example with exhaust outlet to the left:
INFORMATION:
When assembling the flue, we recommend fitting the assembly on
the ground then installing it on the 2 generators. At least 3 people are
required to handle and secure the assembly.

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ITEM MODELS DESCRIPTIONS QTY
550 - 640 kW 780 - 900 kW
1AC-250-180 AC-300-200 Offset increase 2
2ED 250-250 CD ED 250-300 CD Straight element length 250 4
3EC 90-250 CD EC 90-300 CD 90° curved element 2
4ER 26/40 250 CD ER 26/40 300 CD Adjustable element length 260-400 2
5T 135-250 CD T 135-300 CD T 135° 2
6EPMF 250 EPMF 300 Measurement element 1
7ER 55/90 250 ER 55/90 300 Adjustable element length 550-900 1
8CEPL 250 CD CEPL 300 CD Side drain buffer 1
9SIPHON 1" SIPHON 1" Siphon 1
10 JOINT-CD-250 JOINT-CD-300 Seal 19
11 -- -- Tube of grease for seals 1
!IMPORTANT:
The 2 collars delivered with the smoke works kit may be used to
support the assembly either on the ceiling or on the ground (their
position is "greyed out" on each T at 135° - figure 7).
figure 7 - Flue assembly
12
2
3
4
5
6
728
9
1
Indicative values
550 - 640 kW models: 1250 mm
780 - 900 kW models: 1350 mm
10
11
Measurement
(upwards)
!IMPORTANT:
During final connection to the generator exhaust outlet nozzles, make
sure that there are not too many mechanical demands on the 2 offset
increases (item 1) as this may create seal losses for the exhaust.
support collars
to condensation
neutraliser

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VARMAX TWIN - Installation, Use and Maintenance
4.15.2. Connection to a B23 chimney
B23 type connection:
Air from the installation premises, gas evacuation through the roof via a
natural draft pipe.
!IMPORTANT:
Check that the boiler installation premises have high and low
ventilation, that it conforms to current regulations and that it is not
obstructed.
The size of the chimney pipes must be determined taking account of
combustion gas pressure on boiler output equal to 0 Pa (see table § 3.3).
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 able to withstand exhaust temperatures up to 120°C. Horizontal
pipes must be avoided to limit condensation build-up.
Check that the combustion gas is evacuated via a sealed connection.
VARMAX TWIN 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.
!WARNING:
Check:
1. That the flue is not under pressure, with both generators operating.
2. If one of the generators is operating at minimum power, that the
other generator does not discharge into it.
Dimensioning recommendations based on a POUJOULAT type
(Condensor type) supply:
figure 8 - Sizing recommendations
ø connection
ø duct H
(1 m)
hose PROHIBITED
for the elbow joint
!

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Exhaust duct height in linear metres (ml)
(in 50/30°C operating regime)
øconnection 250 mm 300 mm
øduct 300 mm 350 mm 350 mm 400 mm
MODELS
550 15 to 50 3 to 50 -- --
640 16 to 50 3 to 50 -- --
780 -- -- 15 to 50 5 to 50
900 -- -- 33 to 50 6 to 50
!WARNING: The values below are provided for information purposes. They must
be checked by calculation.
!WARNING: The VARMAX TWIN flue must not be made to support the exhaust
duct's weight.
4.15.3. Connection to a B23P chimney
B23P type connection:
Air from the installation premises, gas evacuation through the roof via a
pressurised duct.
!WARNING: For B23P type connection, it is VITAL to use ducts with CONDENSOR
(Poujoulat) type CSTB notice (pressurised ducts).
!WARNING:
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 configuration of the duct, a calculation is
required to check that the pressures at the boiler outlet do not exceed
the maximum allowable values (200 Pa).
Values corresponding to the 50/30°C regime are to be used for this
calculation.
Dimensioning recommendations based on a POUJOULAT (Condensor
type) supply: See the figure on the previous page.
!IMPORTANT:
Check that the boiler installation premises have high and low
ventilation, that it conforms to current regulations and that it is not
obstructed.

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VARMAX TWIN - Installation, Use and Maintenance
!WARNING: The values below are provided for information purposes. They must
be checked by calculation.
Exhaust duct height in linear metres (ml)
(in 50/30°C operating regime)
øconnection 250 mm 300 mm
øduct 250 mm 300 mm
MODELS
550 1 to 100 --
640 1 to 100 --
780 -- 1 to 100
900 -- 1 to 100
!WARNING: The VARMAX TWIN flue must not be made to support the exhaust
duct's weight.
4.16. Hydraulic connection
A water circulation pump integrated into each generator and a smart
regulation logic enable optimum operation up to Pinst/30 (Pinst =
Instant output power expressed as Th/h - 1Th/h = 1.163 kW).
Below this rate of Pinst/30, the generators will continue to operate, but
will gradually reduce their power (shutdown below Pinst/46).
In the main exchanger, as in the condenser on each generator, you must
ensure that the rates recommended in paragraph 3.4 are not exceeded
(i.e. Output power in nominal Th/h generator / 10).
Therefore, a differential pressure valve must be integrated into
the circuit according to the diagam.
Sizing the pipes connecting the boiler to the installation must be done
carefully, to minimise the pressure losses and so avoid oversized circulating
pumps.
In some cases the diameter of the connection pipes will be greater than the
diameter of the boiler tappings. The diameter increase can then be made
advantageously after the union connectors, the stop valves, and/or the
hydraulic balancing valves.
Tichelmann assembly encourages a natural balance of the flow rate between
the 2 generators.
The VARMAX TWIN boilers are equipped with the following elements:
• A drainage valve on each generator's main exchanger,
• A drainage valve on each generator's condenser.

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In accordance with the diagram, it is imperative to fit the boiler and its
installation with the following components:
• powered isolating valve (with an end of run contact*) on the flow tapping
on each generator's main exchanger,
• balancing / isolating valve on each generator's return tapping,
• anti-return flap,
• filters,
• mud cup,
• expansion vessel,
• effective drain mechanism,
• safety valve set at 6 bars, on each generator, sized according to each
generator's heat output (see location figure 1 page 8).
• disconnector on the boiler's filling circuit in relation to the supply network.
(*) The end of run contact only allows the generator to start up when full
opening is reached.
The VARMAX TWIN are delivered either in 2/3 tapping connection
version or in 4 tapping connection version.A2/3 tapping version cannot
be converted into a 4 tapping version and vice versa.
4.16.1. Hydraulic connection using 2 tappings
figure 9 - Hydraulic connection using 2 tappings
B3000 B3000
QAZ36
(fournie)
OCI345
(fourni)
OCI345
(fourni)
câble «bus LPB»
(fourni)
Main exchanger
output
(hot return flange blocked)
Cold return
LPB bus cable
(supplied)
QAZ36
(supplied)
OCI345
(supplied) OCI345 (supplied)