Atmos HE22 Release note

Atmos InterOpen
Installation & Servicing Instructions for HE22
(GC 41-249-06)
Atmos Heating Systems
West March
Daventry
Northants, NN11 4SA
Tel: [phone]
Fax: [phone]
e-mail: [email protected]
internet: www.atmos.uk.com
Issue 22.01.10 (Main revision)

© 2010 Atmos Heating Systems
The information provided applies to the product in the standard model. Atmos Heating
Systems can therefore not be held liable for any damage resulting from the product
specifications that deviate from the standard model.
The information provided has been compiled with the utmost care. However, Atmos
Heating Systems cannot be held liable for any faults in the information nor for the
consequences thereof.
Atmos Heating Systems cannot be held liable for any damage resulting from the
activities carried out by third parties.
To be changed without prior notice
Building Regulations and the Benchmark Checklist
Building Regulations (England & Wales) require notification of the installation of a heating
appliance in a dwelling to the relevant Local Authority Building Control Dept. This can be
achieved via a Competent Persons Self Certification Scheme as an option to notifying the Local
Authority directly. Similar arrangements apply in Scotland and Northern Ireland.
Atmos Heating Systems is a member of the Benchmark Scheme and the Benchmark Checklist
is included at the back of these Instructions. The Benchmark Checklist provides a
Commissioning Checklist and Service Record to be completed by the Installer/ Service
Engineer.
Benchmark places responsibilities on both manufacturers and installers.
The purpose is to ensure thatcustomers are provided with thecorrect
equipment for their needs, thatit is installed,commissioned and serviced in
accordance with the manufacturer’s instructions by competent persons and
that it meets the requirements of the appropriate Building Regulations. The
Benchmark Checklist can beused to demonstrate compliancewith Building
Regulations and should be provided to the customer for future reference.
Installers are required to carry out installation, commissioning and servicing
work in accordance with theBenchmark Code of Practicewhich is available
from the Heating and HotwaterIndustry Council who manage and promote
the Scheme. Refer to www.centralheating.co.uk for more information.
2

TABLE OF CONTENTS
1. Safety Regulations 7
1.1 General.......................................................................................................................................................................7
1.2 CH system...................................................................................................................................................................7
1.3 Gas system.................................................................................................................................................................7
1.4 Electrical system.........................................................................................................................................................7
1.5 Domestic water system...............................................................................................................................................7
1.6 Flue discharge and air supply.....................................................................................................................................7
2. Description of the Appliance 8
2.1 General.......................................................................................................................................................................8
2.2 Operation....................................................................................................................................................................8
2.3 Operating conditions...................................................................................................................................................8
2.4 PC interface..............................................................................................................................................................10
2.5 Test programmes......................................................................................................................................................10
3. Main Components 11
3.1 Accessories...............................................................................................................................................................12
4. Installation 13
4.1 Overall dimensions....................................................................................................................................................13
4.2 Unpacking the appliance...........................................................................................................................................14
4.3 Additional dimensions...............................................................................................................................................14
4.4 Boiler location............................................................................................................................................................15
4.5 Mounting...................................................................................................................................................................16
4.6 Mount the appliance..................................................................................................................................................17
4.7 Fit the pipework cover (optional)...............................................................................................................................17
4.8 Condensate disposal.................................................................................................................................................18
5. Connections 19
5.1 Connect the CH system............................................................................................................................................19
5.2 Connect the gas supply.............................................................................................................................................19
5.3 Electrical connection.................................................................................................................................................20
5.4 General Flue Requirements......................................................................................................................................22
5.5 Flue discharge and air supply...................................................................................................................................23
5.6 Roof outlet prefabricated chimney.............................................................................................................................29
5.7 Atmos MS System.....................................................................................................................................................30
5.8 Atmos Communal Flue System (CFS)......................................................................................................................31
6. Commissioning 32
6.1 Fill and de-aerate the appliance and the system.......................................................................................................32
6.2 Commissioning of the appliance...............................................................................................................................33
6.3 System Shutdown.....................................................................................................................................................34
7. Setting and Adjustment 35
7.1 Directly via operating panel.......................................................................................................................................35
7.2 Settings through the service code.............................................................................................................................35
7.3 Parameters................................................................................................................................................................36
7.4 Setting maximum CH power......................................................................................................................................37
7.5 Setting pump power..................................................................................................................................................37
7.6 Conversion to other gas type....................................................................................................................................38
7.7 Gas-air control...........................................................................................................................................................38
7.8 Setting gas-air control...............................................................................................................................................39
7.9 Carbon monoxide : carbon dioxide ratio....................................................................................................................40
8. Faults 41
8.1 Burner does not ignite...............................................................................................................................................42
8.2 Burner ignites with much noise.................................................................................................................................42
8.3 Burner resonates.......................................................................................................................................................43
8.4 No heating (CH)........................................................................................................................................................43
8.5 Reduced output.........................................................................................................................................................44
8.6 CH does not reach the correct temperature..............................................................................................................44
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9. SERVICING THE BOILER AND COMPONENT REPLACEMENT 45
9.1 SERVICING THE BOILER........................................................................................................................................45
9.2 COMPONENT REPLACEMENT...............................................................................................................................46
10. Technical Specifications 48
10.1 Electrical diagram......................................................................................................................................................49
11. CE Declaration 50
NOTE The Benchmark Checklist & Service Record are included at the back ofthe Manual.
4

This manual
Using this manual you can safely install and maintain thisappliance.
Carefully follow the instructions.
In case of doubt, contact AtmosHeating Systems.
Keep these instructions nearthe appliance.
Abbreviations and names used
Description To be referred
to as
High Efficiency HE
Atmos InterOpen wall-mounted gas heater Appliance
Appliance with piping for central heating CH system
Icons
The following symbols are used in this manual:-
CAUTION
Procedures that, when not carried out with due care,
may result in damage to the product or the
environment or in personal injury.
Service and technical support
For information about specificadjustments, installation, maintenance
and repair activities, please contact:
Atmos Heating Systems,
West March,
DAVENTRY,
Northants, NNII 4SA
Tel: [phone]; fax: [phone]
Email: [email protected]; internet:www.atmos.uk.com
Environment
When the appliance needs replacement, your installer may
arrange for disposal. Should this not be possible, then
make enquiries with your local council about the
possibilities for re-use or environmental-friendly processing
of the materials used, or contacta scrap dealer about
disposal.
Various plastics and metals have been used in producing
the appliance. Also, the appliance contains electronic
components that are electronic waste.
Intended use
The appliance as described in this documentation is intended for heating
rooms with a central heating system and, if required, heating hot water via
an indirect hot water tank. Any other use is outside thescope of intended
use for this appliance. Any liability for damage resultingfrom improper use
shall not be accepted.
5

Atmos Warranty – Short version
1. Atmos Warranty is against anymaterial, construction or operation faults
that are found to be of originalmanufacturing origin. A full statement of
the Atmos Warranty is available (www.atmos.uk.com or 01327 871990).
2. Atmos boiler warranty is, subject to conditions; two years from date of
invoice, or 12 months from dateof installation; whichever is the later.
The warranty shall be 2 years for replacement parts and associated
labour, thereafter any warranty period shall cover parts only. The heat
exchanger warranty is 10 yearsin total, including the first two years
parts and labour warranty.For purchases before 01/01/08 this extended
period was 5 years.
3. We guaranty the free redelivery of parts covered by the warranty. Any
alleged faulty part must be returned to Atmos carriageprepaid. Carriage
will be credited if the part is found to be manufacturer’s fault.
4. Any claim must be accompanied with the serialnumber of the product.
5. All products must be used in an appropriate applicationand manner.
This includes but is not limited to; correct boiler sizing, system design,
system cleansing and use of corrosioninhibitors. Where appropriate
and always in areas of “hard water” (in excess of 200 ppm) anapproved
water conditioner device must be fitted (in accordancewith Building
Regulations)
6. Completion of the Benchmark Checklist & Service Recordis a condition
of the boiler warranty (Customer’s statutory rights not affected); which
must be completed and supplied to Atmos if required. The Warranty
card must be completed and the signed Atmos copy receivedwithin 8
days of installation. By signingthe Warranty card the buyer agrees that
the goods have been delivered in a satisfactory condition.
Exceptions
7. In the event of full payment fora product not being received, Atmos
shall be discharged from all further contractual or warranty obligations.
8. Surface and/or transport damage are outside the scopeof this warranty.
9. Any warranty provision shallnot apply if Atmos determine that the fault
is due to improper application,use, neglect, accidental damage or
injudicious treatment, non-observance of instructions contained in
Atmos Manuals; or due to improper repair, adjustment, installation or
maintenance; or due to workcarried out by unqualified engineers. The
warranty also lapses if the Atmos boiler has not had a yearlyservice in
accordance with instructions.
10. This warranty shall not apply ifthe fault is caused by scale, failure or
abnormality of gas or water supply, or impact of any external influence
that adversely affects the normal operation of the product. This shall
include but not be restrictedto dehydration, abnormal or high voltage,
and hard water.
11. Excluded parts: ignition & ionisation probe, glass fuse,and air vent.
6

1. SAFETY REGULATIONS
The appliance must be installed in accordance with the Gas Safety
(Installation and Use) Regulations; October 1994. Failure to install appliances
correctly could lead to prosecution.
Atmos Heating Systems does not accept any liability for damage or injury
caused by not (strictly) observing the current safety regulations and
instructions, nor by negligencewhile installing the Atmos InterSystem
wall-mounted gas heater andany accompanying accessories.
The manufacturer’s instructions must NOT be taken as overriding statutory
requirements.
The regulations are mentioned separately for the different disciplines.
1.1 General
The entire system should comply with the valid (safety) regulations, as
mentioned in:-
•This installation manual.
•Gas Safety (Installation andUse) Regulations
•The appropriate Building Regulations.
•Health and Safety Document No 635 (Electricity at WorkRegulations)
•The Water Fittings Regulationsor local Water byelaws.
1.2 CH system
The entire system should comply with the valid (safety) regulations, as
mentioned in:-
•BS 5449 Central Heating for Domestic Premises.
1.3 Gas system
The entire system should comply with the valid (safety) regulations, as
mentioned in:-
•BS 6798 Specification for installation of gas fired hot water boilers of rated input
not exceeding 60 kW.
•BS 6891 Installation of low pressure gas pipework installations up to 28mm
(R1).
•I.S.813 Installation of Gas Appliances (for installations in Ireland).
•British Gas Guidance Notes for the Installation of Domestic Gas Boilers.
1.4 Electrical system
The entire system should comply with the valid (safety) regulations, as
mentioned in:-
•BS 7671 The IEE Wiring Regulations.
1.5 Domestic water system
The entire system should comply with the valid (safety) regulations, as
mentioned in:-
•BS 5546 Installation of gas hot water supplies for domestic purposes.
1.6 Flue discharge and air supply
The flue discharge and the airsupply system should comply with:-
•BS 5440 Flues and Ventilation for gas appliances of rated input not exceeding
60 kW. (Part 1 Flues and Part 2 Ventilation).
7

2. DESCRIPTION OF THE APPLIANCE
2.1 General
The Atmos InterOpen wall-mounted gas boiler is suitable foropen vent
systems with a header tank. The appliance is designed for delivering
heat to the water of a CH system and heating hot water viaan indirect
hot water tank.
The air supply and flue discharge can be connected to the appliance by
means of two separate pipesor a concentric connection.
The appliance has its own wallmounting strip, but can also be fitted to
an optional wall mounting frame that allows top connection of the gas
pipe.
The Atmos InterOpen wall-mounted gas boiler has the CE quality mark
and the Gas certification labels HE (Sedbuk B) and IP44Protection
class.
The appliance as delivered issuitable for natural gas (G20). A
conversion kit for propane (G31) can be supplied uponrequest.
2.2 Operation
The Atmos InterOpen wall-mounted gas heater is a modulating high
efficiency boiler. This implies that the power is adjustedto the heat
demand.
In the aluminium heat exchanger is an integrated copper circuit.
The appliance has been provided with an electronic controller that
controls the fan with the heatdemand from the heating system or the hot
water tank, opens the gas valve and ignites the burner, continuously
monitors the flame and controls it dependent on the power required.
2.3 Operating conditions
A code indicates the operating condition of the appliance on the service
display of the operating panel.
- Off
The appliance is not operating, but there is electricalpower. There is no
response to any demand forCH (heating or hot water tank). The frost
protection is active though. This means that the pump starts running and
the heat exchanger is heatedwhen the temperature of the heat
exchanger drops to 5°C.
When the frost protection is activated, code 7 appears (heating of the
heat exchanger).
Waiting position
The LED of the on/off button is on. The appliance is ready for
responding to the demand forCH (heating or hot water tank).
8

Note
Pump overrun is only available if the
pump output is used (terminal X2/8)
– see also §5.3.3.
0 Pump overrun
After the operation of the CH,the pump has an overrun. This overrun
time is set to the value according to parameter 8 (see§ 7.3; factory
setting is 1 min). This setting can be changed. Also, the controller will
automatically run the pump for 10 seconds, once every 24 hours, to
prevent it from getting stuck.This activation of the pump takes place at
the time of the last heat demand 24hrs later. In order to change this
time, set the room thermostat higher for a while at the desired time.
1 Required temperature reached
The controller can temporarily block the heat demandand stop the
burner. This blocking takes place because the requiredtemperature has
been reached. When the temperaturehas dropped sufficiently, the
blocking is cancelled.
2 Self-test
The controller regularly checks the connected sensors. During the
check, the controller does notcarry out any other tasks.
3 Ventilate (Fan)
On starting, the fan is first brought to the starting speed. When the
starting speed has been reached, the burner is ignited.Code 3 is also
visible after stopping the burner, when post-purge takes place.
4 Ignite
When the fan has reached the ignition speed, the burner is ignited by
means of electric spark ignition. During ignition the code 4 appears. If
the burner is not ignited, another ignition attempt is made after about
5 seconds. If the burner hasstill not fired after the fourth ignition attempt,
the controller indicates a fault.See §8.1.
5 CH operation
An on/off thermostat can be connected to the controller. Seethe
Electrical diagram §10.1. Whenheat is demanded by a thermostat
signal, the fan runs (code 3 ) and the burner is ignited(code 4 ),
followed by the CH operating condition (code 5 ).
During CH operation, the fan speed and hence the power of the
appliance is adjusted. This is done in such a way, that the temperature
of the CH water is controlled towards the set CH supply temperature.
The CH supply temperature isset at the operating panel.
During CH operation, the demanded CH supply temperature isdisplayed
on the operating panel.
During CH operation, the actual CH supply temperature canbe read by
pressing the service button.
9

2.4 PC interface
The controller has an interface for a PC. With a special cableand
accompanying software, a PC can be connected. Thisprovision makes it
possible to follow the behaviour of the controller, the appliance and the
heating system during a long period.
2.5 Test programmes
In the controller, there is provision for putting the appliance into a test
status.
By activating a test programme,the appliance will become active witha
fixed fan speed without intervention of the control functions. The safety
functions remain active though.
Simultaneously press + and –to switch off the test programme.
Test programmes
Description of programme Button
combinations Display reading
Burner on with minimum CH
power "service" and "-" “L”
Burner on with maximum
CH power "service" and “+” (1x) “h”
Burner on with maximum
power (set by parameter 4) "service" and “+” (2x) “H”
Switch off test programme "+" and "-" Current
operating
condition
2.5.1 Frost protection
The boiler has provision forprotecting its heat exchanger asdescribed
below.
NOTE! However to avoid thecondensate freezing, the boilermust be
installed in a FROST-FREE room.
•In order to avoid freezing of the appliance (heat
exchanger), it has an appliance frost protection.
When the temperature of the heat exchanger drops
to 5ºC, the burner will be activated and the pump
will start running until the temperature of the heat
exchanger reaches 10ºC.
Code 7 is given when the appliance frost
protection intervenes (heatingheat exchanger).
•When the system (or a part thereof) can freeze, a
frost thermostat should be installed in the area to
be protected. Connect this according to the wiring
diagram. See § 10.1.
Remark
When the appliance is out of action ( - on the service display), the
appliance frost protection is still active. However, there will be no
response to heat demand from an (external) frost thermostat.
10

3. MAIN COMPONENTS
A Gas valve I Flue discharge (or concentric connection)
B Clamping plate J Connecting block / terminallist X
C Supply sensor S1 K Condensate discharge
D Return sensor S2 L Condensate trap
E Fan M Heat exchanger
F 1m connecting cable 230 V ~ N Controller operating panel anddisplay
G Sight glass and mirror O Ionisation/ignition probe
H Air supply (left or right) P Position type plate
Q Drain valve
Additional Components supplied :-
Valve set (supplied separatelywith boiler)
11

3.1 Accessories
Description Part Ref
Rear mounting frame for top pipe connection 092507
Bottom Pipework cover 092527
Conversion set to Propane (LPG or G31) 075537
Interface cable (for Installers) 230677
12

4. INSTALLATION
4.1 Overall dimensions
A= CH flow 22 mm diameter h= 610mm InterOpen HE 22
B= CH return 22 mm diameter H= 750mm InterOpen HE 22
C= Gas 15 mm diameter Z= Flue gas outlet 80 mm diameter
F= Condensate 32 mm dia (after trap 25 mm dia flexib )le Y= Air supply inlet 80 mm diameter
13

4.2 Unpacking the appliance
1. Unpack the appliance.
2. Check the content of the packaging. This consists of:-
•Appliance (A)
•Mounting strip (B)
•Condensate trap (C)
•Installation Instructions
•User Operating Instructions
•Warranty card
3. Valve set (supplied separatelywith boiler) comprising 2 x 22mm
isolation valves, 1 x gas valve.
4. Check the appliance for any damage: report damage tothe Supplier
immediately.
CAUTION: This appliance should be lifted and handled by 2 people.
(Weight: 34 kg)
4.3 Additional dimensions
The diagram shown below gives additional dimensions primarily for the
mounting arrangement using the OPTIONAL mounting bracket.
14

4.4 Boiler location
Clearances
Above casing 200mm min
Below casing 230mm min
RH 30mm min
LH 30mm min
Front 30mm min (in operation)
Front 450mm min (servicing)
Keep 50 mm free space above the front panel in order to be able to
remove the front panel from the casing.
The appliance can be fitted to amounting frame. The assembly or just
the appliance should be mounted to a wall with sufficient bearing
strength. In case of light wallconstructions, resonance sounds may
occur.
The appliance is suitable formounting on a combustible wall (eg stud
wall).
There must be an earthed electrical supply within a distance of 1 m from
the appliance.
In order to avoid freezing of the condensate discharge, the appliance
should be installed in a frost-free room.
4.4.1 Installation in a kitchen cupboard
Make sure there is sufficientventilation above and below the appliance.
When the appliance is placed in a small cupboard, ventilation openings
of at least 50 cm2must be made.
4.4.2 Installation in an airing cupboard
Compartment ventilation is not required for a standard airing cupboard
(eg 0.6 x 0.6 x 2.3m high).
4.4.3 Remove front panel
Remove the optional pipework cover and the front panelfor carrying out
work on the appliance as follows:-
1. Remove the pipework cover(A), if used, forwards.
2. Unscrew both recessed crosshead screws (B) at the bottom of the
appliance.
3. Lift the front panel (C) vertically upwards and remove it forwards.
15

4.5 Mounting
Depending on the mounting option ordered, the followingmounting
methods are available:-
Mounting strip (A) alone,
OR rear mounting frame (C), which is an optional item. This arrangement
allows for vertical pipeworkbehind the boiler.
Note that for this appliance, the CH flow and CH return are at the top
of the casing.
4.5.1 Fitting the mounting strip
C
A
1. Fasten the mounting strip horizontally to the wall, using the screws
and plugs supplied.
2. Mount the appliance.
3. Mount the gas valve.
4. Make the CH flow and CH return connections.
4.5.2 Fitting the rear mounting frame
1. Fasten the frame vertically tothe wall, using screws and plugs.
2. Mount the appliance.
3. Slide the gas pipe into the frame and mount the gas valve.
4. Make the CH flow and CH return connections.
Caution
The appliance is wider than the frame by 20mm.
16

4.6 Mount the appliance
1. Place the appliance: slide it top-down over the mounting strip.
2. The flexible tube from the condensate trap should be inserted into
an open waste pipe of not less than 32 mm diameter. If connected
to a soil pipe or waste system, the waste pipe must include a trap
(similar to arrangement for washing machine). For more information
on condensate disposal, please refer to §4.8.
3. Mount the air supply and the flue discharge.
4. Close the air supply opening that is not used with the plug supplied.
4.7 Fit the pipework cover (optional)
1. Insert the four hooks of the pipework cover in the slots of the
appliance.
2. Slide the cover backwards,sliding the hooks into the slots and
locking the cover.
17

4.8 Condensate disposal
The appliance is provided witha 25 mm flexible pipe from its
condensate trap. As given in§4.6, this should be inserted into an open
waste pipe of not less than 32mm diameter, together with the safety
discharge pipe. The condensate is slightly acidic (pHbetween 3 and
6) and should be disposed of in the following ways, using suitable
plastic waste pipe (Note: copper or steel must not be used):-
•internal stack pipe (see diagram)
•waste pipe (see diagrams)
•external drain or gulley
•purpose made soakaway
The pipework must incorporatea minimum fall of 2.5 degrees (or
44mm/metre) towards its point of termination. The condensate
pipework external to the property, or in an unheated part(eg a
garage), must be suitably insulated to protect against freezing, and the
length of the external pipe restricted to a maximum of 3 metre.
If an external drain or gulley is used, then the open end of thepipe
should be terminated below the grid level, but above thewater level.
If a proprietary soakaway is used, install at least 1 metre away from
the external wall and clear of foundations and services. The soakaway
is buried in the ground and surrounded by limestone chippings to
neutralise the condensate.
18

5. CONNECTIONS
5.1 Connect the CH system
1. Flush the CH system thoroughly.
2. Connect the flow and returnpipes to the top pipes from the
appliance.
All pipes must be mounted tension-free in order to avoidticking of
the pipes.
Existing connections must not be twisted in order to avoid leaks at
the connections with the external pipes.
The CH system should be provided with:-
•A drain tap at the lowest pointof the system.
•A header tank.
5.1.1 Thermostatic radiator valves
Building regulations require aroom thermostat to be fitted on all
installations. Do not fit a thermostatic valve on the radiators in the room
where the thermostat is situated, otherwise the controls will not function
correctly.
5.1.2 System bypass
A bypass is not required for the safe operation of the appliance. It may,
however, be required in conjunction with certain controls ona heating
system.
5.2 Connect the gas supply
1. Connect the appliance gas valve to the gas pipe.
2. Check the boiler's data plate to ensure that the appliance has been
set for the correct gas supply.The boiler is supplied for Natural Gas
(G20). A propane (G31) gasconversion set is available andan
appropriate sticker is included (see §7.7).
3. The meter governor should deliver a dynamic pressure of 20mbar
for natural gas or 37mbar for propane.
4. To prevent the ingress of foreign matter and possible damage to the
gas-regulating block, the gassupply pipe must be checked for
contaminants prior to connection to the boiler. Install agas filter if
necessary.
5. On final connection of the gassupply to the boiler, the complete gas
installation, including the meter, must be tested for gastightness
and purged as described in BS6891.
19

5.3 Electrical connection
CAUTION
The appliance requires a 230 V ac 50 Hz mains supply, and
must be earthed and connected via a double pole isolating
switch fitted with a 3 amp fuse. The switch must be readily
accessible, within 1m of the appliance, andprovide
complete electrical isolation for the boiler and control
system.
The appliance is supplied factory wired complete with 1 m
of mains cable. All electrical connectionsto the mains
supply must be made in full accordance with the current
I.E.E. regulations (BS 7671).
Isolate the supply by opening the double pole switch
when carrying out maintenance activities.
6. Remove the optional pipework cover forwards.
7. Unscrew the screws (A) inorder to gain access to the space ofthe
controller (B).
8. The cover plate (& display)hinges open downwards. This gives
access to the controller andelectrical connections.
9. Consult § 5.3 and § 10.1 formaking connections.
10. After having made the required connections, connect theappliance
to a switched supply, as given above.
Controller Label and Associated Terminals
20