ACV HeatMaster 60N, HeatMaster 70N, HeatMaster 100N INSTALLATION OPERATING AND SERVICING INSTRUCTIONS

®

HeatMaster

Installation, operating and
servicing instructions

HeatMaster® 60N / 70N / 100N

HeatMaster® 60N / 70N / 100N

With ACV BG 2000-S premix gas burner

ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH

HeatMaster

With ACV BM oil burner

®

60N / 70N / 100N

664Y0500.A

EN • 1

INDEX

WARNINGS 3

Who should read these instructions 3
Symbols 3

ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH

Recommendations 3
Applicable standards 3
Warnings 3

DESCRIPTION 4

Operating principle 4
Construction features 4

USERS GUIDE 6

Using the boiler 6
Resetting the pressure jet oil or Gas burner 7
Ressetting the BG 2000-S premix gas burner 7
Burner troubleshooting 7

TECHNICAL CHARACTERISTICS 8

Maximum operating conditions 8
Burner chamber plate 8
General features 8
Domestic hot water features 8

ELECTRICAL CONNECTION 9

Wiring diagram 9

INSTALLATION 10

Dimensions 10
Boiler room 11
Connection to the chimney 11
Domestic hot water connection 12
Heating connections 13
Oil supply connections - ACV BM burners 13
Connection to the gas 13

COMMISSIONING 14

Filling the domestic hot water and heating circuits 14

BURNER FEATURES 15

ACV BG 2000-S premix gas burners 15
ACV BM 102 and BM 152 oil burners 18

MAINTENANCE 19

Servicing intervals 19
Servicing the boiler 19
Servicing the safety devices 19
Servicing the burner 19
Draining the boiler 19

SPARE PARTS See at the end of this manual

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EN • 2

WARNINGS

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 this manual:

Essential instruction for
the correct operation of
the installation.

Essential instruction for
the safety of persons
and the environment.

Danger of electrocution.

• The parts may only be replaced by genuine factory parts. You
will find a list of the spare parts and their ACV reference
number at the end of this document.

• The gas burners are preset in our factory for use with natural

[equivalent to G20].

gas

• Specific regulation applicable in Belgium [for the gas burners]:

The CO2 level, the air and gas flows and the gas / air ratio

are factory set . Any field adjustments of those settings is
not allowed in Belgium.

• It is important to switch the boiler off before carrying out
any work.

• There are no user accessible parts inside the boiler casing.

APPLICABLE STANDARDS

The appliances carry the CE mark in accordance with the
standards in force in the various countries (European Directives
92/42/EC “Efficiency”, 90/396/EC “Gas appliances”).
They also carry the “HR+” label (Gas boilers) and “OPTIMAZ” label
(Oil boilers).

ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH

Risk of scalding

RECOMMENDATIONS

• Please, carefully read this manual before installing and
commissioning the boiler.

• It is prohibited to carry out any modifications to the inside of
the appliance without the manufacturer’s prior and written
agreement.

• The product must be installed and serviced by trained
engineers, in compliance with current standards.

• Any failure to follow instructions relating to tests and test
procedures may result in personal injury or risks of pollution.

• To guarantee safe and correct operation of the appliance, it
is important to have it serviced and maintained every year by
an approved installer or maintenance company.

• In case of anomaly, please call your service engineer.

• Despite the strict quality standards imposed by ACV during
the manufacture, inspection and transport of its appliances,
you might notice some errors. Please report immediately any
fault to your approved installer.

WARNINGS

IF YOU SMELL GAS:

- Immediately isolate the gas supply.

- Open windows and doors to ventilate the area.

- Do not use any electrical appliances and do not operate any
switches.

- Immediately notify your gas supplier and/or your installer.

This documentation is part of the information delivered with the
appliance and must be given to the user and stored in a safe
place!

An approved installer must carry out the assembly, commissioning,
maintenance and repair of the system, in accordance with current
standards in force.

ACV shall not accept any responsibility for damage caused by
non-compliant location of the system or by use of the parts or
connections not approved by ACV for this application.

The manufacturer reserves the right to change the

technical characteristics and specification of its
products without notice.

The availability of some versions and their accessories

is market dependant.

664Y0500.A

EN • 3

DESCRIPTION

OPERATING PRINCIPLE

The HeatMaster® is a high performance, direct fired hot water

ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH

storage heater, which has indirect heat transfer due to its Tank­in-Tank construction.

At the heart of the HeatMaster® is a stainless steel cylinder
through which the flue tubes pass. This is surrounded by a mild
steel shell containing the primary water (neutral fluid). The outer
shell extends down to the combustion chamber and even around
the flue tubes. The area of the heat transfer surface is therefore
much greater than that of standard direct fired water heaters.

A circulating pump fitted to the primary circuit moves the water
around the tank, heating it faster and maintaining an even
temperature across the primary jacket.

The burner, either gas or oil, fires onto the primary water which
indirectly heats the stainless steel cylinder containing the DHW.
As with all Tank-in-Tanks, this is corrugated over its full height
and suspended in the HeatMaster® by its hot and cold water
connections.

The cylinder expands and contracts during use and this, together
with the fact that cold water does not come into contact with the
intense heat of the burner flame, means that limescale buildup
is prevented.

This scale resistant feature, along with the corrosion resistance
of stainless steel, eliminates the need for sacrifical anodes.

The HeatMaster® has one very major advantage over other direct
fired water heaters - because it heats the DHW with a primary
circuit, this primary water can be used to provide central heating
as well.

By connecting two, three, four or more HeatMaster® together in
a module, most hot water and heating demands can be met.

Indeed, when used in conjunction with HR and Jumbo hot water
storage tanks the HeatMaster® can supply even the largest hot
water requirement.

CONSTRUCTION FEATURES

Outer body

The outer body containing the primary fluid is made of thick STW
22 steel.

Tank-in-Tank heat exchanger

The ring-shaped inner tank with its large heating surface for
producing domestic hot water is built of Chrome/Nickel 18/10
stainless steel. It is corrugated over its full height by an exclusive
production process and entirely argon arc welded by the TIG
(Tungsten Inert Gas) method.

Combustion gases within the boiler

The combustion gas circuit is paint-protected and comprises:

• Flueways

Depending on output, HeatMaster® models contain several

steel flueways with an internal diameter of 64 mm. Each
flueway is fitted with a baffle of special steel designed to improve
heat exchange and reduce flue gas temperatures.

• Combustion chamber

The combustion chamber on HeatMaster® models is entirely

water cooled.

Insulation

The boiler body is fully insulated by rigid polyurethane foam with a
high thermal insulation coefficient, sprayed on without the use of
CFCs.

Casing

The boiler is covered by a steel jacket which has been scoured and
phosphated before being stove enamelled at 220 °C.

Burner

All HeatMaster® models can be fitted with pressure jet gas
burners or oil burners. The HeatMaster® 60, 70 and 100 can also
be fitted with the low-NOx pre-mix BG 2000 gas burner.

Standard equipment

The HeatMaster® 60 N, 70 N and 100 N has the following items
as standard :

- ON/OFF switch

- Summer/Winter switch

- Timeclock

- Primary circulating shunt pump

- Primary expansion vessels

- Primary safety valve

- Pressure and temperature gauge

- Drain valve

- Body completely insulated in rigid polyurethane foam

664Y0500.A

EN • 4

DESCRIPTION

10

1

2

3

12

13

14

4

5

6

15

16

7

17

8

18

9

1. Aut omat ic air vent

2. Domes ti c co ld w at er inlet

3. Br ass pocke t

4. Pol yurethane foam insula tion

5. Heating circuit filling valve with removable hose and
non-return valve

6. Ca sing fron t panel

7. P r i m a r y e x p a n s i o n v e s s e l

8. Cont rol p ane l

9. Boiler shunt pump

10. Burner cover

11. Burner chamber plate insulation

12. To p c a s ing

13. Flue reduc tion collar

14. He a tin g f l ow

15. Domestic hot water ou tlet

16. St ainlees steel Tank-in-Tank hot wa ter s tore

17. Flue pipes and turbulators

18. Primary heating cir cuit

19. Hea t i n g r e t u r n

20. Combustion chamber

21. Burner

A. Thermal reset high limit thermostat
B. Manual rese t high li mit thermostat
C. Low water pressure switch
D. Primary safety valve
E. Contro l ther mostat

ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH

19

20

11

Safety features of the HeatMaster® 60 N Safety features of the HeatMaster® 70 N and 100 N

A

21

B A

C

D

E

C

E

B

664Y0500.A

D

EN • 5

USERS GUIDE

USING THE BOILER

ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH

Your system should be serviced at least once a year

by a qualified engineer.

If the boiler is subject to heavy use, it may require

servicing more than once a year - consult your service
engineer for advice.

Starting the burner:
In normal operation, the burner starts automatically

whenever the boiler temperature falls below the set
temperature.

Understanding the control panel

There are no user parts inside the control panel.

• ON/OFF switch
This turns the HeatMaster® on or off.

• Control thermostat - 60 to 90 °C

When using the HeatMaster® as a hot water generator only,
the temperature can be set between 60 °C and 90 °C.
If the HeatMaster® is used for both hot water and central
heating, the control thermostat would normally be set at 80 °C
to achieve optimum operating conditions.

• Summer/Winter switch

This turns the heating pump (if fitted) on or off.

• Manual reset high limit thermostat

If the boiler temperature exceeds 103 °C this safety device
will activate and the high temperature indicator will light up. To
reset - first allow the boiler to cool to below 60 °C, unscrew the
cap and press the reset button using a pencil or similar pointed
device, replace the cap. If the fault persists, turn the boiler off
and call an engineer.

• Time clock

This allows the HeatMaster® to be timed on and off and
operates on a 24 hour sequence. Around the outside of the
clock there are a number of white tabs, these allow 15 minute
switching periods. To set the time clock simply push outwards
the number of tabs required for ON period.

Remember: TAB IN = HeatMaster® OFF
TAB OUT = HeatMaster® ON

Control panel HeatMaster® 60 N

1

2

1. Burner lockout indicator

2. Primary circuit low wa ter pressure indicator

3. High limit cutoff indicator

4. Combined t emperature and pr essure gauge

5. Co nt ro l th ermos tat

6. Ti me cloc k

7. M a n u a l r e s e t h i g h l i m i t t h e r m o s t at

8. ON / OFF switch

9. Summer / Winter switch

4

53

Control panel HeatMaster® 70 N and 100 N

1

53

I

O

I

O

76

8 9

76

• Temperature and pressure gauge

This gauge indicates both the temperature of the HeatMaster®
and the pressure within the primary circuit.
The temperature should not exceed 90 °C - if it does, switch the
boiler off and check the thermostat setting. If the fault persist s,
call an engineer.
The pressure should not fall below 1 bar, if it does the please
see the ‘Heating System Pressure’ paragraph later in this
section.

• Low primary water pressure indicator

If this indicator lights up, the primar y circuit of the HeatMaster
requires topping up with water. Please see the ‘Heating System
Pressure’ paragraph later in this section.

664Y0500.A

EN • 6

2

®

4

8 9

USERS GUIDE

Heating system pressure

From time to time you may need to top up the heating

system pressure. This pressure is indicated by the
combined temperature and pressure gauge on the boiler
control panel.

The minimum pressure when the boiler is cold should be

1 bar. The precise operating pressure required depends
on the height of the building, and your installer will have
informed you of this value at the time of installation
(see Commissioning Section - Filling the hot water and
heating circuits).

If the pressure falls below 1 bar, the boiler water

pressure switch will turn the boiler off until pressure is
restored.

To re-pressurise, the system needs to be topped up with

water.

First, switch the boiler OFF on the ON / OFF switch and

isolate the external electrical supply. Then remove the
casing top front panel by pulling it forward. The filling
valves “A” and “B” can now be seen. Open both valves and
allow the system to fill. When the combined temperature
and pressure gauge shows the required pressure, close
bothvalves. Replace the casing top front panel. Restore
the power supply and switch the boiler on.

RESETTING THE PRESSURE JET OIL OR
GAS BURNER

• HeatMaster® 60 N / 70 N and 100 N
the lockout indicator is situated on the burner and on the

control panel.

The red warning light indicates an operating fault.Wait five
minutes before resetting the burner.To reset : press the button
located on the burner.

If the burner does not relight, call the service engineer after
ensuring that the fault is not due to a power cut or low oil in
the tank.

ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH

Safety Valves

If water discharges from any of the safety valves, switch
the boiler off and call a service engineer.

HeatMaster® 60 N

A

B

HeatMaster® 70 N and 100 N

A

RESETTING THE BG 2000-S PREMIX
GAS BURNER

• HeatMaster® 60 N with BG 2000-S/60
HeatMaster® 70 N with BG 2000-S/70
HeatMaster® 100 N with BG 2000-S/100
the lockout indicator is situated on the burner and on the

control panel.

1. Remove the burner cover.

2. Press the red but ton to restart the burner.

3. If the burner lights, replace the cover.

4. If the fault persists, call a service engineer.

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B

EN • 7

BURNER TROUBLESHOOTING

For all burners - please refer to the relevant servicing and
troubleshooting instructions in your burner’s technical
manual.

TECHNICAL CHARACTERISTICS

MAXIMUM OPERATING CONDITIONS

ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH

Maximum service pressure (tank full of water)

- Primary circuit: 3 bar

- Secondary circuit: 10 bar

Test pressure (tank full of water)

- Primary circuit: 4.5 bar

- Secondary circuit: 13 bar

Operating temperature

- Maximum temperature: 90 °C

Water quality

• Chlorures: < 150 mg/l (304)
< 2000 mg/l (Duplex)

• 6 ≤ ph ≤ 8

GENERAL FEATURES

Maximum Input

Maximum Output

Maintenance loss at 60°C as rated value

Total capacity

Primary circuit capacity

Heating connection [F]

Domestic hot water connection [M]

Domestic hot water tank heat exchanger surface

Pressure drop primary circuit

Pressure drop in the combustion chamber

kW

kW

m

mbar

mbar

BURNER CHAMBER PLATE

The burner chamber plate has 4 threads M8 for attaching the
burner. It is protected from heat by a blanket insulation.

%

L

L

Ø

Ø

2

4x(M8)

®

HeatMaster

60 N HeatMaster® 70 N HeatMaster® 100 N

69,9 69,9 107,0

62,9 62,9 96,3

0,57 0,60 0,65

162 239 330

82 108 130

1”1/2 1”1/2 1”1/2

3/4” 1” 1”

2,46 3,14 3,95

54 46 83

0,6 0,6 1,4

Ø130

60

60

60 60

Ø28

DOMESTIC HOT WATER FEATURES

Operating conditions at 80°C

Peak fl ow at 40°C [ΔT = 30°C]

Peak fl ow at 45°C [ΔT = 35°C]

Peak fl ow at 60°C [ΔT = 50°C]

Peak fl ow at 70°C [ΔT = 60°C]

Peak fl ow at 80°C [ΔT = 70°C]

Peak fl ow at 40°C [ΔT = 30°C]

Peak fl ow at 45°C [ΔT = 35°C]

Peak fl ow at 60°C [ΔT = 50°C]

Peak fl ow at 70°C [ΔT = 60°C]

Peak fl ow at 80°C [ΔT = 70°C]

Constant fl ow at 40°C [ΔT = 30°C]

Constant fl ow at 45°C [ΔT = 35°C]

Constant fl ow at 60°C [ΔT = 50°C]

Constant fl ow at 70°C [ΔT = 60°C]

Constant fl ow at 80°C [ΔT = 70°C]

Pre-heat time

L/10’

L/10’

L/10’

L/10’

L/10’

L/60’

L/60’

L/60’

L/60’

L/60’

L/h

L/h

L/h

L/h

L/h

minutes

HeatMaster® 60 N HeatMaster® 70 N HeatMaster® 100 N

474 646 905

378 543 777

245 346 514

193 268 343

135 207 258

1942 2133 3172

1656 1794 2680

1106 1219 1813

681 971 1226

499 636 893

1835 1835 2776

1573 1573 2379

1101 1067 1665

791 918 1104

455 580 804

91613

664Y0500.A

EN • 8

ELECTRICAL CONNECTION

WIRING DIAGRAM : HeatMaster® 60 / 70 / 100

1. 230 V power connection plug

2. ON/OFF switch

3. Temperature high limit cutoff indidicator

4. Manuel reset high limit thermostat

5. Primary circuit low water pressure indicator

6. Low water pressure switch

7. Time clock

8. Summer / Winter switch

9. Hot water priority link

The wiring shown is designed for
blown gas or oil burners.

It is important to move the link
from points (12 - 15) to (15 - 16)
when using the BG 2000-S burner.

Y/Gr

Y/Gr

B

G

10. Burner lockout indicator

11. Room thermostat (optional)

12. Central heating pump

13. HeatMaster

®

loading pump

14. Burner plug connector

15. Water flow switch connection (optional)

16. Termal reset high limit thermostat 95°C

17. Control thermostat

L1 N T1 T2 S3 B4

14

L1 N T1 T2 S3 B4

Y

B

Br

Y/Gr

G

Gr

12 13

Y/Gr

B

Br

Y/Gr

11

Gr

Or

Y

1234567891011121314151617181920

G

21

B

Y/Gr

G

Or

GG

B

B

B

B

R

Pk

W

10

9

Or

C

ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH

15

G

W

Bk

Pk

B. Blue
Bk. Black
Br. Brown
G. Grey
Gr. Green
Or. Orange
Pk. Pink
R. Red
V. Violet
W. White
Y. Yellow
Y/Gr. Yellow / Green

Or

8

Or

B

Or

5

4

7

3

Br

6

Bk

21

C

103 C

4

G

12

P

B

Or Br

B

I

O

Y/Gr

Br

B

Br

B

Pk

95 C

12

16

17

C

Bk

W

0 - 90 C

12

B

5

B

3

C

B

B

2

B

W

L1 N

1

L1 N

664Y0500.A

EN • 9

INSTALLATION

DIMENSIONS

ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH

The units are delivered fully assembled, tested and packed on a timber
base with shockproof edges and protected by heat-shrunk plastic film.

On reception and after unpacking, check the equipment for damage.
For transport purposes, refer to the weight and dimensions given below.

HeatMaster

60 N

®

HeatMaster

+ BG 2000-S/60

60 N

®

HeatMaster

70 N

®

HeatMaster

70 N

+ BG 2000-S/70

®

HeatMaster

100 N

®

+ BG 2000-S/100

HeatMaster

100 N

®

A mm 1698 1698 1743 1743 2093 2093

B mm 1583 1583 1630 1630 2030 2030

C mm 540 540 678 678 678 678

D mm 625 801 797 937 797 937

E mm 540 540 680 680 680 680

F mm 390390390390390390

G mm 150 150 150 150 15 0 15 0

H mm 1098 1098 1289 1289 1693 1693

J mm 281 281 285 285 285 285

K mm 166 5 16 65 17 20 1720 2120 212 0

Weight empty (kg] 220 232 270 282 320 333

HeatMaster® 60 N

Without burner With ACV BG 2000-S

prem ix gas bu rner

F

G

HeatMaster

®

70 N / 100 N

A

C

D

Without burner With ACV BG 2000-S

A

C

D

C

D

prem ix gas bu rner

C

D

HBAK

C/2

J

E

G

F

A

E

K

HB

C/2

J

664Y0500.A

EN • 10

INSTALLATION

BOILER ROOM

- Make sure that all air vents are unobstructed at all times.

- Do not store any flammable products in the boiler room.

- Do not store any corrosive products, paint, solvents, salts,
chlorine products and other detergent products near the
appliance.

- If you smell gas, do not switch ON or OFF any lights, turn off
the gas tap at the meter, ventilate the rooms and contact
your installer.

- The base on which the boiler rests must be made of
non-combustible materials

ACCESSIBILITY

The appliance must be positioned in such a way to be
accessible any time. In addition, the following minimum distances
are required around the appliance.

- Front 500 mm - Side 100 mm

- Behind 150 mm - Above 700 mm

CONNECTION TO THE CHIMNEY

- The chimney connections must comply with the applicable
standards (in Belgium: NBN D51-003), it must be installed by
an approved engineer, in accordance with the prevailing local
standards and regulations.

- Flue size should not be less then the outlet size of the boiler.

Chimney connection type B23P

The Boiler is connected to the chimney by metal pipe rising at an
angle from the boiler to the chimney. A flue disconnection piece
is required. This must be easy to remove to give access to the
flue pipes when servicing the boiler.

Balanced flue boiler connection type
C13 - C33 - C53 - C63

• C13 : Concentric horizontal connection

• C33 : Concentric vertical connection

• C53 : Parallel chimney connection

• C63 : Concentric vertical connection without terminal
(Only in Germany and Luxemburg).

The maximum flue resistance is 100 Pascal - the table below can be

used to calculate this value.

HeatMaster

60N / 70N

Air

80 mm

1 m straight pipe

90° pipe bende

45° pipe bende

Condensate recovery

Outlet pipe

This table is based on the equipment offered by ACV and cannot be applied
generally.

C33

6162

15 2 15 5

6162

_2_4

20 10 20 20

®

Flue gas

150mm

120

HeatMaster

100 N

Air

100 mm

150 min.

®

Flue gas

150mm

ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH

Due to the high efficiency of our boilers, the flue gasses exit at
low temperature. Accordingly, there is risk that the flue gasses
could condense, which could damage the chimney and the
boiler. In order to avoid this risk, it is strongly recommended
that the chimney be lined and a condensate trap is fitted.

Ventialtion

Min. fresh air requirement m3/h 126 126 194

Bottom dm

Top dm

HM

60 N

2

2,11 2,11 3,20

2

2,0 2,0 2,0

HM

70 NHM100 N

Chimney minimum flue Ø

E = 5 m Ø F min. mm 189 18 9 23 4

F = 10 m Ø F min. mm 159 15 9 178

E = 15 m Ø F min. mm 150 15 0 150

Note :

Regulations vary from the country therefore the

table above is intended only as a guide.

F

A. Top vent
B. Bottom vent
C. Draught regulator
D. Inspection window
E. Height of lined chimney
F. Chimney diameter

A

B

C

D

C13

2 m min.

The maximum length of concentric flue is 6 meters.

A condensation drain outlet must be fitted close to

the boiler to prevent condensation products from the
chimney running into the boiler.

To avoid condensation water running out of the

E

terminal, all horizontal flue runs must fall back
towards the boiler.

C53

664Y0500.A

EN • 11

INSTALLATION

DOMESTIC HOT WATER CONNECTION

ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH

Before pressurizing the central heating circuit (primary)

you should first pressurize the domestic hot water
tank (secondary).

The HeatMaster® boiler can be connected directly on the
domestic hot water circuit.

Flush out the system before connecting the domestic hot water
part.

The installation must be fitted with an approved safety unit with
a 7-bar safety valve, a non-return valve and a shut-of f valve.

During the heating process, the domes tic hot water dilates and
the pressure increases. As soon as the pressure exceeds the
safety valve setting, the valve opens and discharges a small
quantity of water. Using a hot water expansion vessel (2 liters at

least)

will prevent this phenomenon and reduce water hammer

effect.

The hot water output temperature may reach
temperatures in excess of 60°C, which can cause
burns. We therefore recommend that you install
a thermostatic mixer immediately after the
appliance outlet.

Example of parallel connection

Recommended for applications with a high continuous flow.

I

O

I

O

I

O

Example of series connection

Preferable for high temperature applications with up to three
units.

If stop valves are used in the domestic hot water

system, they can cause pressure waves when closed.
Use devices designed to reduce water hammer to
avoid this phenomenon.

6

12

2

3

7

4

8

10

11

5

I

O

9

I

O

I

O

I

O

Example of heating + storage connection

Recommended for applications requiring a high peak flow.

1. Cold water supply tap

2. Non-return valve

3. Pressure reducing valve

4. Safety group

5. Hot water expansion vessel

6. Hot water secondary pump (it fitted)

7. Thermostatic mixing valve

8. Drawoff tap

9. Drain cock

10. Stop cock for cleaning

11. Temperature relief valve (UK-only)

664Y0500.A

EN • 12

I

O

INSTALLATION

HEATING CONNECTION

Before pressurizing the central heating circuit (primary)

you should first pressurize the domestic hot water
tank (secondary).

The HeatMaster® has two connections at the rear that can be
used to connect a central heating circuit. Connecting a heating
system may reduce the domestic hot water performance.

Expansion

The HeatMaster® 60 is fitted with an 8 litre expansion vessel.
HeatMaster® 70/100 models are fitted with two 10 litre

expansion vessels. These expansion vessels are sized for hot
water operation only. If a heating system is connected to the
primary circuit, calculate the expansion capacity necessary for
the total volume of the heating system. (Refer to the technical

instructions from a relevant manufacturer of expansion vessels)

WARNING

The pimary safety valve is supplied with a plastic tube

connected to the discharge outlet - this is for test
purposes only and should be removed. The safety valve
should be connected to a drain using a metallic pipe
eg. copper.

.

1. 4-way valve

2. Heating pump

3. Non-return valve

4. Isolating valves

5. Safety valve set to 3 bar with pressure gauge

6. Expansion vessel

7. Drain cock

8. Controller

9. Contact sensor

8

I

O

1

4

9

7

423

ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH

5

6

OIL SUPPLY CONNECTIONS - ACV BM BURNERS

(if another make of burner is fitted please refer to that manufacturers technical manual)

Installation without return

L (m) (L = H + 1)

H (m) Ø int. 8 mm Ø int. 8 mm

0,5 10 20

12040

1,5 40 80

260100

Installation with return

L (m) (L = H + 1)

H (m) Ø int. 8 mm Ø int. 8 mm

035100

0,5 30 100

125100

1,5 20 9 0

21570

2,5 8 30

3,5 6 20

max 4m

H

H

L1

L1

CONNECTION TO THE GAS

- The HeatMaster® is fitted with a Ø 3/4” (BG 2000-S/60,

BG 2000-S/70) and Ø 1” (BG 2000-S/100) female
fit ting connector, on which you can connect the gas tap.

- The gas connection must comply with the applicable
regulations (e.g. NBN D51-003 in Belgium) in the
country of installation.

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

- Fill the gas line the gas pipe and check in minut e detail
that all the boiler pipes, both inside and outside, are
sealed.

- Check the gas pressure in the system. Consult the
technical characteristics.

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

max 4m

H

L1

664Y0500.A

EN • 13

COMMISSIONING

FILLING THE DOMESTIC HOT WATER AND HEATING CIRCUITS

ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH

Before pressurizing the central heating circuit you should first pressurize the domestic hot water tank.

Both the domestic hot water tank and the central heating circuit must be filled before using the boiler.

1. Close the primary circuit filling valves (A)

2. Open the stop valve (B) and the drawoff tap (C).
When water flows out of the tap, the hot water tank is full

and the drawoff tap (C) should be closed.

3. Fill the primary (heating) circuit by opening the valves (A)

and pressurising to 1 bar.

4. Open the automatic air vent located on top of the boiler.
IMPORTANT - the screw cap must be left loose to allow

future automatic venting to take place.

5. After venting the air from the system, bring the pressure
up to the static head plus 0.5 bar:

1.5 bar = 10m and 2 bar = 15 m.

6. Check that the electrical connection and boiler room
ventilation conform to the relevant standards.

HeatMaster® 60 N HeatMaster® 70 N and 100 N

7. Set the thermostat between 60 and 90 °C.

8. Switch the on/off switch to the ON position.

9. For gas burner, check the gas supply pressure on starting
up.

10. For the oil burner, check the oil supply (and return).
Proceed with the necessary venting, measurements and
settings.

11. Set the heating control to heat demand. When the burner
operates, check the flue gas discharge pipes for leaks.

12. After 5 minutes of operation, vent the primary circuit again
maintaining the water pressure at 1 bar.

13. Then restart the unit and check the combustion.

C

C

B

B

I

O

A

I

O

A

664Y0500.A

EN • 14

BURNER FEATURES

ACV BG 2000-S PREMIX GAS BURNERS

Description

The burner tube is coated with metal fibre (NIT) which, in
addition to its remarkable heat exchange capabilities, gives
greater durability.

The principle componants of the burner are:

- a fan with adjustable speed

- an automatic ignition and flame detection system

- a gas valve and venturi specially developed for air/gas pre-mix
burners with low NOx

The pressure at the gas valve outlet is equal to the air pressure at
the neck of the venturi tube, reduced as the offset is adjusted. The
fan sucks in the combustion air through the venturi tube which the
gas inlet leads into. As it goes through, the air creates a vacuum
to the right of the neck of the venturi tube and sucks in the gas at
the venturi tube outlet. A perfect air/gas mix then goes through
the fan and then goes on towards the burner tube.

This design ensures very quiet and safe operation:

• If there is an air blockage, the pressure differential in the

venturi falls, the gas flow diminishes, the flame goes out
and the gas valve closes: the burner is in safet y shutdown
mode.

• If there is a blockage in the chimney outlet, the air flow

diminishes, and the same reactions as those described
above cause the burner t o shut down in safety mode.

AB

ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH

C

TYPE A B C

BG 2000-S / 60 375 228 272

BG 2000-S / 70 375 248 3 42

BG 2000-S / 100 375 248 342

BG 2000-S burners are preset at factory

for natural gas

Conversion to propane

• The BG 2000-S burner fitted to the HeatMaster® 60, 70

and 100 is controlled by a Honeywell module which controls
burner operation and safety.

Air-gas mixture control system

C

A

F

Not applicable for Belgium.

Conversion kit included with burner

- Restrictor (s)

- Nameplate(s)

- Sticker with settings

- Fitting instructions

D

E

comprising :

A. Air inlet
B. Gas inlet
C. Venturi
D. Fan
E. Air - Gas mixture
F. Offset regulation screw
G. Gas flow regulation screw

B

664Y0500.A

G

EN • 15

BURNER FEATURES

ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH

Input

Output

Combustion effi ciency - natural gas

Natural gas CO

Pressure drop combustion chamber

Flue gas temperature

Mass fl ow rate of combustion products

G20 gas fl ow rate - 20 mbar

G25 gas fl ow rate - 25 mbar

G31 gas fl ow rate - 30/37/50 mbar

Gas categories HeatMaster® N + BG 2000-S

BE

CH

CZ

DE

DK

EE

ES

FR

GB

GR

IE

IT

LU

LT

NL

PL

PT

SI

SK

SE

2

G20

G25

G30

G31

Belgium

Switzerland

Czech republic

Germany

Denmark

Estonia

Spain

France

Great Britain

Greece

Ireland

Italy

Luxembourg

Lithuania

Netherlands

Poland

Portugal

Slovenia

Slovakia

Sweden

I2E(S)B
I2E(R)B * II2H3B/P II2H3P II2E3B/P II2Er3P II2L3B/P II2L3P I3P

20 mbar 20 mbar 20 mbar 20 mbar 20 mbar

25 mbar 25 mbar 25 mbar 25 mbar

30 - 50 mbar 30 - 50 mbar 30 - 50 mbar

30 - 50 mbar 37 - 50 mbar 30 - 50 mbar 37 - 50 mbar 30 - 50 mbar 37 - 50 mbar 37 mbar

kW

kW

mbar

°C

g/sec.

3

m

3

m

3

m

HeatMaster

®

HeatMaster

60 N

+ BG 2000-S / 60

69,9 69,9 107,0

62,9 62,9 96,3

%

%

/h

/h

/h

91,2 91,5 92,1

9,5 9,0 9,5

0,6 0,6 1,4

186 172 165

32,1 32,1 49,2

7,40 7,40 11,32

8,60 8,60 13,17

2,86 2,86 4,50

+ BG 2000-S / 70

70 N

®

HeatMaster

®

100 N

+ BG 2000-S / 100

(*) HeatMaster ® 100 N + BG 2000-S/100

664Y0500.A

EN • 16

BURNER FEATURES

ACV Premix gas burner BG 2000-S/60 and BG 2000-S/70

1. Ig n i t i o n e l e c t r o d e

2. Burne r tu be

3. Ionis at io n pr obe

4. Burner chamber plate insulation

5. Ga s valve

6. Ven tu ri

7. C h a m b e r p l a t e

8. Relay

9. Gas inl et

10. Fan power plug

11. Fan

12. Potentiometer setting

13. Burner plug connector

B. Blue
Bk. Black
Br. Brown
G. Grey
Gr. Green
Y. Yellow
Y/Gr. Yellow / Green

4

1

ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH

5

2

3

6

7 11

L1

NT2

B

Br

Br

Y/Gr

B

Br

Y/Gr

L1 N

B

123456 789101112

S3 B4

T1

B

Gr

Y

Br

Bk

Y

G

Br

Gr

G

Br

Bk

Y/Gr

ACV Premix gas burner BG 2000-S/100

1. Ig n i t i o n e l e c t r o d e

2. Burne r tu be

3. Ionis at io n pr obe

4. Burner chamber plate insulation

5. Ga s valve

6. Ven tu ri

7. C h a m b e r p l a t e

8. Relay

9. Gas inl et

10. Fan power plug

11. Fan

12. Potentiometer setting

13. Burner plug connector

B. Blue
Bk. Black
Br. Brown
G. Grey
Gr. Green
Y. Yellow
Y/Gr. Yellow / Green

8

12

9

10

13

4

1

5

2

6

3

7 11

Br

Y/Gr

L1 N

664Y0500.A

L1

NT2

B

B

Br

Br

Y/Gr

B

B

Gr

123456 789101112

S3 B4

T1

Br

Br

Bk

B

Br

Y

G

Gr

8

12

9

Y

G

Br

Bk

B

Br

Y/Gr

10

13

EN • 17

BURNER FEATURES

ACV BM 102 AND BM 152 OIL BURNERS

ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH

Description

The use of new technology enables our medium output
burners to meet current performance and emissions quality
requirements.
These burners are fitted with high quality components including
a two-stage oil pump that permits soft start.

Features

- Easy to install – fitted with safety closure and new burner

suspension system.

- The burner air pressure adjusts to the pressure in the

burner chamber.

- An automatic damper shuts of f the air flow when the burner

is turned off, preventing the boiler from cooling.

- Quiet and extremely reliable.

- Adjustable to the depth of the boiler burner chamber

thanks to the adjustable bracket at the mouth of the burner
chamber.

- Three air adjustment points to ensure the best air/oil

mixture.

• upstream air presetting

• primary setting

• combustion head setting

BM oil burners dimensions

A mm B mm C mm D mm E mm F mm G Ø L Ø LK Ø Kg

BM 102 350 350 285 325 50 M 8 100 / 82 110 150 16

BM 152 350 350 285 325 50 M 8 100 / 123 110 150 16

DE

G

L

C

B

A

K

L

Oil burner specification and performances

HeatMaster® 60 N HeatMaster® 70 N HeatMaster® 100 N

Burner type BM 102 BM 102 BM 152

Input

Nozzle fl ow

kW

US Gal/h

69,9 69,9 107,0

1,50 1,50 2,00

M 8

Nozzle angle 60° 60° 60°

Oil fl ow

Pump pressure

Flue gas temperature

CO

2

Mass rate combustion products

664Y0500.A

kg/h

bar

°C

g/sec.

5,9 9,9 8,9

10,5 10,5 13,5

175 170 170

%

12,5 12,5 12,5

29,6 29,6 44,8

EN • 18

MAINTENANCE

SERVICE INTERVALS

ACV recommends that boilers should be serviced at least once
a year. The burner must be serviced and tested by a competent
engineer. If a boiler is subject to heav y use, it may require
servicing more than once a year - consult ACV for advice.

SERVICE THE BOILER

1. Turn OFF the on/off switch on the boiler control panel and

isolate external electrical supply.

2. Turn of f the gas or oil supply to the boiler.

3. Remove the flue to gain access to the top of the boiler.

4. Remove the casing top panel and lift off the flue reduction

collar by undoing the fastening bolts.

5. Remove the turbulators from the flue pipes for cleaning.

6. Unscrew the burner chamber plate and remove the

burner.

7. Brush the flue pipes .

8. Clean the burner chamber and the burner.

9. Re-assemble turbulators, flue reduction collar and flue,

checking that the gasket on the flue reduction collar is in
good condition. Replace gasket if necessary.

SERVICING THE SAFETY DEVICES

- Check that all thermostats and safety devices are working

properly.

- Test the safety valves on the central heating and hot water

circuits.

SERVICING THE BURNER

Oil burner

- Check and if necessary clean the main filter on the oil line.

- Check the alignment of the nozzle: check, clean or change

the nozzle and its filter, check that the electrodes and flame
holder are clean and correctly adjusted.

- Reassemble and check that the safet y components are

working properly.

- Set the combus tion parameters.

- Check the combustion (CO2, CO and burner pressure)

Gas burner

- Check that the insulation and gasket on the burner chamber

plate are in good condition - replace if necessary.

- Check and clean the burner and electrodes. Replace

electrodes if necessary (under normal use once a year).

- Check that the safety components are working properly.

- Check the combustion (CO2, CO and gas pressure)

DRAINING THE BOILER

Water flowing out of the drain cock may
be extremely hot and could cause severe
scalding.
Keep people away from discharges of hot
water.

Draining the heating circuit

1. Turn OFF the on/off switch on the boiler control panel,
isolate external electrical supply, and turn off the gas or oil
supply to the boiler.

2. Close the isolating valves (4).

3. Connect a hose to the drain cock (7).

4. Open the drain cock to drain the primary circuit.

8

I

O

5

7

1

Draining the domestic hot water circuit

1. Turn OFF the on/off switch on the boiler control panel,
isolate external electrical supply, and turn off the gas or oil
supply to the boiler.

2. Release the pressure in the heating circuit until the pressure
gauge indicates zero bar.

3. Close stop cock (1) and turn of f tap (8).

4. Open valve (9) then valve (10) (first 9 then 10).

5. Let the water empty into the drain.

3

12

4

5

4

9

423

6

2

6

8

7

10

11

ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH

664Y0500.A

EN • 19

I

O

9

For the tank to be emptied, valve (9) must be situated

at ground level.

ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH

664Y0500.A

EN • 20

537D6224

Ø 150 mm

537D6225

Ø 150 mm

537D6211

Ø 150 mm

537D6212

Ø 150 mm

537D6213

Ø 100 mm

537D6210

Ø 150 mm

537D6219

Ø 150 mm - 45°

537D6214

Ø 150 mm - L 250 mm

537D6215

Ø 150 mm - L 500 mm

537D6216

Ø 150 mm - L 1000 mm

537D6219

Ø 150 mm - 90°

537D6218

Ø 150 mm

664Y0500.A

537D6217

Ø 100 mm - L 500 mm

537D6222

Ø 100 mm - 90°

537D6222

Ø 100 mm - 45°

537D6223

Ø 150 mm

I

O

21477400

HeatMaster® 30 N / 60 N

21475400

21472400

21478400

21474400

21473400

21476342

21471400

21423026

664Y0500.A

507F3033

HeatMaster® 30 N / 60 N

557A0016

63438001

507F2009

49410039

507F2010

55445007

557A4002

55426017

51305000

557A1056

55301200

55426001

664Y0500.A

51401045

21473369

HeatMaster® 70 N

21475369

21472369

21474369

21477369

21478369

21476370

21471369

2147P152

664Y0500.A

HeatMaster® 70 N

507F3033 557A0016

507F2009

63438001

557A7006

497B0001

557A1056

55426017

507F2010

39438046

55445007

664Y0500.A

557A4009

51305000

55426001

51401045

21473370

HeatMaster® 100 N

21475369

21472370

21474370

21477369

21478369

21476370

21471370

2147P152

664Y0500.A

HeatMaster® 100 N

507F3033 557A0016

507F2009

63438001

557A7006

49410071

557A1056

55426017

507F2010

39438047

55445007

664Y0500.A

557A4009

51305000

55426001

51401045

HeatMaster® 30 N / 60 N

54766001 54441008 54322000 54764009

I

O

54764021

54442045

54766016 54766017

54452000

HeatMaster® 70 N / 100 N

54766001 54441008 54322000 54764006

I

O

664Y0500.A

54442045

54764021

54766016 54766017

54452000