ACV uk Compact S 180-640 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS (21/10/2003 - 66402400)

Installation, operating
and maintenance instructions

excellence in hot water

21/10/2003 - 66402400

1

INDEX

INTRODUCTION 1

Who should read these instructions 1
Symbols 1
Applicable standards 1
Important notes 1

DESCRIPTION 2

General description 2
Packing 3

TECHNICAL CHARACTERISTICS 4

Dimensions 4
General characteristics 4

INSTALLATION 5

Boiler room 5
Heating connections 6
Wiring diagram 7
Preparing the boiler and Mounting the casing cover 8
Mounting the burner 8
Commissioning 8

SERVICING 9

Servicing the boiler 9

SERVICE RECORD 10

Details of the installation 10
Service engineer’s report 10

WHO SHOULD READ THESE INSTRUCTIONS

These instructions should be read by:

- specifying engineers

- installers

- users

- service engineers

SYMBOLS

The following symbols are used in these instructions:

Essential instruction for the correct operation
of the equipment.

Essential instruction for the safety of persons
and the environment.

Electric shock hazard.

Burning hazard.

APPLICABLE STANDARDS

The products are “CE” approved, according the standards in force in
the various countries (European Directives 92/42/CEE “Efficiency”,
90/396/CEE “Gas appliances”).

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 current standards in force.

ACV 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 ACV.

Failure to follow the instructions describing the tests
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 prior notice.

Packing

The boiler is supplied on a wooden base with the casing, insulation
and control panel unit in a wooden crate.

Basic settings

1. Thermometer

2. First firing control thermostats

3. Second firing control thermostats

4. Manual reset high limit thermostat

5. Main switch

6. Door safety indicator light

Operating diagram key

1. Control panel

2. Evaporation of condensation at start-up

3. Door double insulation

4. Burner

5. Heat return at low temperature

6. Safety valve connection

7. Heating outlet

8. Flue gas case

9. Cleaning window

10. Heating circuit

11. Combustion chamber

12. Drain

2

DESCRIPTIONS

GENERAL DESCRIPTION

Boiler body

The boiler is made from ST 37/2 heavy gauge steel sheets accord­ing to NBN D 06001 and DIN 4702 Teil 1 with a water-cooled com­bustion chamber.
Pressurised fire-tube boiler with removable baffles The boiler body
is hydraulically tested in the factory

(Max. service pressure = 5 bar).

Burner chamber plate

The very solid burner chamber plate opens to the left or right and is
insulated by a ceramic fibre stone placed on a bed of rock wool.The
chamber plate seal is by means of a ceramic fibre cord and four M12
screw fastening.

Flue gas case

The flue gas case is removable and made from steel 3mm thick,
It is secured with 6 M10 nuts.The flue gas case includes a cleaning
window at the bottom, 150mm in diameter.

Casing

The lining is all steel. It was scoured and phosphated before paint­ing.The casing is stove enamelled at 200°C, providing a guarantee
of both long life and a high-quality finish.Epoxy-polyester protection

Insulation

The COMPACT S boiler is doubly insulated:

-A coating on the boiler body using a rock wool bedding 100mm
thick.

-A coating on the casing panels using 25mm thick rock wool bed­ding with aluminium coating.

Safety

- The COMPACT S boiler includes a safety mode device in the
event the chamber plate is not closed.

-A manual reset high-limit thermostat is triggered every time
the boiler overheats above a temperature of 103°C.

15 4

26 3

2

3

4

1

5 6 7

8

12

11

10

9

3

DESCRIPTIONS

PACKING

The boiler comes in two packages.

• Package 1:the boiler body on a wooden pallet

• Package 2:metal casings in a cardboard box

In the boiler combustion chamber, you will find:

• The control panel in its wrapping.

• The standard accessories

Breakdown of the accessories

COMPACT S 180 - 230:

- Ceramic fibre insulation cord

- Propylene spool

- Lock loop

- Cleaning brush

- Brush handle

- Brush handle extension

- DN 65 companion flanges

- Seal — fastenings - bolts

- 40mm thick rock wool

COMPACT S 290 - 350 - 410:

- Ceramic fibre insulation cord

- Propylene spool

- Lock loop

- Cleaning brush

- Brush handle

- Brush handle extension

- DN 80 companion flanges

- Seal — fastenings - bolts

- 40mm thick rock wool

COMPACT S 470 - 520 - 580 - 640:

- Ceramic fibre insulation cord

- Propylene spool

- Lock loop

- Cleaning brush

- Brush handle

- Brush handle extension

- DN 100 companion flanges

- Seal — fastenings - bolts

- 40mm thick rock wool

Contents of package 2

- Front right and left side panels

- Rear right and left side panels

- Upper right and left side panels

Package 1

Package 2

Breakdown of the accessories

4

TECHNICAL CHARACTERISTICS

Model 180 230 290 350 410 470 520 580 640

A mm 1300 1300 1504 1504 1504 1742 1742 1742 1742
B mm 600 600 720 720 720 780 780 780 780
C mm 1870 1870 2135 2135 2135 2395 2395 2395 2395
D mm 672 672 792 792 792 852 852 852 852
E mm 160 160 160 160 160 190 190 190 190
F mm 960 960 1200 1200 1200 1365 1365 1365 1365
G mm 1295 1295 1540 1540 1540 1700 1700 1700 1700
H mm 1390 1390 1600 1600 1600 1770 1770 1770 1770
L mm 280 280 440 440 440 440 440 440 440
M mm 850 850 830 830 830 1050 1050 1050 1050
N mm 150 150 250 250 320 320 320 320 320
T1 Ø 200 200 200 200 200 250 250 250 250
T2 DN 1”1/4 1”1/4 1”1/4 1”1/4 1”1/4 1”1/4 1”1/4 1”1/4 1”1/4
T3-T4 DN 65 65 80 80 80 100 100 100 100
T5 DN 1”1/4 1”1/4 50 50 50 65 65 65 65

1

C

3

5

3

Key

T1: Ø flue gas outlet
T2: Ø boiler drain
T3: Ø return
T4: Ø outlet
T5: sleeve / clamp for safety valve, if

applicable.
1: Control panel
2: Flame inspection window
3: Boiler clamp

GENERAL CHARACTERISTICS

Model 180 230 290 350 410 470 520 580 640

Output kW 176.5 235.8 294.7 354.4 412.9 471.9 531.9 588.5 648.7
Input kW 190.2 255.7 318.2 384.0 448.3 509.8 575.6 639.7 707.4
Efficiency at rated load % 92.8 92.2 92.6 92.3 92.1 92.5 92.4 92.0 91.7
Heat efficiency at 30% reduced load % 88.5 88.6 88.7 88.9 89.2 89.3 89.4 89.5 89.6
Combustion efficiency % 94.3 93.6 94.0 93.6 93.4 93.8 93.6 93.1 92.7
Maintenance losses % 1.5 1.4 1.4 1.35 1.3 1.3 1.2 1.15 1.05
Losses by chimney when in operation % 5.7 6.4 6.0 6.35 6.6 6.2 6.4 6.85 7.25
Losses by chimney when off % 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1
Percentage of CO2 (note 1) % 13.0 13.0 13.0 12.5 12.6 12.5 12.6 12.7 13.0
Flue gas temperature (note 1) °C 185 188 190 193 195 190 193 195 198
Combustion chamber pressure daPa 91318232627293236
Boiler water content l 290 290 456 456 456 681 681 681 681
Unladen weight Kg 590 620 925 950 990 1130 1150 1170 1190

DIMENSIONS

T

T

5

BOILER ROOM

Boiler positioning and installation

Comply with local standards in force (in Belgium:“Belgique NBN B 61­001”) for al l special characteristics, relative to the dimensions, fire
resistance of the panels, steel chamber plates, chimneys and upper­and lower-level ventilations.

The following formula is used to calculate the flue ways section:

S = 0.0065 Qc / √ H

S expressed in cm

2

/ Qc = Kcal/h: H = m. For the special metal flue
ways, we recommend that you consult the chimney man uf acturer for
each specific case.

To facilitate cleaning the flue gas circuits during servicing, make sure
you leave a space in front of your COMPACT S that is longer than
the length of the boiler itself and ensure that the burner chamber
plate can open easily when assembled.

Your COMPACT S must be placed on a concrete base, approxi-
mately 20 - 30cm high, to ensure the correct burner position and to
protect it from dampness.

To reduce vibrations and noises, make sure the boiler is placed on
the level and that it is stable.

At this point, connect the boiler to the electrical supply and install the
flue gas chimney, in accordance with current standards in force.

INSTALLATION

Model 180 230 290 350 410 470 520 580 640

Minimum fresh air supply m3/h 343 460 573 690 807 918 1036 1151 2122
High-level ventilation dm

2

333333344

Low-level ventilation dm

2

5.7 7.7 9.6 11.5 13.5 15.3 17.3 19.2 21.2

Ø of the chimney pipe:

Height 5m mm 317 366 410 449 485 518 550 579 608
Height 10m mm 267 308 344 378 408 436 463 487 511
Height 15m mm 241 278 311 341 368 394 418 440 462
Height 20m mm 224 259 290 317 343 367 389 409 430

A. High-level ventilation
B. Low-level ventilation
C. Draught stabiliser
D. Flame inspection window
E. Chimney height
F. Chimney diameter
H. Connection nozzle

F

A

C

H

B

D

E

HEATING CONNECTION

Beware!

Each boiler must be fitted with a safety valve, calibrated to a maxi­mum pressure of 5 bar. Fit the safety valve to the top point of the
boiler. You must make sure that no setting or insulation par ts will
allow it to be disabled

(See page 4).

It is vital that the COMPACT S boiler is equipped with a primary “H”
circulation loop:

• to avoid localised overheating in the combustion chamber;

•to mix part of the outlet fluid with the return fluid (increase in the
return temperature);

Important note:

• The installer must place the minimum-temperature thermostat on
the boiler body. This will cut the power to the heating pump when
the return temperature is too low.

• The installer must also connect the primary pump.

6

INSTALLATION

Minimum boiler positioning clearances

Minimum boiler room dimension:

- Minimum height: 2.5 m

- Minimum area: 6.0 m2

- Distance between the walls and the boiler: 600 mm

- Distance between the walls and the burner: 1300 mm

- Distance between the boiler and the ceiling: 1000 mm

- Fire resistance of the structures: 120 minutes

Before installing, check the local regulations in force
in your country.

A. Mixing control valve
B. Pump
C. Expansion vessel
D. Safety valve
E. Drain cock
F. Pressure gauge
G. Non-return valve
H. Recirculation loop with pump and non-return valve
K. Isolating valve

600

600 600

1300

F

G

C

B

A

H

KK

D

E

7

INSTALLATION

ELECTRICAL WIRING DIAGRAM

It is compulsory to install an electrical control box out­side your COMPACT S with a main switch and 6A
fuses. Before carrying out any work on the equipment,
it is vital to switch off the electrical power from this
box.

The connection of the chamber plate safety switch is
payable by the customer.

N.B.:
To wire the burner, please refer to the burner instruc­tions, supplied with the boiler only when supplying a
thermal unit.

Key to the boiler’s electrical wiring

IG. Main switch
MIP. Chamber plate safety dip switch
S. Door closed indicator light
TS. High-limit thermostat
TM1.First firing thermostat
TM2.Second firing thermostat

Setting trip line

• 1st firing

• 2nd firing

• Burner cutout

Burner trip line

TS TM1 TM2

I

O

S

Ph N 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

MIP

8

INSTALLATION

Recommendations:

• If the burner shuts down, wait for a few minutes before trying to
ignite it.

• Shut off the main switch before carrying out any work on the boiler.

•Quality of the heating circuit water - The quality of the water is a
key factor for the lifetime of the boiler:

- total hardness < 15°F

- pH of 6 to 8

- free oxygen < 0.5ppm

- free of sludge:

(clean the system before connecting the new boiler).

Poor quality water can cause lime scale deposits and corrosion of
the inside surface of the heating body
Consult a specialist water treatment company if the heating water
does not comply with the characteristics given above.

•Avoid locating boilers in poorly ventilated basement areas. The
high- and low-level ventilations must comply with current regula­tions.

•Provide a self-regulating draught valve on the chimney.

Thermostat settings:

• Set the slow firing rate thermostat (2) to the desired operating t°.

• Set the high firing rate thermostat (3) to a t° of 10°C lower than
the slow firing speed thermostat.

PREPARING THE BOILER AND
MOUNTING THE CASING

Please refer to the assembly instructions supplied with the casing.

MOUNTING THE BURNER

Only a qualified technician may mount the burner, in compliance
with current standards in force.

When installing the burner, we recommend you:

• secure the burner plate using all the nuts provided to guarantee
the seal;

• guarantee a minimum burner penetration in the combustion
chamber, according to the indications in the table below;

•check that the burner gas tube is sized according to the gas sup­ply pressure;

• check that the burner can exceed the boiler combustion chamber
pressure;

•insert the fiberglass cord supplied into the empty space between
the boiler combustion head and the chamber plate insulating
panel (if the quality is not sufficient — this depends on the Ø of
the burner head — use more cord to fill the space up to the inside
surface of the chamber plate insulation) to prevent the plate from
overheating from the effect of the flue gases, which could defor m
the chamber plate;

• adjust the flame to optimize the use of the combustion chamber
without touching the bottom or the panels.

Please see the previous page for the electrical wiring diagram for the
control panel

COMMISSIONING

Filling the system:

• Make sure that all the system valves are open except the
drain cock. Place the 3- or 4-channel mixing valve to the middle
position.

•Drain the system and monitor the pressure;

- hydrostatic height … with the expansion vessel open.

- hydrostatic height + 0.5 bar in closed systems.

Commissioning the burner:

•Check the burner charge relative to the boiler’s output.

• Check that all the safety parts are correctly calibrated and con­nected: safety valve, expansion vessel and thermostats.

• Check that the pumps are functioning normally.

• Open the system’s valves.

• Commissioning the burner:

Checks:

•First check the burner charge, then adjust the settings and check
the combustion characteristics — flue gas T° - CO

2 - CO and

blackening index.

•check that the settings and high-limit thermostats are operating
correctly; check the low-limit thermostat and the chamber plate
opening switch.

• Check that the safety valve is oper ating correctly (max pressure =
5 bar) by activating it manually.

• Check that the ventilation in the boiler room is adequate and
check that the chimney is conform.

• Check that the return temperature is not less than 40°C, that the
recirculation loop is connected and that it is operating correctly.

15 4

26 3

SERVICING THE BOILER

You should have the boiler serviced at least once a year .Regular serv­icing reduces consumption and extends the lifetime of your boiler.

To clean the boiler, follow the steps below:

•Disconnect the burner (trigger the main switch).

•Open the chamber plate.

• Remove the steel baffles.

•Clean the flue ways with a wire brush.

• Return the baffles.

•Clean the combustion chamber and remove any residues.

•Unscrew and remove the steel plate from the flue gas case.

•Clean the flue gas case, replace the plate and screw to tighten
(check that it is properly sealed).

•Clean the burner combustion head and the ignition electrodes.

•Close the chamber plate and re-start the system.

9

SERVICING

10

SERVICE RECORD

Installation date:
% CO2 (min. load):
% CO2 (max. load):

Gas Propane
Fuel oil

Model:
Serial number:
Heating system pressure setting:

❏❏
❏

Name and signature:

Flue gas T°:
Efficiency:
Gas pressure:

DETAILS OF THE INSTALLATION

Service date:
% CO2 (min. load):
% CO2 (max. load):

Gas Propane
Fuel oil

Comments:

❏❏
❏

Name and signature:

Flue gas T°:
Efficiency:
Gas pressure:

SERVICE ENGINEER’S REPORT

Service date:
% CO2 (min. load):
% CO2 (max. load):

Gas Propane
Fuel oil

Comments:

❏❏
❏

Name and signature:

Flue gas T°:
Efficiency:
Gas pressure:

Service date:
% CO

2

(min. load):

% CO

2

(max. load):

Gas Propane
Fuel oil

Comments:

❏❏
❏

Name and signature:

Flue gas T°:
Efficiency:
Gas pressure:

Service date:
% CO2 (min. load):
% CO2 (max. load):

Gas Propane
Fuel oil

Comments:

❏❏
❏

Name and signature:

Flue gas T°:
Efficiency:
Gas pressure:

Service date:
% CO2 (min. load):
% CO2 (max. load):

Gas Propane
Fuel oil

Comments:

❏❏
❏

Name and signature:

Flue gas T°:
Efficiency:
Gas pressure:

11

SERVICE RECORD

Service date:
% CO2 (min. load):
% CO

2

(max. load):

Gas Propane
Fuel oil

Comments:

❏❏
❏

Name and signature:

Flue gas T°:
Efficiency:
Gas pressure:

Service date:
% CO2 (min. load):
% CO2 (max. load):

Gas Propane
Fuel oil

Comments:

❏❏
❏

Name and signature:

Flue gas T°:
Efficiency:
Gas pressure:

Service date:
% CO2 (min. load) :
% CO2 (max. load) :

Gas Propane
Fuel oil

Comments:

❏❏
❏

Name and signature:

Flue gas T°:
Efficiency:
Gas pressure:

Service date:
% CO2 (min. load) :
% CO2 (max. load) :

Gas Propane
Fuel oil

Comments:

❏❏
❏

Name and signature:

Flue gas T°:
Efficiency:
Gas pressure:

Service date:
% CO2 (min. load) :
% CO2 (max. load) :

Gas Propane
Fuel oil

Comments:

❏❏
❏

Name and signature:

Flue gas T°:
Efficiency:
Gas pressure:

Service date:
% CO2 (min. load):
% CO2 (max. load):

Gas Propane
Fuel oil

Comments:

❏❏
❏

Name and signature:

Flue gas T°:
Efficiency:
Gas pressure:

12

SERVICE RECORD

Service date:
% CO2 (min. load):
% CO

2

(max. load):

Gas Propane
Fuel oil

Comments:

❏❏
❏

Name and signature:

Flue gas T°:
Efficiency:
Gas pressure:

Service date:
% CO2 (min. load):
% CO2 (max. load):

Gas Propane
Fuel oil

Comments:

❏❏
❏

Name and signature:

Flue gas T°:
Efficiency:
Gas pressure:

Service date:
% CO2 (min. load) :
% CO2 (max. load) :

Gas Propane
Fuel oil

Comments:

❏❏
❏

Name and signature:

Flue gas T°:
Efficiency:
Gas pressure:

Service date:
% CO2 (min. load) :
% CO2 (max. load) :

Gas Propane
Fuel oil

Comments:

❏❏
❏

Name and signature:

Flue gas T°:
Efficiency:
Gas pressure:

Service date:
% CO2 (min. load):
% CO2 (max. load):

Gas Propane
Fuel oil

Comments:

❏❏
❏

Name and signature:

Flue gas T°:
Efficiency:
Gas pressure:

Service date:
% CO2 (min. load):
% CO2 (max. load):

Gas Propane
Fuel oil

Comments:

❏❏
❏

Name and signature:

Flue gas T°:
Efficiency:
Gas pressure:

INTERNATIONAL

ACV international n.v

KERKPLEIN, 39
B-1601 RUISBROEK - BELGIUM
TEL.: [phone]
FAX:[phone]
E-MAIL: [e-mail]

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ACV BELGIUM nv/sa

KERKPLEIN, 39
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ACV WÄRMETECHNIK GMBH & CO KG

GEWERBEGEBIET GARTENSTRASSE
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FAX:[phone]
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ACV ESPAÑA

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POL. IND. LES HORTES
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BOILERNOX LDA

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ALFEREZ BOUCHARD 4857
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FAX:[phone]
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AUSTRALIA

HUNT HEATING PTY LTD

10 GARDEN BOULEVARD
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SIMETAL INDUSTRIA E COMERCIO
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PROXIMUS ENGINEERING LTD

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BEIJING HUADIAN HT POWER TECHNOLOGY
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TERMOX AS

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MOLDAVIA

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