Charot MAX'O GAZ User manual

MAX’O GAZ
Condensing water heater
TECHNICAL MANUAL
PO Box 11 Ashton Under Lyne OL6 7TR
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3
CONTENTS
THE COMPONENTS OF THE MAX’O GAZ………….….……………………………………1
BALANCED FLUE AND CONVENTIONAL FLUE MAX’O GAZ FEATURES……….…3
INSTALLATION OF THE MAX’O GAZ…………………..……………….……………………5
STANDARD PIPEWORK ARRANGEMENT………….……………………………….………8
PIPEWORK ARRANGEMENT WITH A TANK…………….……..……………………………..9
PIPEWORK ARRANGEMENT WITH A BUFFER STORAGE……………………………10
THE GAS PIPEWORK CONNECTIONS…………………………………………………….11
MAX’O GAZ GAS SUPPLY FROM A PRESSURE REGULATING VALVE…………...14
CONVENTIONAL FLUE ARRANGEMENT……………………………………………..…15
BALANCED FLUE CONNECTIONS ON WALL OUTLET………………………………..16
HORIZONTAL BALANCED FLUE…………………..………………………………………17
ELECTRIC CONNECTION……………………………………………………………………19
ELECTRIC DIAGRAM………………………………………………………………………….20
SETTINGS………………………………………………………………………………………..21
CHECKINGS BEFORE STARTING THE WATER HEATER……………………………..24
STARTING THE WATER HEATER…………………………………………………………25
THE COMMISSIONING OF THE MAX’O GAZ……………………………………………27
DEFAULT FINDING CHART…………………………………………………………………30
THE GUARANTEE ON THE MAX’O GAZ………………………………………………….32
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6
8
11
12
13
14
17
18
19
20
22
23
24
28
29
31
34
36
5
7
10
11
12
13
16
17
18
19
21
22
23

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THE COMPONENTS OF THE MAX’O GAZ
1) COMBUSTION CHAMBER AND HEAT EXCHANGER
-stainless steel combustion chamber
-stainless steel coils of flue tubes
-an access door with ceramic fibre insulation and flame inspection point
2) A STAINLESS STEEL HOT WATER STORAGE
-cold water feed inlet
-hot water supply outlet
-drain outlet
-three sensors points
3) A PRESSURISED GAS BURNER
-aluminium body
-motorised fan air supply
-gas valve with controlled rate of opening
-ignition transformer
-air/gas mixing combustion head
-differential pressure switch
-ignition pressure switch
-control box with ionization flame protection
-balanced flue pressure switch control
4) A CONTROL PANEL
-stop/start switch
-Pack Control regulator
-additional adjustable thermostat
-limit water thermostat set at 95ºC
-burner green run lamp
-
5) AN ENCLOSING JACKET
-50mm thick glass silk thermal insulation
-enamelled steel jacket in four removable sections
6) OPTIONAL ITEM
-anti-legionella pump assembly
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5
1 - Hot water outlet
2 - Mineral wool insulation
3 - Outer jacket
4 - Limit thermostat
5 - Control panel
6 - Control thermostat
7 - Inspection Glass
8 - Anti-legionella package
9 - Burner
10 - Refractory
11 - Inspection cover
12 - Drain point
13 - Condensate outlet
14 - Cold water inlet
15 - Flue outlet
16 - Heat exchanger
17 - Combustion Chamber
18 - Hot water storage
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6
BALANCED FLUE AND CONVENTIONAL FLUE MAX’O GAZ
FEATURES
Standard Balanced Flue (variations are available, contact Atlantic 2000)
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MODEL
A
B
C
D
E
Ø
45/400
1885
1830
1900
470
290
125
55/700
2050
2170
2250
470
300
160
69/700
2050
2170
2250
470
300
160
69/1200
2255
2220
2300
470
300
160
MODEL
45/400
55/700
69/700
69/1200
90/1200
110/1200
Input
kW
46.4
56.1
70.5
70.5
91.8
112.2
Output
kW
45
55
69
69
90
110
Gas used
m3/hr
4.86
5.94
7.45
7.45
9.12
11.8
LPG used
m3/hr
1.88
2.3
2.88
2.88
3.76
4.6
Water content
ltr
390
720
720
1190
1190
1190
Volume recovery rate -10/60ºC-
mins
31
46
36
60
45
37
Litres continuous -10/60ºC-
ltr/hr
774
946
1187
1187
1548
1892
ltr/mins over 10 mins -10/60ºC-
ltr/mins
74
121
124
195
200
205
ltr/hr -10/60ºC-First hour from hot
ltr/hr
893
1310
2078
1901
2400
2394
Thru the wall piece

7
Conventional flue
CONNECTIONS
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MODEL
45/400
55/700
69/700
69/1200
90/1200
110/1200
A
1810
2150
2150
2200
2200
2200
B
1125
1280
1280
1485
1485
1485
C
160
190
190
160
160
160
D
430
490
490
500
500
500
E
585
645
645
660
660
660
F
965
1130
1130
1200
1200
1200
G
1515
1825
1825
1835
1835
1835
Ø
750
900
900
1100
1100
1100
Weight in kg
355
470
470
605
605
605
45/400
55/700
69/700
69/1200
90/1200
110/1200
*1* Hot water outlet
Ø
50
50
50
50
50
50
*2* Flue outlet
Ø
200
200
200
200
200
200
*3* Cold water inlet
Ø
32
50
50
50
50
50
*4* Drain point
Ø
32
32
32
32
32
32
*5* Gas supply
Ø
20
20
20
20
20
20
MODEL

8
INSTALLATION OF THE MAX’O GAZ
MAX’O GAZ requires the installation of gas ( or LPG), water and electricity supplies which
must be provided by currently qualified installers. Relevant CE and BS requirements and local
regulation must be observed.
(Atlantic 2000 welcomes any queries at any time on 0161-621-5960)
1) LOCATION
MAX’O GAZ must be located on a hard standing and preferably a concrete base
extending at least 50mm beyond the unit on all sides
The most economic route should be selected for the evacuation of flue gases with
consideration for nuisance at the exit point from the building and for the trapped
drainage of condensate.
(See advice in the section on products of combustion).
Preferably, an access of 500mm should be allowed on the sides and rear of MAX’O
GAZ. Access at the front, to allow for burner withdrawal, should be 1500mm.
(Discuss restricted access with Atlantic 2000 on 0161-621-5960)
2) COLD WATER CONNECTION
Cold water supply should be connected to MAX’O GAZ in approved materials.
On a main cold water supply connection, an unvented kit is necessary and is offered
with the unit. This consists of a ball valve, a high capacity strainer, a pressure
regulating valve with manometer, a non return valve and one or two expansion vessels
fitted into the cold water supply line. In addition, a combined temperature/pressure
relief valve is supplied for fitting in the MAX’O GAZ storage vessel or DHW flow
outlet.
On a tank cold water supply connection, two ball valves and a high capacity strainer is
recommended.
On both types of connection, a mounting pack is recommended and will consist of a
pressure relief valve, a high capacity automatic air eliminator, an anti-vacuum plug and
a drain valve. The installation of unions is recommended to ease the cleaning of filters
and working equipment.
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9
3) DOMESTIC HOT WATER FLOW CONNECTION
Hot water supply should be connected to MAX’O GAZ in approved materials.
On the MAX’O GAZ hot water outlet of a mains cold water s ystem, the combined
temperature/pressure relief valve may be fitted. Then a full-bore tee should be installed
to take the high capacity automatic air eliminator with isolating ball valve.
These items should be isolated together with the MAX’O GAZ storage vessel and
fitted with a union to allow future access for maintenance.
On the MAX’O GAZ hot water outlet of a tank cold water system, a pressure relief
valve must be fitted. Then a full-bore tee should be installed to take an open vent pipe
leading over the cold water tank.
4) DOMESTIC HOT WATER RETURN CONNECTION
A hot water return connection is provided in the MAX’O GAZ. It must not be used as a
cold water inlet
In a hot water pumped circulation system, the return will include a ball valve, a strainer,
the pump, a non return valve, a ball valve and a thermometer; then a connection to the
MAX’O GAZ vessel with a union.
In a hot water system without circulation, a blending valve and thermometer should be
considered in an arrangement to mix the hot water flow with the cold water feed.
5) RELIEF VALVES
Do not connect pipework directly to the relief outlet. Leave an air gap leading to a
tundish, enabling relief water to be visually noted.
6) CONDENSATE DRAIN
MAX’O GAZ is a high efficiency condensing wate r heater. The condensing starts to
occur in the combustion gases as they pass down the vertical heat exchanger tubes, and
the condensate collects in the flue gases chamber and outlet. This must be drained away
to a gulley or drain using rigid PVC tube resistant to 60ºC temperature and running at a
slope 2-3º. Copper pipe should not be used,
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Additional condensing will occur in the flue exhaust system and this may be separately
drained through its own trap to the same gulley or drain. Normally, 20 mm or 32mm
PVC tube will carry the condensate flow.
IMPORTANT
Never fire the MAX’O GAZ burner without water in the water store.
Never fire the MAX’O GAZ without open cold and hot water connections.
Never plug off the relief valve outlets.
Never over-ride the control system, without knowledge.
For any further information you can contact Atlantic 2000 on
Technical 0161 621 5960
Commissioning 0161 621 5961
Servicing 0161 621 5961
Spares 0161 621 5962
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11
STANDARD PIPEWORK ARRANGEMENT
PO Box 11 Ashton Under Lyne OL6 7TR
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1 – Non return valve
2 – Pressure relief valve
3 – Anti-legionnella package
4 – Electric panel
5 – Automatic air vent
6 – Pressure and temperature relief valve
7 – Secondary circulating pump
8 – Anti vacuum plug
9 – Ball valve
10 – Strainer
11 – Pressure regulating valve
12 – Expansion vessel
Condensate
Cold water
8
9
+
10
+
11
+
12
+
9
+
Drain point

12
PIPEWORK ARRANGEMENT WITH A TANK
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1 – Non return valve
2 – Pressure relief valve
3 – Anti-legionnella package
4 – Electric panel
5 – Ball valve
6 – Strainer
7 - Secondary circulating pump
Drain point
Condensate
2
5
6
6

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PIPEWORK ARRANGEMENT WITH A BUFFER STORAGE
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1 – Non return valve
2 – Pressure relief valve
3 – Anti-sediment cold water inlet
4 – Entire drain
5 –Pump
6 – Hot water transfer valve
7 – Electric panel
8 – Automatic air vent
9 – MAX’O GAZ
10 – Buffer storage
11 –Pressure and temperature relief valve
12 – Secondary circulating pump
13 – Anti vacuum plug
14 – Ball Valve
15 – Strainer
16 – Expansion vessel
17 – Pressure regulating valve
Cold water
Condensates
13
+
13
+
14
+
15
+
14
+
16
+
17
+

14
3
6
9
12
15
20
25
30
40
50
20
9.7
6.6
25
18
12
10
8.5
7.5
32
39
27
21
18
16
14
12
11
9.2
8.1
40
59
40
32
27
24
21
18
16
14
12
50
110
76
61
52
46
39
34
31
26
23
65
220
150
120
100
92
79
70
63
54
47
80
340
230
190
160
140
120
110
97
83
73
100
690
470
380
330
290
250
220
200
170
150
Length of pipe (metres)
Nominal
size (mm)
Discharge (m³/h)
10
20
30
40
50
60
70
80
90
100
125
150
3/4
340
230
1
640
440
350
1¼
1400
930
740
630
560
500
460
430
400
380
1½
2100
1400
1100
960
850
760
700
650
610
570
510
460
2
3900
2600
2100
1800
1600
1400
1300
1200
1100
1000
960
860
2½
7700
5300
4300
3600
3200
2900
2700
2500
2300
2200
1900
1800
3
12000
8200
6600
5600
5000
4500
4100
3800
3600
3400
3000
2700
4
24000
1700
1300
11000
10000
9200
8400
7800
7300
6900
6100
5500
Discharge (FT³/h)
Length of pipe (feet)
Nominal
size (ins)
THE GAS PIPEWORK CONNECTIONS
The size of the gas pipework to the boilers should be chosen to ensure the necessary minimum pressure for the nominal required flow
rate at the upstream entry point of the gas train.
The diameter of the pipe lines will be calculated as a function of the allowed pressure drop, the length of the pipework distribution &
the number of fittings in the distribution.
There are a number of ways of carrying out these calculations and the attached is based on C.P. 331 1974.
Discharge in a straight horizontal steel pipe (to table 2, medium, of BS 1387:1967) with 1m.bar 0.4 in w.g. differential
pressure between the ends, for gas of relative density 0.6 (air=1)
GAS FLOW IN
STEEL TUBE

15
3
6
9
12
15
20
25
30
40
50
22
8.7
5.8
28
18
12
9.4
8
7
5.9
35
32
22
17
15
13
11
9.5
8.5
7.2
6.3
42
54
37
29
25
22
18
16
15
12
11
54
110
75
60
51
45
38
33
30
26
23
76
280
190
150
130
120
98
86
78
66
58
108
750
510
410
350
310
260
230
210
180
160
Nominal
size (mm)
Discharge (m³/h)
Length of pipe (metres)
10
20
30
40
50
60
70
80
90
100
125
150
3/4
630
420
340
1
1100
740
580
500
440
390
360
1¼
1800
1200
950
810
710
640
590
540
510
480
420
380
1½
3900
2600
2100
1800
1600
1400
1300
1200
1100
1000
930
830
2
7000
4800
3800
3200
2800
2600
2300
2200
2000
1900
1700
1500
2½
11000
7700
6200
5200
4600
4200
3800
3500
3300
3100
2800
2500
3
17000
12000
9400
8000
7100
6400
5800
5400
5100
4800
4200
3800
4
25000
17000
13000
11000
10000
9100
8400
7800
7300
6900
6100
5500
Discharge (FT³/h)
Length of pipe (feet)
Nominal
size (ins)
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Discharge in a straight horizontal copper tube (to table of BS 659:1967) with 1m.bar 0.4 in w.g. differential pressure
between the ends, for gas of relative density 0.6 (air=1)
GAS FLOW IN
COPPER TUBE

16
Mild Steel
Copper
Elbows
Tees
90º Bends
up to 25
up to 28
0.5
0.5
0.3
32 top 40
35 to 42
1
1
0.3
50
54
1.5
1.5
0.5
80
76.1
2.5
2.5
1
Nominal size (mm)
Appropriate additional lenghts
to be allowed (m)
Mild Steel
Copper
Elbows
Tees
90º Bends
up to 1
up to 1
2
2
1
1 ¼ to 1 ½
1 ¼ to 1 ½
3
3
1
2
2
5
5
2
3
3
8
8
3
Nominal size (ins)
Appropriate additional lenghts
to be allowed (ft)
The effects of elbows, tees or bends inserted in a run of pipe (expressed as
the approximate additional lengths to be allowed)
To make use of the tables on pages 14 and 15 the run of gas pipework from the meter to
the water heater must first be decided. Then, the length of the run (or the longest run
when more than one water heater is installed) is measured together with the numbers of
elbows and/or bends and tees counted.
The gas flow requirements of the water heaters are taken from the table on page 6. The
pipe size of the run, or the main part of the run for several water heaters, is assessed from
the tables on pages 14 and 15.
The effect of the fittings is then taken, from that pipe size, out of the tables on page…
The whole run is the re-checked for this size to ensure the overall pressure drop from the
meter to the water heater is within the prescribed limit. If several water heaters are
involved, the prescribed limit is proportioned over the different lengths of pipe with
different flow rates.
If you have any queries concerning the gas pipe work,
call Atlantic 2000 on 0161 621 5960
PO Box 11 Ashton Under Lyne OL6 7TR
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17
MAX’O GAZ GAS SUPPLY FROM A PRESSURE
REGULATING VALVE
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1 –Pressure regulating valve
2 – Union brass
3 – Filter
4 – Gas valve

18
CONVENTIONAL FLUE ARRANGEMENT
Flue made from high grade plastic or austenitic stainless steel
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Stack
Condensate outlet
at base of vertical
stack
Condensate outlet
Drain or lift Pump
Slope/3%
Bull nose 25 mm
mesh terminal
(cowls not to be
fitted)

19
BALANCED FLUE CONNECTIONS ON WALL OUTLET
Flue made from high grade plastic or austenitic stainless steel
IMPORTANT: All the plastic connections must be air & gas tight
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Slope/3%
Balanced flue outlet
Concentric balanced flue
Stainless steel union
Stainless steel union
Stainless steel union
Flue Outlet

20
HORIZONT
AL
BALANCED
FLUE
PO Box 11 Ashton Under Lyne OL6 7TR
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Balanced flue outlet
R = 4m
Balanced flue outlet
Balanced flue outlet
Balanced flue outlet
Air inlet for
ventilation
purposes
Fitting of the balanced flue outlet on a
façade with windows or doors
Fitting of the balanced flue outlet under a
balcony or a roof
BALCONY
Fitting of the balanced flue outlet in a wall
angle
Fitting of the balanced flue outlet on a
façade with air inlet
R=4000 mm
1500 mm
2500 mm
2000 mm