ACV uk BNE 1 - BNE 2 - BNE 3 INSTALLATION OPERATING AND SERVICING INSTRUCTIONS (28/10/2004 - 66401200)

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excellence in hot water

Installation, operating and maintenance instructions

BNE 1 - BNE 2 - BNE 3

28/10/2004 - 66401200

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INDEX

INTRODUCTION 2

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

USER GUIDE 2

Use of the boiler 2 Setting the burner to safety mode 3

DESCRIPTION 4

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

TECHNICAL CHARACTERISTICS 5

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

INSTALLATION 6

Boiler room 6 Chimney connections 6 Fuel oil supply 6 Heating connection 7 Hot water connection 7 Electrical connections 8

BURNER CHARACTERISTICS 10

Description of the burner 10 Factory setting parameters 11 Burner dimensions 11

COMMISSIONING AND MAINTENANCE 12

Filling the hot water and heating circuits 12 Using the boiler for the first time 12 Servicing recommendation 12 Boiler maintenance 12 Safety equipment maintenance 12 Draining the boiler 12

SPARE PARTS 14

Casings 14 Accessories 14 Electrical accessories 15

SERVICE RECORD 15

Details of the installation 15 Service notes 15

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WHO SHOULD READ THESE INSTRUCTIONS

These instructions should be read by:

- the specifying engineer

- the installer

- the user

- the service engineer

SYMBOLS

The following symbols are used in these instructions:

APPLICABLE STANDARDS

The products described in this document have been certified at European level (European Directive 92/42/EEC “Efficiency”). They have also been awarded the Belgian “OPTIMAZ” label (for oil-fired boilers).

IMPORTANT NOTES

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

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

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

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

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

INTRODUCTION USER GUIDE

Essential instruction for correct operation of the installation.

Burning hazard.

Electric shock hazard.

Essential instruction for the safety of persons and the environment.

USE OF THE BOILER

To ensure that your system operates correctly, please have it serviced annually, before the start of the heating season, by a qualified engineer.

In normal operation the burner starts automatically if the temperature of the boiler is below setpoint.

Before carrying out any work on the boiler, isolate it from the electrical supply at the switch on the external control box. Also move the main switch on the control panel to “OFF”.

• You should familiarise yourself with the control panel

(Fig. 1)

The user must not attempt to gain access to the components inside the control panel.

1. Main switch

This switch is used to start or stop the boiler.

2. Summer/Winter switch

This is used to switch the heating pump on or off.

3. Energy selection switch

This is used to switch the heating pump and the burner off (or on). It is used to switch a 2.4 kW resistor on (or off) for the provision of hot water.

4. Resistor indicator lamp

This lamp indicates that the electrical resistor is energised.

5. Optimiser

This device switches the boiler on and off according to the time, operating on a 24-hour cycle. There are small white lugs around the circumference of the programmer. Each lug represents a 15 minute switching period. To set the 24-hour programmer, simply push outwards the lugs that correspond to the boiler operating period.

Reminder: Lug in inner position = BNE off

Lug in outer position = BNE on

6. Hot water temperature control thermostat

In hot water mode, the temperature of the hot water can be adjusted from 60 to 80°C.

7. Thermostat-pressure gauge

This dial shows the boiler temperature and the pressure in the primary circuit. The temperature should not exceed 90°C. If it is higher than this, stop the boiler and check that the thermostat is operating correctly. If the problem persists, call an engineer. The pressure should not fall below 1 bar. If it does, refer to the paragraph entitled “Gauge pressure in the heating system”, later in this section.

8. Heating temperature control thermostat

In “Winter” position the boiler temperature can be set to between 60 and 90°C. It is advisable to set this thermostat 10°C above the hot water thermostat setting.

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USER GUIDE

Operation of the pump:

The pump is controlled by the minimum thermostat, at the rear of the boiler. This is pre-set to 45°C, delaying the activation of the boiler pump when the burner starts, thus avoiding any risk of corrosion in the combustion chamber.

Gauge pressure in the heating system

Your system must be equipped with a heating safety valve calibrated to 3 bar.

Ensure that the system is always under water pressure. When the system is cold and the air inside it has been vented, the gauge must indicate a pressure of between 1 and 1.5 bar, depending on the height of the building.

To add water:

(Fig. 9, page 7)

• Open the filling valve (5).

•

Close the valve properly after filling.

• Vent the system and the boiler in order to obtain an accurate reading of the pressure inside the heating circuit.

Safety valves (heating circuit) (Fig. 9, page 7 - item 2)

If water is found to be escaping from the safety valve, stop the boiler and contact your installer for advice.

A monthly test is recommended: Lift the lever on the drain cock for a few seconds to ensure that the safety valve is working correctly.

If there is a problem after this short test, please contact your installer for advice.

The water escaping from the safety valve may be extremely hot and can cause severe burns.

Safety group (hot water circuit)

It is normal for water to escape from the safety group each time the hot water tank is heated. Ahot water expansion vessel may reduce or even prevent this escape. (Fig. 10, page 7 - item 6)

A monthly test is recommended: Lift the lever on the drain cock for a few seconds to ensure that the safety valve is working correctly.

If there is a problem after this short test, please contact your installer for advice.

Fig. 1: Control panel

GRASSLIN

The water escaping from the safety group may be extremely hot and can cause severe burns.

SETTING THE ACV BURNER TO SAFETY MODE

If the burner is not working:

1. The burner indicator lamp lights.

2. Press the burner reset button

(Fig. 2) on the burner.

3. If the burner still does not work, remove the boiler front panel and reset the high limit thermostat on the top of the boiler body

(Fig. 3).

4. If the problem persists, check your fuel oil level before contacting your installer for advice.

1 3 4 5 8762

Fig. 2

Fig. 3

Min

GRASSLIN

Max

Min

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DESCRIPTION

GENERAL DESCRIPTION

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

• Hot water generated by an indirect storage system.

• Equipment required: a water connection kit for the heating circuit supply

(optional).

• The control panel contains a main switch, a Summer/Winter switch, an energy selection switch, an indicator lamp, an optimiser, a hot water control thermostat, a thermostat-pressure gauge and a heating control thermostat.

• The boiler may be connected directly to the chimney using a B23 chimney connection.

• Model BNE 1: output between 20 and 25 kW.

• Model BNE 2: output between 28 and 36 kW.

• Model BNE 3: output between 36.5 and 51 kW.

OPERATING PRINCIPLE

Two thermostats are used to adjust the temperature settings for the heating and hot water. The addition of the hot water priority device incorporated in the wiring ensures an ample supply of hot water.

A manual reset high limit thermostat locks the burner if the boiler temperature exceeds 103°C.

In summer, when heating is not required, the heating pump and burner can be switched off and a 2.4 kW resistor used for the hot water requirements.

(BEWARE: The water heating efficiency will be

lower than that with the oil-fired burner).

DESIGN CHARACTERISTICS

Outer body

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

Smoke flues

The boiler smoke flues are accessed via the front and contain a set of removable stainless chromium steel turbulators, specially designed to provide optimum combustion efficiency.

Combustion chamber

The boiler has a large, water-cooled combustion chamber, designed to ensure good development of the burner flame.

Removable burner chamber plate

The burner chamber plate, mounted on a hinge (left or right) is made of STW 22 steel. It is insulated from the flame by a ceramic fibre pad and a vermiculite brick.

Insulation

The boiler body has full sprayed-on rigid, CFC-free polyurethane foam insulation with a high insulation coefficient.

Casing

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

Storage exchanger

The inner hot water tank with integrated heating surface is made of stainless steel that has been fully argon welded using the TIG (Tungsten Insert Gas) method.

Electrical resistor

The electrical resistor, made entirely of stainless steel, is mounted on a flange.

BOILER VIEWS AND KEY TO PARTS

1. Cold water inlet

2. Hot water thermostat pocket

3. Hot water outlet

4. Steel outer tank

5. Stainless steel inner tank

6. Heating return

7. Chimney connection

8. Heating outlet

9. Heating circuit drain cock

10. Combustion chamber

11. Steel base

12. Exchanger (flues)

13. Burner

14. Flame inspection window

15. Left/right removable burner chamber plate

16. Electrical resistor

17. Polyurethane foam insulation

18. Front panel

19. Control panel

20. Heating circuit vent

1112

20 2 3

Fig. 4

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TECHNICAL CHARACTERISTICS

GENERAL

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

DIMENSIONS

OPERATING CONDITION LIMITS

Maximum service pressure (tank filled with water)

- Heating circuit: 3 bar

- Hot water circuit: 10 bar

Test pressure

(tank filled with water)

- Heating circuit: 4.5 bar

- Hot water circuit: 13 bar

Operating temperature

- Maximum temperature: 90°C

Ø D

HOT WATER OUTPUT DATA BNE 1 BNE 2 BNE 3

• Operating conditions at 80°C

Peak flow at 40°C (∆T = 30°C) l/10 min. 311 311 311 Constant flow at 40°C (∆T = 30°C) l/h 716.4 898.8 898.8

GENERAL CHARACTERISTICS BNE 1 BNE 2 BNE 3

Input kW 22/28 30/41 40/57 Output kW 20/25 28/36 36.5/51 Loss of head mbar 20.0 25.5 30.0 Flue gas pressure loss mbar 0.15 0.17 0.15 Total capacity l 184 186 248 Heating circuit capacity l 64 66 128 Hot water connection (male) Ø 3/4” 3/4” 3/4” Heating connection (female) Ø 1” 1” 1” 1/4 Boiler heating surface m

1.1 1.1 1.1

D Ø

Kg (*)

BNE 1 590 1505 640 130 463 260 615 1390 270 300 700 204 BNE 2 590 1570 640 130 526 260 615 1450 270 300 700 222 BNE 3 690 1610 740 150 564 260 715 1475 270 350 800 283

(*) The weights shown are drained weights.

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BOILER ROOM

Important

• Never obstruct the ventilation.

• Do not store inflammable products in the boiler room.

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

Accessibility

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

- at the front 500

- at the rear 150

- at the sides 100

- above 300

Ventilation

The boiler room must have both low and high level ventilation

(see Fig. 5).

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

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

A. High level ventilation B. Low level ventilation C. Draught stabiliser D. Flame inspection window E. Height of lined chimney F. Chimney diameter

BNE 1 BNE 2 BNE 3

Ventilation

Min. fresh air supply m3/h 50.0 72 102 High level ventilation (A) dm

150 150 150

Low level ventilation (B) dm

150 150 170

Base

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

CHIMNEY CONNECTIONS

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

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

Chimney connection type: B23 (Fig. 5)

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

A chimney connection is required.

Fig. 5: Boiler ventilation and B23 chimney connection

Note: The above table is shown by way of information only, as regulations vary from country to country.

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

BNE 1 BNE 2 BNE 3

Chimney

E = 5 m Ø min. F mm 130 143 170 E = 10 m Ø min. F mm 130 130 143 E = 15 m Ø min. F mm 130 130 130

INSTALLATION

Height H Ø 8 mm Ø 10 mm

0.5 m L = 10 m L = 20 m

1.0 m L = 20 m L = 40 m

1.5 m L = 40 m L = 80 m

2.0 m L = 60 m L = 100 m

Height H Ø 8 mm Ø 10 mm

0 m L = 35 m L = 100 m

0.5 m L = 30 m L = 100 m

1.0 m L = 25 m L = 100 m

1.5 m L = 20 m L = 90 m

2.0 m L = 15 m L = 70 m

3.0 m L = 8 m L = 30 m

3.5 m L = 6 m L = 20 m

Installation with two pipes (Fig. 7)

FUEL OIL SUPPLY

Installation with one pipe (Fig. 6)

max 4m

Fig. 6 Fig. 7

max 4m

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INSTALLATION

ACV water kit

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

• A pump;

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

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

• Two isolating valves;

• Connectors for the right or left hand mounting of the expansion vessel, the safety valve with pressure gauge and the filling valve. The expansion vessel is not included.

Typical single circuit configuration

Drain

The drain cock and safety valve must be connected to the building drain.

Fig. 9: Heating system layout

HEATING CONNECTION

1. Motorised 3-way mixer valve

2. Safety valve calibrated to 3 bar, with pressure gauge

3. Pump

4. Isolating valve with non-return valve

5. System filling valve

6. Expansion vessel

7. Room thermostat

8. Isolating valve, heating system

9. Drain cock

Fig. 8: ACV water kit

HOT WATER CONNECTION

Pressure reducing valve

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

Safety group

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

Hot water expansion vessel

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

Hot water circulation

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

Typical hot water configuration

Fig. 10: Hot water system layout

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

Optional accessories

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

1. Safety group

2. Pressure reducing valve

3. Thermostatic mixer

4. Hot water pump

5. Non-return valve

6. Hot water expansion vessel

7. Cold water supply tap

8. Drawoff tap

9. Drain cock

10. Air vent

11. Isolating valve

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INSTALLATION

ELECTRICAL CONNECTIONS

Principle of supply

The boiler operates on a 230 V/50 Hz single-phase supply. You should install a control box with main switch and fuses externally to the boiler to allow the boiler to be isolated from the supply for servicing and repairs.

Statutory compliance

The installation must comply with your local standards and codes of practice.

Safety

The stainless steel water tank must be provided with a separate earth.

The boiler must be isolated from the electrical supply before any work is carried out on it.

The heater consists of two 2.4 kW electrical resistors. One of these two resistors is wired and used as the main resistor. The other resistor is not used, and serves only as a back-up if the first resistor becomes faulty. The two resistors must never be connected to operate together, as this will damage the internal wiring of the boiler.

Wiring diagram key

1. Main switch

2. Hot water control thermostat

3. 24-hour programmer

4. Heating control thermostat (60/90°C)

5. Manual reset high limit thermostat (103°C max.)

6. Electrical resistor indicator lamp

7. Energy selection switch

8. Burner

9. Pump

10. Room thermostat

(optional)

11. Summer/Winter switch B. Blue

Bk. Black

Br. Brown

G. Grey

Or. Orange

Pk. Pink

R. Red

V. Violet

W. White

Y/Gr. Yellow/Green

Schematic diagram of the boiler electrical circuit

4 5

T1 T2

10 11

S3 B4

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INSTALLATION

Wiring diagram of the boiler electrical circuit

Y/Gr

Bk Bk

3 4

230 V ˜ 50 Hz

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BURNER CHARACTERISTICS

DESCRIPTION OF THE BURNER

This new generation of oil-fired burners meets current requirements for the performance and cleanliness of combustion gases. The burner is made from top quality components using the latest technologies, and includes a fuel oil preheating device.

Components:

• “Landis & Gyr” relay

• “A.E.G.” motor

• “Suntec” pump

• “May & Christe” transformer

• “Danfoss” oil preheating device

Advantages

• Easy to install, fitted with a safety shut-off and a new burner suspension system.

• Aspecial tool supplied with the burner is used for all maintenance work.

• The burner air pressure adapts to the combustion chamber pressure.

• An automatic check valve stops the air flow when the burner stops, and thus prevents the boiler cooling down.

• Quiet and very reliable.

• Adapts to the depth of the boiler via the adjustable flange on the throat.

• Three air adjustment points to ensure optimum air/oil mixture.

- Presetting of the upstream air;

- Primary adjustment;

- Combustion head adjustment.

Burner reset

Motor capacitor

High voltage transformer

Pump/nozzle connection pipe

Throat

Nozzle line adjustment screw

Air damper

Solenoid valve

Motor

Fuel oil pump

Control relay

Burner inlet

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BURNER CHARACTERISTICS

SETTING PARAMETERS BM R 31 BM R 51

BNE 1 BNE 2 BNE 3

Input kW 23.0 30.0 49.0 Electrical output W 150 150 150 Nozzle gal/h 0.50 0.75 1.25 Nozzle angle 60° 60° 60° Fuel oil flow rate Kg/h 1.94 2.53 4.13 Pump pressure bar 13.5 10.5 10 Flue gas index 0.6 0.6 0.6 Air damper setting 3 4.5 4 Combustion head setting 2 1 2 Weight Kg 12 12 12

BURNER DIMENSIONS A mm B mm C mm D mm E mm F mm G Ø mm L Ø mm LK Ø mm

BM R 31 240 270 215 280 60-130 M 8 80 85 140-165

BM R 51 240 270 215 280 60-130 M 8 80 85 140-165

Fig. 11:

Electrode distance

Fig. 14 Fig. 16Fig. 15

Fig. 12: Combustion head adjustment screw

Fig. 13:

Air flow adjustment screw

(precision adjustment)

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SAFETY EQUIPMENT MAINTENANCE

- Check that all thermostats and safety devices are in good working order: boiler thermostat and 103°C manual reset high limit thermostat.

- Check the safety valves in both the heating circuit and hot water circuit.

DRAINING THE BOILER

The water draining from the drain cock is very hot and can cause severe burns. Keep all persons away from running hot water.

Draining the heating circuit (Fig. 18)

1. Move the main switch on the control panel to “OFF” and isolate

the boiler from the electrical supply at the switch on the external control box.

2. Close the isolating valves (8) in the heating circuit.

3. Connect a flexible tube to the drain cock (9).

4. Open the drain cock (9) to drain the heating circuit.

Draining the hot water circuit (Fig. 19)

1. Move the main switch on the control panel to “OFF” and isolate

the boiler from the electrical supply at the switch on the external control box.

2. Reduce the pressure in the heating circuit until the pressure

gauge reads zero.

3. Close the tap (7) and isolating valve (11).

4. Open the drain cock 9 first, then 10.

5. Allow the hot water circuit to discharge to the drain.

The drain cock (9) must be at ground level for the circuit to drain fully.

COMMISSIONING AND MAINTENANCE

FILLING THE HOT WATER AND HEATING CIRCUITS

IMPORTANT It is essential that the hot water circuit is filled before the heating circuit.

1. Fill the hot water circuit opening valves 7 and 8 and pressurise it. (Fig. 19, page 13)

2. Fill the heating circuit opening valves 4, 5 and 8 - do not exceed a pressure of 2 bar. (Fig. 18, page 13)

3. Vent the air in the system and the boiler.

4. Once you have vented the system, return the pressure to static pressure plus 0.5 bar.

Height of the heating system:

• 10 m ➠ heating circuit pressure = 1.5 bar

• 15 m ➠ heating circuit pressure = 2 bar

USING THE BOILER FOR THE FIRST TIME

1. Check the fuel oil supply connection and ensure that it is free from leaks.

2. Check the electrical connection of the boiler and the boiler room ventilation, and ensure that the flue gas discharge pipes and the burner chamber plate are properly gas tight.

3. Set the boiler thermostat to between 60 and 90°C.

4. Move the Summer/Winter switch to the “Winter” position.

5. Move the main switch to “ON”.

6. Carry out the necessary venting operations, measurements and settings.

SERVICING RECOMMENDATION

It is essential that you have the boiler serviced once a year. Boiler servicing and checking the burner must be carried out by a qualified engineer.

BOILER MAINTENANCE (Fig. 17)

1. Isolate the boiler from the electrical supply at the switch on the external control box, and close the fuel oil supply valve.

2. Move the main switch on the control panel to “OFF”.

3. Remove the front panel from the boiler (1).

4. Open the burner chamber plate (2) by undoing the two nuts.

5. Take out the stainless steel turbulators (3).

6. Brush the flue ways, clean the combustion chamber and vacuum up the soot deposits.

7. Check the condition of the insulation on the burner chamber plate (4).

8. Before re-assembly, clean the burner combustion head (5).

9. Check that the thermostats and safety valves are in good working order.

Fig. 17

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COMMISSIONING AND MAINTENANCE

Fig. 18: Heating connection

Fig. 19: Hot water connection

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SPARE PARTS

No. Casings BNE 1 BNE 2 BNE 3

A01 Right side 21471384 21471385 21471386 A02 Left side 21472384 21472385 21472386 A03 Front panel 21473384 21573385 21473386 A04 Rear panel 21474384 21474385 21474386 A05 Top cover 21475384 21475384 21475386 A06 Unequipped control panel 21477384 21477384 21477376

No. Accessories

B01 Body shell 30465156 30465157 30465158 B02 Burner chamber plate 2147P380 2147P381 2147P382 B03 Brick backplate - 2147E381 2147E382 B04 Insulating cover - 51401128 51401129 B05 Burner chamber plate insulating brick 51701001 51404029 51404030 B06 Ceramic fibre door insulating cord 51401113 51401113 51401113 B07 PVCC plunger, Ø 19.5 mm / L 800 mm 49410045 49410045 49410045 B08 Aerator 50423066 50423066 50423066 B09 Thermometer-pressure gauge 54441008 54441008 54441008 B10 Drain cock, Ø 1/2” 55426001 55426001 55426001 B11 Hinge pin M 10 19x33 mm 47405252 47405252 47405252 B12 Sensor retainer spring 47438008 47438008 47438008 B13 Turbulators 50423097 50423097 50423098 B14 H.D.P.E. handle 49410280 49410280 49410280 B15 Flame inspection window 50423008 50423008 50423008 B16 Grommet 54428001 54428001 54428001 B17 Brass pocket, Ø 1/2” / L. 100 mm 63438001 63438001 63438001 B18 Stainless steel pocket 12/10 - Ø 1/2” / L. 350 mm 39438023 39438023 39438023 B19 Control panel self-adhesive label 617G0054 617G0054 617G0054 B20 Clip retainer 47405004 47405004 47405004 B21 Stud 47405005 47405005 47405005

No. Electrical accessories

C01 Full control panel 24614110 24614110 24614111 C02 ON/OFF switch 54766014 54766014 54766014 C03 Summer/Winter switch or energy selection switch 54766013 54766013 54766013 C04 90°C control thermostat 54442045 54442045 54442045 C05 Manual reset high limit thermostat (103°C) 54764010 54764010 54764010 C06 Indicator light 54766001 54766001 54766001 C07 Electrical resistor 2 x 2.4 kW 54428182 54428182 54428182

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