Connection to the chimney13
Connection to the gas15
Domestic hot water connection15
Heating connections16
Installation of a single high temperature circuit with room thermostat ACV 15 control17
Installation of a weather depending heating circuit high or low temperature18
Installation of two heating circuit controlled by control unit and ZMC-1 module20
COMMISSIONING AND MAINTENANCE22
Commissioning the system22
Inspection and maitenance22
Temperature sensor resistance tables22
Disassembling the burner23
Disassembling and checking the electrode23
Cleaning the heat exchanger23
MCBA PARAMETERS FOR THE SPECIALIST24
Standby mode24
Setting the MCBA parameters25
Request for information on the installation26
Entering the code26
MCBA parameters with code restricted access27
Communication mode30
Error mode30
Safety stop [error mode]31
SPARE PARTSSee at the end of this manual
664Y2800.E
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.
• Specific regulation applicable in Belgium:
The CO
• It is important to switch the boiler off before carrying out
• There are no user accessible parts inside the boiler casing.
2 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.
any work.
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-TOP” label (Gas condensation 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. Remember to note the
fault code displayed on the screen.
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 manufacturer reserves the right to change the
technical characteristics and specification of its
products without notice.
• 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 burners are preset in our factory for use with natural
gas [equivalent to G20].
664Y2800.E
EN • 3
INTRODUCTION
TOTALLY CONDENSING :
The HeatMaster® TC combines the
unique ACV Tank-in-Tank concept with
ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH
a dual primary circuit resulting in
exceptional performance from a totally
condensing combination boiler.
Tank-in-Tank technology
ACV’s advanced implementation of thermal storage technology is
tried and tested and is remarkably simple, efficient and reliable.
At the heart of the HeatMaster® TC is a stainless steel tank
through which the flue tubes pass.
This is surrounded by a mild steel shell containing the primary
water, which extends down to the combustion chamber and even
around the flue tubes. The burner fires onto the primary water
which indirectly heats the stainless steel tank containing the hot
water. As with all Tank-in-Tanks, this is corrugated over its full
height and is suspended in the HeatMaster® TC by its hot and
cold water connections.
The area of the heat transfer surface is therefore much greater
than that of standard direct fired water heaters. A much larger
heat transfer surface means that Tank-in-Tank units recover much
faster than any other kind of hot water storage device - and keeps
boiler cycling to a minimum. The high storage temperature within
the inner tank also results in exceptional hot water outputs.
Dual primary circuit technology
The HeatMaster® TC primary circuit is split into two sections a high temperature upper circuit and a low temperature lower
circuit, divided by a separation plate. The hot water storage
tank is located in the upper circuit which always operates
at a temperature of between 60°C and 90°C. This is ideal
for hot water production as it maintains the stored water at
constantly high temperatures, eliminating bacterial formation
such as Legionellae, as well as resulting in high volume hot water
production.
The down-firing flue tubes pass through the upper circuit, through
the separation plate and into the lower circuit. The primary water
here operates at a temperature typically between 30°C and
60°C for heating (dependent on the heating return temperature),
perfect for condensing when working in heating mode.
Operating modes
In both heating and hot water modes, the premix
gas burner fully modulates the power to match
the system demand.
Heating
1
The heating return
enters the lower circuit
of the boiler, which allows
the boiler to operate in
condensing mode.
The upper circuit of the
HeatMaster® TC is kept
at a consistently high
temperature due to the
internal shunt pump which
ensures that the primary
water circulates around
the heat exchanger flue
tubes.
Hot water
2
With the upper circuit
maintained at high
temperature, the
HeatMaster® TC is always
ready to supply hot water
on demand.
The cold water enters
through the indirect water
preheater at the base of
the heat exchanger and is
preheated before entering
the hot water tank.
The low temperature of the
bottom circuit results in
continuous condensation of
the flue gases in hot water
mode.
Dual domestic hot water tank technology
During hot water mode, the bottom circuit operates at a much
lower temperature, typically 5°C to 20°C depending on the cold
water inlet temperature. The incoming cold water enters the
lower primary circuit via an indirect water preheater.
As this preheater is wrapped around the lower flue tubes of the
combustion chamber, it is able to absorb the remaining heat
from the flue gases. The result is that during hot water mode the
HeatMaster® TC totally condenses whether on full or part-load.
664Y2800.E
EN • 4
Heating and
3
hot water
Once up to temperature,
the HeatMaster® TC is
capable of producing
heating and hot water
simultaneously.
INTRODUCTION
1
10
11
2
12
3
4
5
6
7
13
14
15
16
17
8
HeatMaster® 35 TC
1. Flue connection concentric Ø 80/125 mm convertible to
parallel connection Ø 80/80 mm.
2. Domestic hot water out let
3. He at ing f lo w
4. Stainless steel heat exchanger
5. Stainless steel Tank-in-Tank hot wat er stor e
6. Indirect water preheater
7. H e a t i n g r e t u r n
8. Cold water inlet
9. Co ndenst rap
10. Modulating premix gas burner
11. Gas connec tion
12. Combustion chamber
13. Control panel
14. Primary heating cir cuit
15. Polyurethane foam insulation
16. Boiler shunt pump
17. Separation plate
18. Primary safety valve (3 bar)
19. Drain cock
ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH
18
9
1
2
3
4
5
6
7
8
19
12
13
14
15
16
17
HeatMaster® 85 TC
1. Flue connection concentric Ø 100/150 mm conver tible to
pa r a l lel c o n nec ti o n Ø 10 0/100 m m
2. Domestic hot water outlet
3. He at ing f lo w
4. Combustion chamber
5. St ainless steel heat exchanger
6. St ainless steel Tank-in-Tank hot water s tore
7. Auxiliary tank primary return
8. Indirect water preheater
9. Heat ing re tur n
10. Cold water inle t
11. Separation plate
12. Gas connect ion
13. Modulating premix gas burner
14. Control panel
15. Primary heating circuit
16. Primary expansion vessel (2x)
17. Polyurethane foam insulation
18. Boiler shunt pump
19. Primary safety valve (3 bar)
9
10
11
664Y2800.E
18
19
EN • 5
INTRODUCTION
DESCRIPTION OF THE SPECIFICATIONS
The HeatMaster® TC is an hot water producer combined in
a condensing boiler in accordance to the Belgium "HR-Top"
standard. The boiler is certified compliant with "CE" standards as
a connected appliance C13(x) - C33(x) - C43(x) - C53 - C83(x),
ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH
but it can also be connected as an open appliance in category
B23 or as an appliance of category B23P, which can operate
with a positive pressure.
Lining
The boiler is protected by a steel lining that first of all undergoes a
degreasing and phosphation process before being lacquered and
heated at 220°C. The inside of this lining is coated with a layer of
thermal and acoustic insulation, reducing losses to a minimum.
Heat exchanger
The core of the HeatMaster® TC features a new stainless steel
heat exchanger. This piece of technology represents the fruit of
exhaustive research and intensive laboratory testing. It reflects
ACV’s eighty years of experience in using stainless steel for
heating and hot water functions. The particular geometry of the
exchanger pipes is calculated to obtain a very large Reynolds
number throughout its cycles.
The HeatMaster® TC achieves an exceptional output that
remains stable throughout the boiler’s life, given that it causes
no oxidation on the exchanger, which is manufactured entirely
from quality steel.
Burner
ACV uses its BG 2000-M burner for the HeatMaster® TC: this
is an air/gas premix burner providing safe and silent operation
while limiting emissions (NOx and CO) to an incredibly low level.
Although the ACV BG 2000-M boiler is very modern, it uses
proven technology and is manufactured from standard spare
parts that are easily available on the market.
PRODUCTION OF HOT WATER
In addition to its exceptional hot water performances, the ACV
Tank-in-Tank concept provides the follwoing advantages :
- A solution for scale deposits: thanks to the specially designed
corrugations, the hot water tank expands and contracts during
the heating cycle, preventing the formation of scale.
- A guarantee against the risk of Legionnellae Disease and
bacteria: the hot water tank is fully immersed in the primary
circuit and the hot water is constantly kept at a temperature
above 60°C.
- Exceptional resistance against corrosion and aggression:
provided by the stainless steel.
FROST PROTECTION
The boiler is equipped with an integrated frost protection: as soon
as the boiler temperature drops below 7°C, the system activates
the central heating pump. As soon as the NTC1 flow temperature
drops below 3°C, the system automatically ignites the burner until
the temperature rises above 10°C. The pump continues to run
for about 10 minutes.
If an outdoor temperature sensor is connected to the system,
the pump is activated as soon as the outside temperature drops
below the specified threshold.
To provide efficient protection for the whole system against frost,
all the valves on the radiators and the convectors should be
completely open.
Temperature regulation
The basic version of the HeatMaster® TC is fitted with a
microprocessor controlled regulator (MCBA) which takes over
both the safet y functions (ignition, monitoring the flame, limiting
the temperature, etc.) and control of the boiler temperature.
This MCBA also includes a weather-dependent regulator. All you
need to do is connect the outdoor temperature sensor available
as an option to the device. However, this regulator can also
operate with a standard ON/OFF room thermostat In addition,
with the combination of a weather-dependent regulator and a
room thermostat, you can control the temperatures based on
the weather with compensation for the indoor temperature.
There are four user adjustable parameters. By entering a
special maintenance code, qualified installers can access
several other parameters to adapt the boiler to special
requirements. In principle, these parameters are factory set
for all normal applications.
664Y2800.E
EN • 6
USERS GUIDE
DIRECTIONS FOR USE
Your system must be checked once a year by an approved
installer or maintenance company.
Starting the burner
During operation, the burner star ts automatically as soon as
the boiler temperature drops under the required set point and
it stops as soon as the boiler reaches that temperature.
Control panel
2
1O3
bar
4
Pre-cut for an optional
Control Unit controller
MCBA display
Pressure gauge
ON/OFF switch
Summer/Winter switch
SETTINGS PARAMETERS
Setting the domestic hot water temperature:
(Hot water temperature)
- Press Mode: The screen displays PARA.
- Press Step: the first character is 1 and the last two characters
give the current hot water temperature set ting.
- To change this temperature, press + or - until the last t wo
digit s show the desired temperature value.
- Press Store to save the new temperature setting.
- Press Mode twice to return to Pilot mode (normal operating
mode).
Enabling or disabling the hot water heating mode:
(hot water)
- Press Mode: The screen displays PARA.
- Press Step twice: the first character is 2 and the last two
characters give the current setting:
00 = disabled; 01 = enabled.
- To change this parameter, press + or - until the screen displays
the desired value:
00 = disabled; 01 = enabled.
- Press Store to save.
- Press Mode twice to return to Pilot mode (normal operating
mode).
Enabling or disabling Central Heating mode:
(heating)
- Press Mode: The screen displays PARA.
- Press Step three times: the first character is 3 and the last
two characters give the current setting:
00 = disabled; 01 = enabled.
- To change this parameter, press + or - until the screen displays
the desired value:
00 = disabled; 01 = enabled.
- Press Store to save.
- Press Mode twice to return to Pilot mode (normal operating
mode).
ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH
Heating system
The central heating circuit must be pressurized (see in the
chapter “Installation” how to define the system pressure).
The pressure indicator is located on the right-hand side of the
display.
If your system needs to be refilled more than twice
a year, please contact your installer.
The CH pressure must be a minimum of 1 bar and must be
checked by the end user on a regular basis. If the pressure
drops under 0.5 bar, the integrated water pressure switch
blocks the appliance until the pressure in the system returns to
a level above 0.8 bar. The connection for a fill valve is provided
underneath the appliance. The installer can also fit the system
with a separate valve. Make sure that the appliance is powered
off when filling the system. To do this, toggle the Start/Stop
switch located on the lef t of the screen to Of f. (see the Control
panel).
For more information, please ask your installer when the system
is delivered.
A safety valve is provided at the underneath of the appliance.
If the system pressure exceeds 3 bars, this valve opens and
drains the water from the system. In this case, please contact
your installer.
Setting the central heating temperature:
(maximum temperature for the heating circuit)
- Press Mode: The screen displays PARA.
- Press Step four times: the first character is 4 and the last
two characters give the current central heating temperature
setting.
- To change this temperature, press + or - until the last two
digit s show the desired temperature value.
- Press Store to save the new temperature setting.
- Press Mode twice to return to Pilot mode (normal operating
mode).
Fault:
The temperature setting for the appliance and the safety
functions for its various parts are continuously monitored by
a regulator controlled by a microprocessor (the MCBA). In the
event of a fault, this MCBA disables the appliance and displays
an error code: the screen flashes displaying E as the first
character, followed by the error code.
To reset the appliance:
- Press "Reset" on the screen.
- Contact your installer of the fault happens again.
664Y2800.E
EN • 7
TECHNICAL CHARACTERISTICS
HeatMaster® 35 TCHeatMaster® 85 TC
Central heatingNatural gasPropaneNatural gasPropane
- Make sure that all air vents are unobstructed any 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 any lights, turn off the
gas tap at the meter, ventilate the rooms and contact your
installer.
ACCESSIBILITY
The appliance must be positioned in such a way to be
accessible any time. In addition, the following distances
are required around the appliance.
Kit “Easy Fit” only for
HeatMaster® 35 TC
I
3 x 65
180
J
K
L
1736
M
N
O
Min. 25 mm Min. 25 mm
Min. 300 mm
690
730
2
1 O 3
bar
4
664Y2800.E
EN • 12
INSTALLATION
CONNECTION TO THE CHIMNEY
- The chimney connections must comply with the applicable
standards (in Belgium: NBN D51-003), the local energy
supplier’s instructions, the fire regulation and neighbourhood
good practices.
- The HeatMaster
which makes it largely independent of the pressure drop in
the air intake and flue gas extraction system. However, the
maximum pressure drop for this system may not be exceeded,
or the pressure will diminish. Nevertheless, the gas/air ratio
regulator continuously guarantees optimum combustion with
very low emission levels.
- The horizontal flue gas pipes must always be installed with a
min. slope of 5 mm per meter, upwards from the boiler side.
- There must be no obstruction or openings for any other
appliances within a radius of 0.5 metres around the flue
terminal of the HeatMaster
- The maximum flue resistance is 130 Pascal for the
HeatMaster® 35 TC and 150 Pascal for the HeatMaster® 85
TC. You can use the following table as the basis for calculating
this value (please also refer to the specimen calculation presented
under the table).
Sample calculation:
The diagram below consists of the following parts: pipe with
monitoring section + 2 * 90° pipe bends + 2 metres of horizontal
pipe + 2 * 45° pipe bends + (2 + 1 + 1) metres of vertical pipe
and fall back + discharge.
Therefore, the resistance of this system is as follows:
2.5 + (2 x 6.0) + (2 x 5.0) + (2 x 4.0) + (4 x 5.0) + 20
= 72.5 Pa.
®
TC has an inbuilt gas/air ratio regulator,
®
TC.
Table of flue resistance in Pascal
(1 Pascal = 0,01 mbar)
Pipe
concentric
HM
35 TC
Ø 80/125
mm
1 m
straight pipe
Pipe with a
monitoring
section
90° pipe bend
45° pipe bend
Vertical pipe
Horizontal pipe
This table is based on the equipment offered by ACV and cannot be applied
generally.
5.013,51.54,12.05,5
2.56,8——1.02,7
6.016,41.95,23.49,3
4.010,91.33,52.36,3
20.054,5————
15.040,9————
HM
85 TC
Ø 100/150
mm
Air inlet
separate
HM
35 TC
Ø 80
mm
HM
85 TC
Ø 100
MM
Air extraction
separate
HM
35 TC
Ø 80
mm
1000 mm
ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH
HM
85 TC
Ø 100
mm
This value is less than the maximum authorised resistance,
therefore the installation is compliant.
1000 mm
2000 mm
2000 mm
2
1 O 3
bar
4
664Y2800.E
EN • 13
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