Groupe Atlantic CONDENSINOX 40 Quick start guide

U0627512 / 00CNO0192-E
08.04.2021
For professional.
To be retained by the user for future reference
Gas condensing
boiler 40, 50, 60,
80 or 100 kW with
modulating burner
for natural gas and
propane gas
CONDENSINOX
INSTALLATION, USE AND MAINTENANCE INSTRUCTIONS

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CONTENTS
1. WARNINGS AND RECOMMENDATIONS...........................................................................5
1.1. Transport and storage ................................................................................................................................... 5
1.2. Symbols used in this document .................................................................................................................... 5
1.3.Sta󰀨qualication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.Removing/rettingthefrontpanel ............................................................................................................. 16
4.3.Removing/rettingtheuppercover ........................................................................................................... 16
4.4. Exhaust connection..................................................................................................................................... 17
4.5. Hydraulic connection................................................................................................................................... 25
4.6. Connecting the gas supply.......................................................................................................................... 27
4.7. Changing the gas ........................................................................................................................................ 27
4.8. Electrical connection ................................................................................................................................... 31
5. COMMISSIONING...............................................................................................................36
5.1. Checks before commissioning .................................................................................................................... 36
5.2. Commissioning............................................................................................................................................ 36
6. CHECKS AFTER COMMISSIONING.................................................................................37
6.1. Condensate removal ................................................................................................................................... 37
6.2. Gas supply .................................................................................................................................................. 37
7. MAINTENANCE OPERATIONS.........................................................................................38
7.1. Draining the boiler ....................................................................................................................................... 38
7.2. Checks on the boiler environment............................................................................................................... 39
7.3. Cleaning the combustion chamber/exchanger............................................................................................ 39
7.4. Checking the ignition and ionisation electrodes .......................................................................................... 40
8. END-OF-LIFE CYCLE OF THE APPARATUS ..................................................................41

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9. HYDRAULIC DIAGRAMS AND CONFIGURATIONS ......................................................42
9.1. Selection diagrams...................................................................................................................................... 42
9.2. Symbols used in the diagrams .................................................................................................................... 44
9.3. List of diagrams........................................................................................................................................... 44
9.4.Speciccongurationswhenconnectingto0-10Voutputs(Ux) ................................................................. 88
10. SPARE PARTS LIST ...........................................................................................................92
11. CUSTOMER PARAMETERS TABLE...............................................................................100
12. ANNEX A............................................................................................................................115

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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 +60°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. 󰀨
Theappliancemustbeinstalled,conguredandmaintainedbyaqualied,
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. 
• Always switch o󰀨 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:

•            
electrical contacts or switches.
• Cut the gas supply.
• Ventilate the room.
• Trace the leak and repair it.
DANGER:

• 󰀨
• Ventilate the room.
• Trace the leak and repair it.
DANGER:



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rsttypeofcleaningmustbedone
beforeconnectingthenewboiler,andwiththesecondtype,alter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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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ll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ll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signicant
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ll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ow.
- If the water in the system does not have the required qualities (e.g.
highhardness),itmustbetreated.Thell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rst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 a󰀨ect 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lledfor
thersttimereactswiththeequipmentmaterialsandquicklydisappears.If
theoxygenisnotrenewedthroughsignicant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owing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 (ll 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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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e󰀨ects.
1.5.6. Setting up a ltration system
A ltration system on the boiler return circuit is recommended in order to
removesuspendedparticlesfromtheunit(lter,dirtseparatoretc.).

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2. CERTIFICATION
2.1. 

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
benet,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.


󰀩

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.

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
.
For an installation on a 300 mbar gas network, place a gas lter 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qualiedprofessional.
INFORMATION: 

WasteElectricalandElectronicEquipment.Seechapter8.

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Categories
CH-ES-GB-EI-PT-IT-AT CZ-HU-SK-LT-NO-AT-LV-DK-EE-FI-GR-
RO-SE-SI
CONDENSINOX
40-60 kW
B23 - B23 P II2H3P I2H
C13 - C33 - C53
C43 - C83 I2H I2H
CONDENSINOX
50 kW B23 - B23 P I2H
CONDENSINOX
80-100 kW
B23 - B23 P II2H3P I2H
C13 - C33 - C53
C43 - C83 I2H I2H
2.4. Gas supply pressures
INFORMATION:        

H G20
natural gas
L G25
natural gas
G31 propane
(only with B23 and B23P)
 20 25 37
 17 20 25
 25 30 45

12 / 116 00CNO0192-E (U0627512)
CONDENSINOX - Installation, Use and Maintenance
3. TECHNICAL SPECIFICATIONS
3.1. Dimensions
gure 1 - Dimensional characteristics
Gas
(cylindrical male)
Flow
(conical male)
Hot return
Cold return
Condensate
discharge
MODEL A B C D E F G H I J Ø K L M Ø N O P*
(mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm)
40 - 60 1494 595 708 1449 58 100 336 400 406 76 1"1/4 1354 209 G1/2" 114 670
70 - 80 - 100 1707 695 813 1626 102 110 336 400 550 85 1"1/4 1529 130 G3/4" 114 773
P* : gas connection removed (see paragraph "4.6. Gas connection")
U0627216-C
20 mini 40 maxi
B
A
P
E
O
GH I
ØN
ØK
MF
J
ØK
ØK
Ø25
D
L
C

08.04.2021 13 / 116
CONDENSINOX - Installation, Use and Maintenance
MODEL
40 50 60 80 100
 G20
G25 set up for G20 ** kW 40.0
33.2
49.9
--
60.0
49.8
80.0
65.6
97.0
80.5
Nominal power when

G20
G25 set up for G20 ** kW 43.8
36.3
54.1
--
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
51.3
--
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
--
--
12.4
10.3
20
16.5
13.5
20.7
19.5
16.2
19.5

G20
G25
G25 set up for G20 **
G31 ***
m3/h
4,4
5,1
4,2
1,7
5,5
--
--
--
6,6
7,6
6,3
2,5
8,8
10,2
8,4
3,4
10,6
12,3
10,2
4,1
2% See paragraph 4.7.1.
 g/s 19 / 4.0 28.3 /
5.9
28.3 /
5.9
38.5 /
7.9
46.5 /
9.6
 g/s 17.8 /
3.5
21 /
5.5
25.3 /
5.5
35.9 /
7.3
43.5 /
8.9
 °C 74 / 56 67 / 54 85 / 55 76 / 57 82 / 57
 °C 48 / 29 43 / 34 58 / 30 56 / 30 56 / 30
 Pa 135 130 162 145 140
 mm 80 80 80 100 100

 Pa 160 / 6 130 /
1.4 160 / 5 120 / 7 120 / 5

 Pa 129 / 5 --/-- 129 / 5 101 / 5 105 / 5
 m3/h 53 66 80 108 131
 6

B23,
B23P
C13,
C33,
C43,
C53,
C83
B23,
B23P
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. 

14 / 116 00CNO0192-E (U0627512)
CONDENSINOX - Installation, Use and Maintenance
3.3. 
MODEL
40 50 60 80 100
 °C 80
 °C 85
 °C 106
 hPa (bar) 4000
(4)
Minimum cold pressure hPa (bar) 1000
(1)
 daPa 160 350 350 210 300
 m3/h 1.7 2.15 2.6 3.4 4.2
 m3/h 3.4 4.3 5.2 6.8 8.4
Water capacity L 94 88 88 136 130
Weight without water kg 134 140 140 215 225
  5 / 45
 5% to 95%
 IP20
 m2000
3.4. Electrical connection
MODEL
40 50 60 80 100
Electrical power supply V 230VAC(+10%-15%),50Hz
Electrical power consumption
 W 120 142 160 210 280
Electrical power consumption
in standby mode W 5
 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 1 A

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CONDENSINOX - Installation, Use and Maintenance
4. INSTALLATION
4.1. Boiler location
CONDENSINOX boilers must not be installed on an inammable surface
(woodenoor,plasticoorcoveringetc.).

Su󰀩cient clearances must be provided to permit easy maintenance
operations on the boilers.
The minimumvalues(inmm)areindicatedingure2andthetablebelow.
   
MODEL
40 - 50 - 60 200 150 200 1750
80 - 100 500 365 500 1980
gure 2 - Clearance around the boiler
Zone that must
remain clear to

the combustion
chamber door
(note: the
combustion
chamber door can
only be opened to
the right)
H
A
U0627218-#
AA B B
C
800

16 / 116 00CNO0192-E (U0627512)
CONDENSINOX - Installation, Use and Maintenance
        

ATTENTION:
          
 󰀨        

Toadjustthelevel,screworunscrewthe4adjustablefeetasrequiredusing
a 13 mm wrench.
4.2. 
1. Tilt the front panel forward (use the handles
located on the door thickness).
Disconnect the earth wire (on the top left of the
boiler).
2. Lift the front panel to remove it.
4.3. 
Pull the upper cover forward.
Lift the cover to remove it.
U0627230-2
gure 3 - Removing the front panel


gure 4 - Removing the upper cover

08.04.2021 17 / 116
CONDENSINOX - Installation, Use and Maintenance
4.4. 
It is essential to comply with the regulations and codes of practice in force in
the country where the boiler is installed.


4.4.1. 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
         
that they are not obstructed.
For the CONDENSINOX 40-50-60, 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:
         



These materials
must also be capable of supporting exhaust temperatures up to 120°C.
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:

 
boilers are operating.
            
others do not discharge into it.
CONDENSINOX
40 50 60 80 100
Code 040940 041050
Ø duct Ø 125 Ø 160
 1690 1925

18 / 116 00CNO0192-E (U0627512)
CONDENSINOX - Installation, Use and Maintenance
gure 5 - Connection to a chimney
The dimension A indicates the
upper position of the completely
inserted chimney adapter
4.4.2. Connection to a B23P chimney
B23P type connection:
Air from the installation room, gas evacuation through the roof via a
pressurised duct.
ATTENTION:

a CONDENSINOX boiler to a B23P chimney duct. The table below

ATTENTION:
Ensure that the room where the boiler is installed has high and low
         
that they are not obstructed.
Filter sheet


A

08.04.2021 19 / 116
CONDENSINOX - Installation, Use and Maintenance
Ø duct CONDENSINOX
40 50 60 80 100
Ø 80 Code 040945
(contains part ) * --
Ø 110 Code 041096
(contains part +) *
Code 041052
(contains part ) *
Ø 125 Code 040940
(contains part +) *
Code 041051
(contains part +) *
Ø 160 -- Code 041050
(contains part +) *
*Seegure4onthepreviouspage.
ATTENTION:            

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
.
The Ø 125 Chimney Adaptor accessory (code 040940) has a 125 diameter
outlet that cannot be recut.

Ø duct CONDENSINOX
40 50 60 80 100
Ø 80 1605 min / 1910 max --
Ø 110 1635 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ttingcoatthejointswithliquidsoaporanappropriategrease.
4.4.2.1. Single boiler installation case
ATTENTION:
        
using the parameters set out in the table in chapter 3.2.
          


   
calculation.

20 / 116 00CNO0192-E (U0627512)
CONDENSINOX - Installation, Use and Maintenance
4.4.4. Rules for installing air vent terminals
Please refer to national standards and regulations.
4.4.3. 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:


            
accessory is mandatory to connect a CONDENSINOX boiler with a

4.4.2.2. Cascade installation case
ATTENTION:
        
using the parameters set out in the table in chapter 3.2.
          


   
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conguration,itmaybenecessarytoinstallavalveattheboiler
outlet.
For this type of connection, the manufacturer o󰀨ers exhaust connection
accessories with duct diameter A = 160 mm for the 40, 50 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di󰀨erentpowerratingsarebeingconnected,themostpowerful
models should be closest to the chimney.
        
