Atlantic Boilers VF 100 Installation & Maintenance

ADDRESS: ATLANTIC BOILERS, PO BOX 11, ASHTON UNDER LYNE, OL6 7TR

WEB: WWW.ATLANTICBOILERS.COM EMAIL: INFO@ATLANTICBOILERS.COM

TEL: 0161 621 5960 FAX: 0161 621 5966

VF Model

INSTALLATION &

MAINTENANCE

WALL-MOUNTED GAS CONDENSING BOILER

40, 60, 80 & 100KW OUTPUT

MODULATING BURNERS

After sales service is guaranteed by Atlantic Boilers

The boilers conform to the following CE Directives

Directive 2006/95/CD - low voltage

Directive 2004/108/CEE - electromagnetic compatibility

Directive 92/42/CEE - efficiency

Directive 90/396/CEE - gas fired equipment

0RNOxxxx-#_TR Installation Entretien VARFREE page 2/41

Summary

1. Dimensions and components ...............................................................................................5

1.1. Dimensions....................................................................................................................................... 5

1.2. VF Components ................................................................................................................... 6

2. Technical Characteristics .................................................................................................7

2.1. Acceptable gas pressure ................................................................................................................. 7

2.2. Combustion conditions...................................................................................................................... 7

2.3. Operating conditions......................................................................................................................... 8

2.4. Electrical conditions.......................................................................................................................... 8

3. Installation ..............................................................................................................................9

3.1. UK Regulations................................................................................................................................... 9

3.2. Single boiler installation...................................................................................................................... 9

3.3. Multi-boiler installtion. ...................................................................................................................... 10

3.4. Flue gas pipework connection to boiler............................................................................................ 11

3.5. Conventional flue arrangement........................................................................................................ 16

3.6. Balanced flue arrangements............................................................................................................ 18

3.7. Heating pipework connections......................................................................................................... 18

3.8. Gas pipework connections............................................................................................................... 20

3.9. Internal electrical connections.......................................................................................................... 21

3.10. External electrical connections........................................................................................................21

3.11. VARFREE wiring connections.........................................................................................................21

4. Boiler Control Panel.............................................................................................................22

4.1. Control panel fascia........................................................................................................................ 22

4.2. Control panel display arrangements............................................................................................... 22

4.3. Control panel functions................................................................................................................... 23

4.4. Adjustment of the settings .............................................................................................................. 25

4.5. Information on boiler condition........................................................................................................ 26

4.6. Adjustin the settings........................................................................................................................ 29

5. Function of the LMU64 060D168 Controller.......................................................................30

6. Commissioning.....................................................................................................................30

6.1. Check all preparatory conditions..................................................................................................... 30

6.2. Adjustment of the gas pressure...................................................................................................... 31

6.3. Commission ................................................................................................................................... 33

7. Checks after commissioning ..............................................................................................33

7.1. Check for correct draining of condensate....................................................................................... 33

7.2. Check for correct flow of gas.......................................................................................................... 33

7.3. Check that maintenance can be properly carried out......................................................................33

8. Maintenance Operations...................................................................................................... 33

8.1. Annual maintenance....................................................................................................................... 34

8.2. Draining the boiler........................................................................................................................... 35

9. Spares lists ...........................................................................................................................36

9.1. VF 60 ................................................................................................................................36

9.2. VF 100 ...............................................................................................................................37

9.3. VF control panel.................................................................................................................. 38

page 4/41

10. Adjustment of parameters................................................................................................. 39

11. Installation of Condensate Siphon ...................................................................................42

11.1. VF 60 Siphon....................................................................................................................42

11.2. VF 100..............................................................................................................................43

11.3.VF safety valve.................................................................................................................. 44

page 5/41

1. Dimensions and Components

1.1. Dimensions

model 40 and 60 = 472

model 80 and 100 = 626

model 60 = 125

model 100 = 135

VF 40 / 60 VF 80 / 100

R heating return G 1’’ G 1’’ 1/4

M heating flow G 1’’ G 1’’ 1/4

G gas inlet G ¾’’ G ¾’’

C water feed inlet G ½’’ G ½’’

S1 safety valve ½’’ ½’’

CA combustion air inlet Ø 80 Ø 80

CS flue gas outlet Ø 80 Ø 100

S3 condensate outlet Ø 22 Ø 22

page 6/41

1.2. VF Components

1A – gas valve models 40 / 60

1B – gas valve models 80 / 100

2 – combustion air fan

3 – ionisation probe

4 – ignition probe

5 – ignition transformer

6 – flue gas temperature sensor

7 – automatic air vent

8 – return water temperature sensor

9 – differential air pressure switch

10 – high limit thermostat

11 - differential water pressure switch

12 – flow water temperature sensor

13 – water pressure switch

14 – non-return valve

15 – heating circulation pump

16 – drain valve

17 – safety valve (supplied loose)

18 – condensate siphon (supplied loose)

19 - control panel

page 7/41

2. Technical Characteristics

The V F boiler is set in the Factory to operate

on Natural Gas Group H with a supply pressure of 20mBar.

For higher gas pressure up to 300mBar, a filter and

a pressure regulator must precede the V F gas valve.

2.1. Acceptable gas pressure

Gaz naturel H

G20

Nominal (mbar) 20

Minimum (mbar) 17

Maximum (mbar) 25

2.3. Combustion conditions

VF

40 60 80 100

Nominal output Pn (80/60°C) kW 56,5 92,6

Nominal condensing output P (50/30°C) kW 61,8 100

Nominal heat outflow Qn kW 58 95,1

Minimum heat outflow Qmin kW 14,5 25,5

G20 gas flow rate at Pn m3/h 6,1 10,1

Recommended CO2 values % see chapter 6.2

Mass flow of flue gases Qn / Qmin (80/60°C) g/s 27 / 6,1 44 / 12

Mass flow of flue gases Qn / Qmin (50/30°C) g/s 25,3 / 5,7 39,6 / 10,4

Temperature of flue gases Qn / Qmin (80/60°C) °C 70 / 55 76 / 60

Temperature of flue gases Qn / Qmin (50/30°C) °C 46 / 32 56 / 32

Pressure loss for flue gas circuit Qn Pa 75 74

Diameter of flue gas outlet mm 80 100

Maximum pressure at flue gas output (B23P)

Qn / Qmin (80/60°C) * Pa 150 / 8 110 / 6

Maximum pressure at flue gas outlet (B23P)

Qn / Qmin (50/30°C) * Pa 123 / 3 97 / 5

Combustion air at Qn m

3/h 76 124

NOx class to EN 483:2000 4 / 5 5 / 5

Types of flue gas and combustion air arrangements

B23, B23P, C13, C33, C53

page 8/41

2.3. Operating conditions

VF

60 100

Maximum flow water temperature °C 80

Temperature Limit thermostat °C 100

Maximum working pressure hPa

(bar)

4000

(4,0)

Minimum working pressure hPa

(bar)

1000

(1,0)

Minimum water flow rate :

primary / secondary circuits (P/20) l/s 0.67 / 0.67 1.11 / 1.11

Water content l 6,1 9,4

Dry weight kg 73 88

2.4. Electrical conditions

VF

60 100

Electrical supply V 230 V AC (+10% -15%), 50Hz

Requirement at Qn

W 190 300

Requirement at standing load W 7

Maximum length for sensor cables m

domestic hot watersensor : 10

external sensor : 40

room thermostat : 40

room sensor : 50

Control panel requirement V

A

230V AC (+10%, -15%)

5 mA à 1 A

Temperature °C

Ohm resistance

flow/return sensor QAK36.095/109

flue gas sensor QAK36.670/109

NTC 10 KΩ at 25°C

0°C 32 555 Ω

10°C 19 873 Ω

20°C 12 488 Ω

25°C 10 000 Ω

30°C 8 059 Ω

40°C 5 330 Ω

50°C 3 605 Ω

60°C 2 490 Ω

70°C 1 753 Ω

80°C 1 256 Ω

90°C 915 Ω

100°C 677 Ω

110°C 508 Ω

120°C 387 Ω

page 9/41

3. Installation

3.1. UK Regulations

The V F installation must be installed and maintained according to the

Recommendatios of this Manual, the recommended cods of practice of the CIBSE

the BSI, the BSRIA and the ATLANTIC BOILERS commissioning check list

3.2. Single boiler installation

The VF must not be installed on an inflammable surface,

the air for combustion must not include agents arising from

aerosols, paints, adhesives detergents etc. Equally the air must

not be drawn from locations where similar agents are present,

such as swimming pools, dry cleaners and hair dressing salons.

Clearance around the VF

The access space around the boiler are shown on

the adjoining drawing

These spaces may alter where influenced by specific

requirements

The dimensions H will vary according to the types of flue

outlet and air inlet which are explained in section 3.4

type exhaust fumes B23/B23P C13/C33 C53

VF 60

Ø110

60

Ø125

100

Ø110

100

Ø125

100

Ø160

60

Ø80/125

100

Ø100/150

60

Ø80/80

100

Ø100/100

H mini* 405 475 465 450 655 475 525 310 350

page 10/41

3.3. Multi-boiler installation

Important : With one boiler or several, it is essential that a balancing vessel

is also installed.

The boiler(s) must not carry the weight of the balancing vessel

Wall fixing with

Ø 2x M10 screws

Installation of one VF

with a balancing vessel

M:heating circuit flow

R:heating circuit return

VF 60 100

F 125 135

P 472 626

Installation of 4 VF

in cascade

M:heating circuit flow

R:heating circuit return

Model 60

Nbre 2 3 4

A 507

Ø B 160

H 2235 2265 2295

L 1122 1674 2226

A

Ø B

Model 100

Nbre 2 3 4

A 532

Ø B 200

H 2393 2423 2453

L 1122 1674 2226

page 11/41

3.4. Flue gas pipework connection to boiler

Important : The boiler(s) must not carry the weight of the flue assembly

The flue offtake from the boiler should include

a tapping to allow analysis of the combustion

gases.

To ensure correct readings, the offtakes should

have the lengths 'F' and 'L', as shown on the

adjacent drawing.

3.5. Conventional flue arrangement B23 and B23P

When fitting B23 and B23P, it is essential the

minimum dimension 'A' is observed. This allowes space

to adapt the flue to give a pressure at the boiler outlet of 0 Pa

The flue assembly must be resistant to condensate and

capable of withstanding temperatures up to 120°C

The VF boiler will have very low outlet temperatures;

consequently, to encourage lift of the flue gases and draining

of the ondensate, the flue pipework should slope upwards at

an incline of 3°C. In addition, to avoid leakage, the joints

should be sealed tightly using soapy liquid or an

appropriate grease.

adapter air filter

c

d

e

+5

0

+5

0

VF 60 100

Ø ext 80 100

F 125 135

L 160 170

page 12/41

IMPORTANT

In a multi-boiler installation serving onto a flue header, ensure that

1.) calculations show the header is not in pressure when all boilers are operation

2.) When one boiler is off or on minimum output, all the boilers are not upset

Accessories B23-B23P Reference

VF 60 A

mini 100 A

mini

Flue gas adapter

+ air filter Ø 80

Ø80M / Ø110F : 059499

Ø80M / Ø125F : 059500

2000

2055

Ø100M / Ø110F : 059501

Ø100M / Ø125F : 059502

Ø100M / Ø160F : 059503

2060

2030

2195

For the B23P adaptor, the flue pipework must be capable of working under pressure

The range of pressures are given in section 2.3

Calculation ust prove that the total resistance will be within these parameters

page 13/41

3.6 Balanced flue arrangement C53

VF

60 100

Balanced Vertical balanced flue Vertical balanced flue

flue kit 80/125 + combustion 100/150 +combustion

air terminal 80 air terminal 100+100/80

Black

flue 059510 059513

Brown

flue 059511 -

Take note of the acceptable balanced flue outlets

on the following pages

In calculating the length of a flue

Allow one metre equivalent for a 90degree elbow

Allow half a metre equivalent for a 45degree elbow

For both flue and combustion air pipes, a 3degree slope

upwards in direction of flow is recommended

0

2

4

6

8

10

12

14

16

18

024681

01214161820

L air inlet (m)

L1 flue

(m)

- maximum duct length Type C53 -

- VF 60 -

-1

1

3

5

7

9

11

13

15

024681

01214161820

L air inlet (m)

L1 f

lue (m)

- maximum duct length Type C53 -

- VF 100 -

VF

60 100

A (mm) 1890 2005

page 14/41

The dimensions given are the minimum requirements and they should be

exceeded if possible.

≤ 70 kW

page 15/41

3.6 Balanced flue arrangement C13 and C33

The table below lists the components required for

this arrangement.

VF

60 100

Terminal C13 Code 059506 Code 059507

Ø of flue Concentric

80/125

Concentric

100/150

A min (mm) 2125 2165

Horizontal

type C13

Lmax* 9 m 9** m

Terminal C33 noir Code 059508 Code 059512

Terminal C33 ocre

Code 059509 -

Ø of flue Concentric

80/125

Concentric

100/150

A mini (mm) 2035 2060

Vertical

type C33

Lmax* 9 m 9** m

* The dimension Lmax C13 + 90degC bend or C33

Calculations and recommendations carried out as on the previous page

For C13, make a 150mm hole in the wall for the 80/125 concentric flue

make a 180mm hole in the wall for the 100/155 concentric flue

** The V F 100 is set at Factory for balanced flues from 0-5 metres

for balanced flues between 5 metres and 9 metres, certain parameters

need adjustment as follows:-

page 16/41

3.7. Heating pipework connections

3.7.1. Available pressure

Filling the Installation :

The system should be fully purged by flushing water through the header and boiler in turn.

.

Blockage may be caused by air locks and the autopmatic air vent can be used to solve this.

If the airlock is in the system, similar outlets must be found.

If a blockage occurs when the boiler is running, the error code E164

will appear on the control panel

On completion of filling :

• Check the system water pressure

minimum 1BAR, maximum 4BAR when hot

• Therefor generally set pressure on cold start at 1.5bars

Parameters LMU

Length of

balanced flue

L

H608

start

ignition

H609

start

H611

run

ignition

H612

run

low

H613

run

high

0 to 5 m 22,5 10,5 3500 1750 5900

VF

100

5 to 9 m 23 11,5 3600 1850 6400

Pressure available between

outlet M and inlet R of VF

e

0

5

10

15

20

25

30

35

40

45

0.55 0.69 0.83 0.97 1.11 1.25

water flow (l/s)

kPA

He

ad available

VF 100

0

5

10

15

20

25

30

0.44 0.47 0.5 0.52 0.55 0.58 0.61 0.63 0.66 0.69

water flow (l/s)

kPA

H

ead available

VF 60

page 17/41

The condition of system water may reveal one or more of the following:-

1. excess acidity - reduce to PH 8.2 to 9.5

2. excess oxygen

3. excess metal particles

• to eliminate these, treatment must occur



•

.



•





Removal of condensate

Use a 32mm PVC as the condensate is PH 3 to 5

page 18/41

3.8. Gas pipework connections

The VF gas train supllied has a 125 micron

pre-filter

If the gas supply is dirty, please fit an additional

50micron filter

Ensure there is a union fitted between the isolating

valve and the gas train

The gas train can accept a supply pressure between

17mBAR and 25mBAR

3.9. Internal electrical connections

For access to the electrical terminals on the rear of

the control panel:

1) remove two screws on the external front face

of the jacket

2) lift off the front face off the jacket

3) removing transport fixings, tilt the control panel

fully forward

4) the terminals are now accessible

5) use the prepared openings for the external cables

cd

page 19/41

take care to note cable locations - polarities, neutral and earth

please observe BS15,100/2002 and EN 60 335-1

3 openings for power cables 3 openings for signal cables

2 power cable clips

1 signal cable clip

power terminals signal terminals

page 20/41

3.10. External electrical connections

Connections to the boiler must be permanent

The boiler must have a permanent isolator

Power terminals Signal terminals

Power supply

3x1,5mm², ext 9 maxi

P

ower heating circulator

1 A

3x1,5mm², ext 9 maxi

Power DHW circulator

1 A

3x1,5mm², ext 9 maxi

Programmable space

control

Space thermostat

External sensor

DHW sensor

page 21/41

3.11. VF wiring connections

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Atlantic Boilers VF 100 Installation & Maintenance

Atlantic Boilers VF 100 Installation & Maintenance

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