ACV SMART Line Installation Manual

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A1004777 - 661Y3100 • B

INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS,

for the User and the Installer

320 - 420 - 420 Duplex - 600

SMART Line

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Smar t Line : A1004777 - 661Y3100 • B

TABLE OF CONTENTS

GENERAL RECOMMENDATIONS ...............................................................4

Energy labelling ....................................................................................................................................................... 5

Rating Plate .................................................................................................................................................................6

APPLIANCE DESCRIPTION .........................................................................7

Models - SL 320 - 420 - 420 Duplex - 600 ........................................................................................................... 7

TECHNICAL CHARACTERISTICS ...............................................................8

Dimensions and Main Characteristics ................................................................................................... 8

Electrical Characteristics ................................................................................................................................. 10

Performance ............................................................................................................................................................. 11

G3 Requirements and Guidance - UK only ..................................................................................12

INSTALLATION .........................................................................................16

Safety Instructions ............................................................................................................................................... 17

Packing Contents ..................................................................................................................................................18

Tools.................................................................................................................................................................................18

Connection ................................................................................................................................................................19

Parallel Tank Assembly (Typical - 3 tanks) ........................................................................................21

Connection Kits (option) ................................................................................................................................21

STARTIN G UP ............................................................................................22

Safety Instructions to Fill the Tank ..........................................................................................................22

Filling ..............................................................................................................................................................................23

Checks before Starting up .............................................................................................................................24

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Smar t Line : A1004777 - 661Y3100 • B

TABLE OF CONTENTS

MAINTENANCE ........................................................................................25

Periodic Checks by the User ........................................................................................................................25

Annual Maintenance .........................................................................................................................................25

Draining ........................................................................................................................................................................26

Bringing back into Service after Maintenance .............................................................................26

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We accept no liability should any damage result from the failure to comply with theinstructions contained in this technical manual.

Essential recommendations for safety

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

•

The product must be installed by a qualified engineer, in accordance with

applicable local standards and regulations.

• The installation must comply with the instructions contained in this manual and with the standards and regulations applicable to domestic hot water tanks.

• Failure to comply with the instructions in this manual could result in personal injury or a risk of environmental pollution.

• The manufacturer 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 the manufacturer.

Essential recommendations for the correct operation of the appliance

• In order to ensure that the appliance operates correctly, it is essential to have it serviced by a certified installer or maintenance contractor every year.

• In case of anomaly, please call your installer for advice.

• Faulty parts may only be replaced by genuine parts.

• Our water heaters are designed and manufactured for the exclusive purpose of heating and storing domestic hot water.

• The domestic hot water heaters must only be heated using hot water in a closed circuit.

General remarks

• The availability of certain models as well as their accessories may vary according to markets.

• The manufacturer reserves the right to change the technical characteristics and features of its products without prior notice.

• The part number (P/N) and serial number (S/N) of the appliance are indicated on its rating plate and must be provided to ACV in case of warranty claim. Failure to do so will make the claim void.

•

In spite of the strict quality standards that ACV applies to its appliances during

production, inspection and transport, faults may occur. Please immediately notify your approved installer of any faults.

NOTES

This manual contains important information with respect to the installation, the starting up and the maintenance of the appliance.

This manual must be provided to the user, who will read it carefully and keep it in a safe place.

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GENERAL RECOMMENDATIONS

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ENERGY LABELLING

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PRODUCT INFORMATION

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PRODUCT INFORMATION

RATING PLATE

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APPLIANCE DESCRIPTION

1. Auxiliary connection DHW

2. Domestic cold water inlet

3. Polyurethane foam insulation 50 mm

4. Flow connection [primary circuit]

5. Stainless steel (304 or Duplex) inner tank

6. Return connection [primary circuit]

7. Outer steel tank [primary circuit]

8. Manual air valve

9. Domestic hot water outlet

10. Polypropylene top lid

11. Polypropylene shell

12. Polypropylene bottom lid

MODELS  SL 320 - 420 - 420 Duplex - 600

Large capacity storage water tanks, to be installed on the oor.

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Smar t Line : A1004777 - 661Y3100 • B

TECHNICAL CHARACTERISTICS

DIMENSIONS AND MAIN CHARACTERISTICS

Tank dimensions

320 420 420 D 600

A mm 1,602 2,024 2,024 1,901

B mm 1,280 1,705 1,705 1,583

C mm 250 250 250 255

D mm 673 673 673 817

Empty weight Kg 141 167 167 238

POSITION

The hot water cylinder must be installed in an area that is dry and protected from the elements. Choose the most suitable location according to the position of the boiler and distance tothedomestic hot water supply, in order to reduce temperature and pressure drops within the pipe work.

The unit should be positioned to allow the replacement, if required, of the dip tube

and dry well during servicing.

135

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TECHNICAL CHARACTERISTICS

Main characteristics

320 420 420 D 600

Total capacity L 318 413 413 606

Primary capacity L 55 55 55 161

DHW capacity L 263 358 358 445

Primary connection [F] " 1 1/2 1 1/2 1 1/2 2

DHW connection [M] " 1 1/2 1 1/2 1 1/2 1 1/2

Auxiliary DHW loop connection [M] " 1 1/2 1 1/2 1 1/2 1 1/2

Primary pressure drop* mbar 90 95 95 92

Heating surface area m² 2.65 3.24 3.24 3.58

Max Design Pressure* bar 10 10 10 10 Reheat Performance - Primary

Heating Power Input*

kW 60 65 65 71

Primary ow rate (to achieve Reheat Performance) *

L/sec. 1.81 1.81 1.81 2.08

Standing Heat Loss*

kWh/24h 1.82 2.02 2.02 2,64

W 76 86 84 110

* According to EN12897:2016

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TECHNICAL CHARACTERISTICS

Main characteristics

320 420 420 D 600

Rated voltage V~ 230 230 230 230

Rated frequency Hz 50 50 50 50

Max. Amp rating A 6 6 6 6

ELECTRICAL CHARACTERISTICS

Wiring diagram

1. Control thermostat [60/80°C]

2. Load pump [in option]

3. Manual reset high limit thermostat [89°C max.]

B. Blue Bk. Black Br. Brown G. Grey Or. Orange W. White Y/Gr. Yellow/Green

Y/Gr

OrOr

Y/Gr

N L1

L1 N

Y/Gr

OrOr

Y/Gr

N L1

L1 N

Y/Gr

T2S3 T1 N L1

T2 S3T1NL1

NO NC

SL 320 - 420

SL 320 - 420 (UK version) SL 600

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Smar t Line : A1004777 - 661Y3100 • B

TECHNICAL CHARACTERISTICS

PERFORMANCE

DHW performance*

320 420 420 D 600

Peak ow at 40 °C L/10' 922 1,195 1,195 1,345 Peak ow at 45 °C L/10' 790 1,012 1,012 1,153 Peak ow at 60 °C L/10' 504 620 620 706 Peak ow rst hour at 40 °C L/60' 2,666 3,151 3,151 3,437 Peak ow rst hour at 45 °C L/60' 2,285 2,608 2,608 2,946 Peak ow rst hour at 60 °C L/60' 1,368 1,513 1,513 1,733 Constant ow at 40 °C L/h 2,093 2,536 2,536 2,511 Constant ow at 45 °C L/h 1,794 2,058 2,058 2,152 Constant ow at 60 °C L/h 1,037 1,153 1,153 1,232 Power drawn kW

73 88 88 88

Initial heating time Minutes

23 24 24 35

Conditions: Primary circuit temp.: 85°C, water supply temp.: 10°C

Maximum Operating Conditions

320 420 420 D 600

Max. operating pressure - primary bar 4 4 4 4

Max. operating pressure - DHW bar 8.6 8.6 8.6 8.6

Supply pressure (DHW circuit) bar 6 6 6 6

Maximum temperature - heating side °C 90 90 90 90

Maximum temperature - DHW side °C 80 80 80 80

Water quality

• Chlorides < 150 mg/L

• 6 ≤ pH ≤ 8

• If hardness > 20°fH, water softener recommended.

Tanks built with Duplex material provide identical DHW performance but have a better resistance to chlorides (2000 mg/L) than those built with 304 Stainless steel (150 mg/L).

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G3 REQUIREMENTS AND GUIDANCE  UK ONLY

Discharge pipe from safety valves

The Building Regulation G3 requires that any discharge from an unvented system is conveyed to where it is visible, but will not cause danger to persons in or about the building.

The tundish and discharge pipes should be tted in accordance with the requirements and guidance notes of Building Regulation G3. The G3 Requirements and Guidance sections 3.50 - 3.63 are detailed below.

For discharge pipe arrangements not covered by G3 Guidance advice should be sought from your local Building Control Ocer.

Main characteristics :

• Any discharge pipe connected to the pressure relief devices (Expansion Valve and Temperature/Pressure Relief Valve) must be installed in a continuously downward direction and in a frost free environment.

• Water may drip from the discharge pipe of the pressure relief device.

• This pipe must be left open to the atmosphere.

• The pressure relief device is to be operated regularly to remove lime deposits and to verify that

it is not blocked.

A typical discharge pipe arrangement is shown further on.

General remarks

• Discharge pipe-work D2 can now be a plastic pipe but only pipes that have been tested to a minimum 110°C must be used.

• Discharge pipe D2 can now be plumbed into the soil stack but only soil stacks that can handle temperatures of 99°C or greater should be used.

Extract from “The Building Regulation G3” :

Discharge pipe D1

3.50 Safety devices such as temperature relief valves or combined temperature and pressure and pressure relief valves (see paragraphs 3.13 or 3.18) should discharge either directly or by way of a manifold via a short length of metal pipe (D1) to a tundish.

3.51 The diameter of discharge pipe (D1) should be not less than the nominal outlet size of the temperature relief valve.

3.52 Where a manifold is used it should be sized to accept and discharge the total discharge from the discharge pipes connected to it.

3.53 Where valves other than the temperature and pressure relief valve from a single unvented hot water system discharge by way of the same manifold that is used by the safety devices, the manifold should be factory fitted as part of the hot water storage system unit or package.

Tundish

3.54 The tundish should be vertical, located in the same space as the unvented hot water storage system and be fitted as close as possible to, and lower than, the valve, with no more than 600mm of pipe between the valve outlet and the tundish.

Note: To comply with the Water Supply (Water Fittings) Regulations, the tundish should incorporate a

suitable air gap.

3.55 Any discharge should be visible at the tundish. In addition, where discharges from safety devices may not be apparent, e.g. in dwellings occupied by people with impaired vision or mobility, consideration should be given to the installation of a suitable safety device to warn when discharge takes place, e.g. electronically operated.

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TECHNICAL CHARACTERISTICS

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Discharge pipe D2

3.56 The discharge pipe (D2) from the tundish should: (a) have a vertical section of pipe at least 300mm long below the tundish before any elbows or

bends in the pipework; and

(b) be installed with a continuous fall thereafter of at least 1 in 200.

3.57 The discharge pipe (D2) should be made of: (a) metal; or (b) other material that has been demonstrated to be capable of safely withstanding tempera-

tures of the water discharged and is clearly and permanently marked to identify the product and performance standard (e.g. as specified in the relevant part of BS 7291)

3.58 The discharge pipe (D2) should be at least one pipe size larger than the nominal outlet size of the safety device unless its total equivalent hydraulic resistance exceeds that of a straight pipe 9m long, i.e. for discharge pipes between 9m and 18m the equivalent resistance length should be at least two sizes larger than the nominal outlet size of the safety device; between 18 and 27m at least 3 sizes larger, and so on; bends must be taken into account in calculating the flow resistance. See figure, table and the worked example.

3.59 Where a single common discharge pipe serves more than one system, it should be at least one pipe size larger than the largest individual discharge pipe (D2) to be connected.

3.60 The discharge pipe should not be connected to a soil discharge stack unless it can be demonstrated that that the soil discharge stack is capable of safely withstanding temperatures of the water discharged, in which case, it should:

(a) contain a mechanical seal, not incorporating a water trap, which allows water into the

branch pipe without allowing foul air from the drain to be ventilated through the tundish;

(b) be a separate branch pipe with no sanitary appliances connected to it; (c) if plastic pipes are used as branch pipes carrying discharge from a safety device they should

be either polybutalene (PB) to Class S of BS 7291-2:2006 or cross linked polyethylene (PE-X) to Class S of BS 7291-3:2006; and (d) be continuously marked with a warning that no sanitary appliances should be connected to the pipe.

Note:

1. Plastic pipes should be joined and assembled with fittings appropriate to the circumstances in which they are used as set out in BS EN ISO 1043-1.

2. Where pipes cannot be connected to the stack it may be possible to route a dedicated pipe alongside or in close proximity to the discharge stack.

Termination of discharge pipe

3.61 The discharge pipe (D2) from the tundish should terminate in a safe place where there is no risk to persons in the vicinity of the discharge.

3.62 Examples of acceptable discharge arrangements are:

(b) to a trapped gully with the end of the pipe below a fixed grating and above the water seal; (c) downward discharges at low level; i.e. up to 100mm above external surfaces such as car

parks, hard standings, grassed areas etc. are acceptable providing that a wire cage or similar guard is positioned to prevent contact, whilst maintaining visibility; and

(d) discharges at high level: e.g. into a metal hopper and metal downpipe with the end of the di-

scharge pipe clearly visible or onto a roof capable of withstanding high temperature discharges of water and 3m from any plastic guttering system that would collect such discharges.

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TECHNICAL CHARACTERISTICS

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3.63 The discharge would consist of high temperature water and steam. Asphalt, roofing felt and non-metallic rainwater goods may be damaged by such discharges.

600mm maximum

300mm minimum

temperature relief valve to tundish

Metal discharge pipe (D2) tundish with continuous fall. See 3.56, Table G3 and worked example

Tundish

Discharge below fixed grating (3.61 gives alternative points of discharge)

Fixed grating

Trapped gulley

Valve

outlet

size

Minimum size

of discharge

pipe D1

Minimum size of

discharge pipe D2

from tundish

Maximum resistance

allowed, expressed as a

length of straight pipe

(i.e. no elbows or bends)

Resistance created by

each elbow or bend.

G½ 15mm

22mm

28mm

35mm

Up to 9m

Up to 8m

Up to 27m

0.8m

1.0m

1.4m

G¾ 22mm

28mm

35mm

42mm

Up to 9m

Up to 8m

Up to 27m

1.0m

1.4m

1.7m

G1 28mm

35mm

42mm

54mm

Up to 9m

Up to 8m

Up to 27m

1.4m

1.7m

2.3m

Figure G3: Typical discharge pipe arrangement

Table G3 – Sizing of copper discharge pipe ‘D2’ for common temperature relief valve outlet sizes

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TECHNICAL CHARACTERISTICS

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Worked example of discharge pipe sizing

Figure on the left shows a G1/2 temperature relief valve with a discharge pipe (D2) having 4 No. elbows and length of 7m from the tundish to the point of discharge.

From Table:

Maximum resistance allowed for a straight length of 22mm copper discharge pipe (D2) from a G1/2 temperature relief valve is 9.0m.

• Subtract the resistance for 4 No. 22mm elbows at 0.8m each = 3.2m

• Therefore the permitted length equates to: 5.8m

• 5.8m is less than the actual length of 7m therefore calculates the next largest size.

Maximum resistance allowed for a straight length of 28mm pipe (D2) from a G1/2 temperature relief valves equates to 18m.

• Subtract the resistance of 4 No. 28mm elbows at 1.0m each = 4.0m

• Therefore the maximum permitted length equates to: 14m

• As the actual length is 7m, a 28mm (D2) copper pipe will be satisfactory.

Essential recommendations for safety

• The temperature/pressure relief valve should only be replaced by a competent person.

• No control or safety valves should be tampered with or used for any other purpose.

• The discharge pipe should not be blocked or used for any other purpose.

• The tundish should not be located adjacent to any electrical components

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TECHNICAL CHARACTERISTICS

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SAFETY INSTRUCTIONS

General remarks

• Connections (electrical, hydraulic) must be carried out in accordance with applicable standards and regulations.

• If the water drawing off point is far from the tank, installing an auxiliary DHW loop can allow to get hot water more quickly at all times.

Essential instructions forthecorrect operation ofthesystem

• The tank must be installed in a dry and protected area.

• Install the appliance to ensure easy access at all times.

• To avoid any risk of corrosion, connect the stainless steel tank directly to the earth. Use an adjustable earth clamp (see example below) on one of the DHW connections to connect to the earth. Advised copper wire section: 2.5mm².

• Make sure to install a pressure reducing valve set at 4.5 bar in the DHW circuit if the supply pressure is higher than 6 bar.

• On the DHW circuit, install an approved safety group, comprised of a safety valve set at 7 bar, a check valve and a stop valve.

• Make sure that the outlet of the safety unit goes directly to the sewer to avoid any potential damage.

• Do not install the safety group above the tank to avoid water discharge on to the tank.

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INSTALLATION

• The installation of a domestic expansion vessel avoids discharge from the safety valve (loss of water).

• Capacity of domestic water vessels:

• 18 Litres for SL 320

• 24 Litres for SL 420 / 420D

• 35 Litres for SL 600

Refer to the manufacturer’s technical instructions on the expansion vessel for more

details.

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Essential instructions forthe safety of persons and the environment

• Hot water can burn! In the event of small amounts of hot water repeatedly being drawn off, a stratification effect can develop in the tank. The upper hot water layer may then reach very high temperatures.

• ACV recommends using apre-set thermostatic mixing valve in order to provide hot water at a maximum of 60°C.

• Water heated to wash clothes, dishes and for other uses can cause serious burns.

• In order to avoid exposure to extremely hot water that can cause serious burns, never leave children, old people, disabled or handicapped people in the bath orshower alone.

• Never allow young children to turn on the hot water or fill their own bath.

• Adjust the water temperature in accordance with usage and plumbing regulations.

•

The risk of developing bacteria exists, including “Legionella pneumophila”,

ifaminimum temperature of 60°C is not maintained in both the DHW tank andthe hot water distribution network.

Essential instructions for the electrical safety

• Only an approved installer is authorized to carry out the electrical connections.

• Make sure that the appliance is connected to the earth.

• Install a 2-way switch and a fuse or circuit breaker of the recommended rating outside the appliance, so as to be able to shut power down when servicing the appliance or before performing any operation on it.

• Shut down external electrical supply of the appliance before performing any operation on the electrical circuit.

• This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless supervised or unless they have been given instruction concerning the use of the appliance by a person responsible for their safety.

Smar t Line : A1004777 - 661Y3100 • B

INSTALLATION

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Smar t Line : A1004777 - 661Y3100 • B

INSTALLATION

Package

• One SL hot water tank.

• One multilingual Installation, Operation and Maintenance Instructions.

• One energy label

PACKING CONTENTS

All appliances are delivered, tested and packaged separately.

TOOLS

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2 3

Cold water Hot water

CONNECTION

Essential instructions forthe safety of persons and the environment

• Refer to the safety instructions for the installation. Failure to comply with these instructions can result in damages to the system, severe injuries or death.

• Hot water can burn! ACV recommends using a pre-set thermostatic mixing valve in order to provide hot water at a maximum of 60°C.

Essential instructions forthecorrect operation ofthesystem

• The filling circuit of the DHW tank must be equipped with a safety group, comprised at least of a stop valve, a check valve, a safety valve set at 7 bar, and possibly, an expansion vessel of the appropriate size. Make sure that the circuit between the tank and the safety valve is always open.

• The third DHW tank connection, if any, can be used for the auxiliary DHW loop. If the connection is not used, replace the protec tive plug by a brass plug of the appropriate size.

General remarks

• In certain countries the domestic kits must be approved.

• The circuit illustrations are basic principle diagrams only.

CONNECTION TO THE DHW CIRCUIT (Typical floor installation)

Key

1. Filling valve

2. Pressure reducing valve (set at 4.5 bar)

3. Check valve

4. Expansion vessel

5. Safety valve (set at 7 bar)

6. Drain valve

7. Hot water outlet

8. Pressure gauge

9. Grounding

10. Stop valve

11. Thermostatic mixing valve

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INSTALLATION

If there is a risk of low pressure in the

hot water circuit (installation of the tank on the roof of a building), it is essential to install a vacuum breaker device onto the cold water supply.

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Cold water

Hot water

1 2 3

8 5

CONNECTION TO THE PRIMARY CIRCUIT Typical floor installation

Key

1. Primary circuit filling valve

2. Charging pump

3. Check valve

4. Primary circuit stop valve

5. Expansion vessel

6. Pressure gauge

7. Safety valve

8. Drain valve

9. Stop valve

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INSTALLATION

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Smar t Line : A1004777 - 661Y3100 • B

INSTALLATION

PARALLEL TANK ASSEMBLY Typical - 3 tanks

Recommended assembly for any waste heat recovery system and for district heating applications.

This type of connection reduces the water heating performance of the system. Make

sure to oversize the assembly. A specific connection kit is required to build this type of assembly.

Legend

1. Primary circuit filling valve

2. Safety valve

3. Expansion vessel

4. Drain valve

5. Primary circuit stop valve

6. Room thermostat

7. Boiler control (option)

8. Charging pump

9. Primary circuit pump

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CONNECTION KITS OPTION

Reference codes : 10800179 - 10800180

108

425

850

10800179 + 10800180

10800180

850

10800179

108108

425

1"1/2

2"2"

1"1/2

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SAFETY INSTRUCTIONS TO FILL THE TANK

Essential instructions forthe safety of persons and the environment

• The DHW tank must always be filled and pressurised before filling and pressurising the primary circuit.

• Do not use vehicle antifreeze. This can cause serious injury or death, or damage facilities.

• If antifreeze is needed in the primary circuit, it must comply with Public Hygiene Regulations and must be non-toxic. A food-grade Propylene Glycol is recommended. It must be diluted according to the ratio recommended in the local regulations.

• Consult the manufacturer to determine the compatibility of the antifreeze with the tank's construction materials.

Essential instructions forthecorrect operation ofthesystem

• Before bringing the tank into service, check the connections to avoid any risk ofleaks during filling.

• Only use drinking water to check that the DHW tank is watertight. The on-site testpressure must not exceed a pressure surge of 8,6 bar.

• Using antifreeze in the primary circuit will lead to a reduction in the heating performance. The higher the concentration of antifreeze in the circuit, the lower the performance.