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

HeatMaster

Installation, operating and servicing instructions

HeatMaster® 60N / 70N / 100N

With ACV BG 2000-S premix gas burner

ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH

HeatMaster

With ACV BM oil burner

60N / 70N / 100N

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EN • 1

INDEX

WARNINGS 3

Who should read these instructions 3 Symbols 3

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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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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).

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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.

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DESCRIPTION

OPERATING PRINCIPLE

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

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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

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EN • 4

DESCRIPTION

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

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

B A

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USERS GUIDE

USING THE BOILER

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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. 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

Control panel HeatMaster® 70 N and 100 N

8 9

• 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.

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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.

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Safety Valves

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

HeatMaster® 60 N

HeatMaster® 70 N and 100 N

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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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

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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

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.

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

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/60’

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

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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

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

Y/Gr

12 13

Y/Gr

1234567891011121314151617181920

Y/Gr

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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

103 C

Or Br

Y/Gr

95 C

0 - 90 C

L1 N

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