ACV delta performance ventouse SV, delta performance ventouse MV INSTALLATION OPERATING AND SERVICING INSTRUCTIONS

Installation, Operating and Servicing Instructions

delta

excellence in hot water

delta

performance

performance ventouse SV/MV

24/09/2004 - 66401501

INDEX

INTRODUCTION 2

Who should read these instructions 2 Symbols 2 Applicable standards 2 Important notes 2

DESCRIPTION 3

General description 3 Operating principle 3 Design characteristics 3 Boiler views and key to parts 4

TECHNICAL CHARACTERISTICS 5

General 5 Operating condition limits 5 Dimensions 5 Hot water output data 5 General characteristics 5

INSTALLATION 6

Boiler room 6 Chimney connections 6 Heating connection 8 Hot water connection 8 Control kit 9 Connection to the gas supply 9 Electrical connections 10

BURNER CHARACTERISTICS 12

Description of the burner 12 Operating principle of the burner 14 Control parameters 15 Gas categories 15 Burner dismantling procedure 16 Setting procedure in the event of fan replacement 16 Procedure for setting the % of CO2 16 Electrode distance and gap 17 Burner maintenance 17 Fault table 18 Table of corrective measures 19

COMMISSIONING 20

Filling the hot water and heating circuits 20 Using the boiler for the first time 20

MAINTENANCE 20

Recommendation 20 Boiler maintenance 20 Safety equipment maintenance 20 Draining the boiler 20

USER GUIDE 21

Use of the boiler 21 Setting the burner to safety mode 22

SPARE PARTS 23

SERVICE RECORD 29

Details of the installation 29 Service engineer's report 29

WHO SHOULD READ THESE INSTRUCTIONS

These instructions should be read by:

- the specifying engineer

- the installer

- the user

- the service engineer

SYMBOLS

The following symbols are used in these instructions:

APPLICABLE STANDARDS

The products described in this document have been certified at European level (European Directives 92/42/EEC “Efficiency”, 90/396/EEC “Gas Appliance”). They have also be awarded the Belgian label “HR+”.

IMPORTANT NOTES

These instructions are an integral part of the equipment to which they relate and must be handed to the user.

The product must be installed and serviced by qualified engineers in accordance with the regulations in force.

ACV declines all liability for any damage caused as a result of incorrect installation or in the event of the use of appliances or accessories that are not specified by ACV.

Failure to follow the instructions describing test operations and procedures may cause injury to persons or a risk of environmental pollution.

N.B.: ACV reserves the right to change the technical characteristics and specification of its products without notice.

INTRODUCTION

Essential instruction for the correct operation of the installation.

Burning hazard.

Electric shock hazard.

Essential instruction for the safety of persons and the environment.

GENERAL DESCRIPTION

• Combined boiler and water heater (heating and domestic hot water).

•Hot water generated by the TANK-IN-TANK indirect storage system.

• Equipment required: a water connection kit for the heating circuit supply (optional).

• The control panel contains a main switch, a control thermostat for the SV model or potentiometer for the MV model, a thermometer, a Summer/Winter switch and a knockout for the built-in ACV control system

(optional).

• Delta Performance models SV and MV can be connected as a balanced flue system using a type C concentric or parallel chimney adapter

xx, or connected directly to the chimney with a

type B23 chimney adapter.

• Delta Performance models SV 35 and 50 have fixed outputs of 35 and 50 kW respectively and are fitted with the ACV BG 2000-SV gas burner.

• Delta Performance models MV 35 and 50 have modulating outputs of 10 to 35 kW and 15 to 50 kW respectively, and are fitted with the ACV BG 2000-MV gas burner.

OPERATING PRINCIPLE

The “Tank-in-Tank” concept

The Delta Performance ventouse range of boilers differs from conventional hot water heaters in that it features a ring-shaped tank which is immersed in the primary water, and which is itself contained in the outer body. The thermostat/potentiometer activates the burner when the heating system or the hot water circuit calls for heat.The combustion gases quickly heat up the primary water and set up a natural circulation around the tank.

Indirect hot water heating

This circulation causes heat to be exchanged between the primary water and the domestic water; heat is exchanged across the entire surface of the tank.Corrugations on the inner and outer shells of the ring-shaped tank further increase the heat exchanger surface, thereby accelerating the water heating process.

Simple to control, safety assured

The temperature of the water in both the heating circuit and the hot water circuit is regulated by a single control. This is achieved by means of the control thermostat or the potentiometer whose bulb is located under the tank in the heating circuit. A thermal reset high limit thermostat positioned at the top of the boiler automatically cuts out the burner when the temperature of the water in the heating circuit reaches 95°C. A manual reset high limit thermostat locks the burner out if the temperature of the primary water reaches 103°C.

DESIGN CHARACTERISTICS

Outer body

The outer body which holds the primary water is made from STW 22 heavy gauge steel.

“Tank-in-Tank” type storage exchanger

The ring-shaped inner tank is made from 18/10 austenitic stainless steel and features a large heat exchanger surf ace f or rapid hot water heating. It is corrugated over its full height by means of an exclusive production process, and is fully argon welded using the TIG (Tungsten Inert Gas) method.

Combustion gas circuit

The combustion gas circuit is protected by high temperature paint. The circuit comprises:

•Flue ways. The Delta Perfor mance ventouse range has 8 steel flue ways with an inside diameter of 64 mm. Each flue way has baffles made of special steel designed to improve the heat exchange and reduce the flue gas outlet temperature.

• Sealed combustion chamber. The combustion chamber is water-cooled.

Insulation

The boiler body has full sprayed-on rigid polyurethane foam insulation with a high insulation coefficient. No CFC emissions are created by the spraying process.

Casing

The boiler is covered with a steel casing that has been stove enamelled at 220°C after scouring and phosphating.

DESCRIPTION

BOILER VIEWS AND KEY TO PARTS

1. Control panel

2. Detachable casing cover

(access to baffles)

3. Chimney reducing pipe

4. Measuring unit with condensate trap

(optional)

5. Polyurethane foam insulation

6. Outer body containing the primary water

7. Side casing

8. Base

9. Burner cover

10. Burner chamber plate

11. Control thermostat bulb

(model SV)

Potentiometer bulb (model MV)

12. Detachable front panel

13. Air supply pipe to venturi

14. Manual reset high limit thermostat (103°C)

15. Bulb of the thermal reset high limit thermostat (95°C)

16. Balanced flue adapter

17. Heating return

18. Cold water inlet

19. Inner annular tank containing hot water

20. Combustion chamber

21. Boiler drain cock

22. Heating return

23. Flue ways

24. Baffles

25. Hot water outlet

26. Heating out

DESCRIPTION

1 32

Fig. 1:Right-hand side view of boiler

Fig. 2:Rear view of boiler

TECHNICAL CHARACTERISTICS

GENERAL

The appliances are supplied fully assembled, tested and packed standing on a timber base with impact protection strips and wrapped in heat-shrunk plastic film. When the appliance arrives, remove the packaging and check that no parts have been damaged in transit. Refer to the dimensions and weights listed below for handling purposes:

OPERATING CONDITION LIMITS

Maximum service pressure (tank filled with water)

- Heating circuit: 3 bar

- Hot water circuit: 10 bar

Test pressure

(tank filled with water)

- Heating circuit: 4.5 bar

- Hot water circuit: 13 bar

Operating temperature

- Maximum temperature: 90 °C

Water quality

• Chlorides: < 150 mg/l (304 stainless steel) < 2000 mg/l (Duplex)

• 6 ≤ ph ≤ 8

DIMENSIONS

HOT WATER OUTPUT DATA SV/35 SV/50 MV/35 MV/50

• Operating conditions at 80°C

Peak flow at 40°C (≤T = 30°C) l/10’ 291 328 291 328 Peak flow at 40°C (≤T = 30°C) l/60’ 1044 1393 1044 1393 Constant flow at 40°C (≤ T = 30°C) l/h 920 1352 920 1352

•Tank refill time at 60°C

Initial heating time minutes 20 13 20 13 After drawoff of 140 l at 45°C minutes 10 8 10 8

GENERAL CHARACTERISTICS SV/35 SV/50 MV/35 MV/50

Input kW 34.9 50 10 / 34.9 15 / 50 Output kW 32 46.7 9.5 / 32 14.5 / 46.7 Maintenance loss (60°C) % 0.5 0.5 0.5 0.5 Total capacity l 127 162 127 162 Heating circuit capacity l 62 82 62 82 Heating connection Ø 1” 1” 1” 1” Hot water connection Ø 3/4” 3/4” 3/4” 3/4” Water tank heat exchanger surface m

1.99 2.46 1.99 2.46 Combustion efficiency % 92.9 93.5 96.4 / 92.9 97 / 93.5 Average CO2 % 9999 Mass flow rate of combustion products g/sec. 16.1 23 4.6 / 16.1 23

kg (*)

Delta Performance SV/35 1585 390 200 542 125 645 80/80/125 1610 800 182 Delta Performance SV/50 1830 390 200 542 125 645 100/100/150 1880 800 220 Delta Performance MV/35 1585 390 200 542 125 645 80/80/125 1610 800 182 Delta Performance MV/50 1830 390 200 542 125 645 100/100/150 1880 800 220

(*) The weights shown are drained weights.

BOILER ROOM

Important

•Never obstruct the ventilation.

• Do not store inflammable products in the boiler room.

•Avoid storing corrosive products such as paint, solvents, chlorine, salt, soap or other cleaning products near the boiler.

Accessibility

The boiler room should be big enough to allow easy access to the boiler.Minimum clearances around the boiler (mm):

- to the front 500

- to the rear 150

- to the sides 100

- above 700

Ventilation

The boiler room must have both low and high level ventilation (see

Fig. 3)

By way of information, the table below gives the minimum ventilation requirements according to Belgian regulations.

The user must ensure that his boiler room ventilation complies with local regulations.

Chimney connector type: B23 (Fig.3)

The chimney must be connected to the boiler by means of a metal pipe rising at an angle from the boiler to the chimney.

A chimney connection is required.

A. High level ventilation B. Low leve l ventilation C. Draught stabiliser D. Flame inspection window E. Height of lined chimney

F. Chimney diameter

SV - MV / 35 SV - MV / 50

Ventilation

Fresh air supply min. m3/h 63 90 High level ventilation (A) dm

1.5 1.5

Low level ventilation (B) dm

1.5 2

Draught stabiliser (C) Ø 80 100

N.B.: The figures for (B) and (C) only apply to type B23 connectors.

Base

The base on which the boiler will be mounted must be made from non-combustible materials.

CHIMNEY CONNECTIONS

IMPORTANT The boiler must be installed by a qualified engineer in accordance with the local standards and codes of practice.

The diameter of the chimney must not be less than the diameter of the boiler's chimney reducer.

Fig. 3:Boiler ventilation and chimney connection type B23

Important note: The above table is shown by way of indication only as regulations vary from country to country.

The high efficiency of our boilers means that the flue gases exit at low temperature.The attendant risk of condensation may cause damage to some chimneys. To avoid this risk we strongly advise that you line the chimney. Please contact your installer for further information about chimney lining.

SV - MV / 35 SV - MV / 50

Chimney

E = 5 m Ø min. F mm 213 236 E = 10 m Ø min. F mm 179 199 E = 15 m Ø min. F mm 162 179

INSTALLATION

CHIMNEY CONNECTORS TYPE: C XX (Figs. 4, 5 and 6)

• C 13 (x): Concentric / parallel connector with horizontal terminal.

• C 33 (x): Concentric / parallel connector with vertical terminal.

• C 43 (x): Concentric / parallel connector for several boilers in a common chimney.

• C 53 (x): Parallel chimney connector with air intake and flue gas outlet in different pressure zones (different locations).

• C 63 (x): Connector for connection to an approved discharge system

(Netherlands, Germany and Luxembourg only).

INSTALLATION

Fig. 5:

Concentric co

nnector

Fig. 6:

Parallel connector

Fig. 4:Chimney connectors type C xx

C33

Concentric connector

Maximum length concentric tubing: 6 metres due to the maximum air temperature at the venturi (70°C).

Note:

-A 90 degree bend = 1 metre equivalent length.

Example:

-6 metres concentric = one 90° bend + 4 metres horizontal + outlet 1 metres.

“CE” approved according to EN 483

A drain outlet must be provided near the boiler to prevent condensation from the chimney entering the boiler.

All horizontal pipe runs must fall to the boiler to prevent condensation water escaping from the terminal.

Parallel connector

Table of flue resistance in Pascal (max. 100 Pa)

(1 Pascal = 0,01 mbar)

SV - MV / 35 SV - MV 50

Ø 80 mm Ø 100 mm Straight pipe L. 500 mm 1.18 1.82 Straight pipe L. 1000 mm 2.55 2.3 Straight pipe L. 2000 mm 5.1 4.6 90° pipe bend 4.32 6 45° pipe bend 2.75 3.1 30° pipe bend 1.67 1.7 5° pipe bend 0.69 0.76 Vertical terminal 5.4 3.53 Horizontal terminal 5.5 3.53 Condensation drain 2.06 1.53

This table is based on the equipment offered by ACV and connot be applied generally.

Sample calculation

The diagram below consists of the following parts (Ø 80 mm) :

•1 x Pipe bend 90°

•2 x Straight pipe L 2000 mm

•2 x Pipe bend 45°

•2 x Straight pipe L 1000 mm

•1 x Vertical terminal

•1 x Condensation drain vertical

Calculation:

•1 x 4,32 = 4,32

•2 x 5,1 = 10,2

•2 x 2,75 = 5,50

•2 x 2,55 = 5,10

•1 x 5,4 = 5,4

•1 x 2,06 = 2,06

Total: 32,58 x 2 = 65,16 Pa

This value is less than the maximum authorised resistance, therefore the installation is compliant.

A condensation drain outlet must be fitted close to the boiler to prevent condensation products from the chimney running into the boiler.

120

150 min.

C43

C13

2 m min.

C13

C53

1000 mm

2000 mm

Drain

The drain cock and safety v alve must be connected to the building dr ain.

HOT WATER CONNECTION

Pressure reducing valve

If the mains water pressure exceeds 6 bar, a pressure reducing valve calibrated to 4.5 bar must be installed.

Safety group

The safety group of the water tank must be approved by ACV and calibrated to 7 bar; the group's valve discharge must be connected to the drain.

Hot water expansion vessel

Installing a hot water expansion vessel will prevent any risk of excess pressure due to water hammer or pressure fluctuations.

Hot water circulation

If the water tank is a long way from the point of use, installing a closed recirculation circuit can ensure a faster hot water drawoff at any time.

Typical circuit with thermostat valve

1. Safety group

2. Pressure reducing valve

3. Thermostatic mixer

4. Hot water pump

5. Non-return valve

6. Hot water expansion vessel

7. Cold water supply tap

8. Drawoff tap

9. Drain cock

10. Air vent

11. Isolating valve

Fig. 8:Heating system layout

Fig. 9:Hot water system layout

INSTALLATION

8 8

IMPORTANT As a safety measure, we strongly advise the installation of a thermostatic mixer to prevent any risk of burning to persons.

ACV kit water

ACV can supply an optional pre-assembled water kit.This kit comprises:

•A pump;

•A 3-way manual valve. This valve can be motorised if required;

• Connection pipes that can be used to connect a second heating circuit;

•Two isolating valves;

• Connectors for the right or left hand mounting of the expansion vessel, the safety valve with pressure gauge and the filling valve.

(The expansion vessel is not

included)

Typical single circuit configuration

CONNECTING THE HEATING SYSTEM

1. 3-way motorised mixer valve.

2. Safety valve calibrated to

3 bar, with pressure gauge.

3. Pump.

4. Non-return valve.

5. System filling valve.

6. Expansion vessel.

7. Controller ACV 13.00

(see Controller Kit on page 9)

8. Isolating valve, heating system.

9. Drain cock.

fig. 7 :ACV water kit

INSTALLATION

Optional accessories

CONTROLLER KITS

KIT 1: ACV 13.00 / Basic

This basic kit is used to control the hot water circuit outlet temperature as a function of ambient conditions. It comprises: a temperature controller with analog clock, a surfacemounted primary water temperature sensor (-30/130°C), an outdoor sensor (-30/50°C), a servomotor SSY 319 230 V - 3-pin and an intermediate socket.

Circuit diagram of ACV control kits

B2. Temperature sensor B9. Outdoor sensor B5. Analog/digital room sensor P1. Pump

Y1/Y2/N. Servomotor (SSY 319 or SQK 349)

bl. Blue N

n/z. Black Y2

br. Brown Y1

Safety group Ø 3/4” Pressure reducing valve Ø 3/4” Thermostatic mixer Ø 3/4” Expansion vessel 5 litres

KIT 2: ACV 13.00 / Standard

Please contact your installer for further details about this.

CONNECTION TO THE GAS SUPPLY

- The boiler is fitted with a 3/4” M connector, to which you can connect the gas tap.

-You must comply with the NBN D51-003 standard for connections to the gas and, if applicable, with the other standards in force in the location of the connection.

-Where there is a risk of dirt stemming from the network, place a gas filter upstream from the connection.

-Drain the gas pipe and check in minute detail that all the boiler pipes, both inside and outside, are sealed.

- Check the gas pressure in the system.

- Check the gas pressure and consumption when commissioning the appliance.

SSY 319 / SQK 349

P1 B5 B9 B3 B2

QAAD50

(QAAD70)

QAC32 QAD22

bk br

20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2

P1Y1Y2NB5B9B3B2

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