Page 1
66400501
Installation, Operating and
Servicing Instructions
HM 60 N / 70 N / 100 N / 150 JUMBO
HM 60 N / 70 N / 100 N
With ACV BG 2000-S premix gas burner
HM 60 N / 70 N / 100 N
With ACV BM 101 oil burner
HM 150 JUMBO
With ACV BM 151 oil burner
HeatMaster
excellence in hot water
Page 2
1
INTENDED USERS OF THESE INSTRUCTIONS
These instructions are intended for
- specifying engineers
- installing engineers
- end-users
- servicing engineers
SYMBOLS
The following symbols are used in these instructions:
Essential instruction for operating the system
correctly.
Essential instruction for personal safety or
environmental protection.
Danger of electrocution.
Risk of scalding.
APPLICABLE STANDARDS
The products have received the “CE” certificate in accordance with
the standards prevailing in different countries (European Directives
92/42/EEC, “efficiency”, 90/396/EEC “gas appliances”). These
products have also received the Belgian “HR+” (gas boilers) marks
and “OPTIMAZ” (oil boilers) marks.
WARNINGS
These instructions are an integral part of the equipment to which
they refer and must be supplied to the user.
The product must be installed and serviced by qualified engineers,
in compliance with the prevailing standards.
ACV accepts no liability for any damage resulting from incorrect
installation or from the use of components or fittings not specified by
ACV.
Failure to observe instructions regarding tests and
test procedures can result in personal injury or
pollution risks.
Note:
ACV reserves the right to modify the technical specifications and
components of its products without prior notice.
INDEX INTRODUCTION
INTRODUCTION 1
Intended users of these instructions 1
Symbols 1
Applicable standards 1
Warnings 1
DESCRIPTION 2
Operating principle 2
Construction features 2
TECHNICAL SPECIFICATION 5
Maximum operating conditions 5
Burner chamber plate 5
Domestic hot water performances 5
General features 5
Dimensions 6
INSTALLATION 8
Boiler room 8
Chimney connections 8
Hot water connections 10
Heating connection 11
Oil supply connections 11
Electrical connections 12
Wiring diagram 12
COMMISSIONING 14
Filling the hot water and heating circuits 14
BURNER FEATURES 15
ACV BG 2000-S premix gas burners 15
ACV BM 101 and BM 151 oil burners 19
MAINTENANCE 20
Service intervals 20
Servicing the boiler 20
Servicing the safety devices 21
Servicing the burner 21
Draining the boiler 21
Spare parts 21
USER GUIDE 22
Using the boiler 22
Boiler safety shutdown 23
Resetting the oil burner 23
Resetting the BG 2000-S premix burner 23
Burner troubleshooting 23
SERVICE RECORD 24
Page 3
2
DESCRIPTION
OPERATING PRINCIPLE
The HeatMaster is a high performance, direct fired hot water storage
heater, which has indirect heat transfer due to its Tank-in-Tank
construction.
At the heart of the HeatMaster is a stainless steel cylinder through
which the flue tubes pass. This is surrounded by a mild steel shell
containing the primary water (neutral fluid). The outer shell extends
down to the combustion chamber and even around the flue tubes.
The area of the heat transfer surface is therefore much greater than
that of standard direct fired water heaters.
A circulating pump fitted to the primary circuit moves the water
around the tank, heating it faster and maintaining an even
temperature across the primary jacket.
The burner, either gas or oil, fires onto the primary water which
indirectly heats the stainless steel cylinder containing the DHW.As
with all Tank-in-Tanks, this is corrugated over its full height and
suspended in the HeatMaster by its hot and cold water connections.
The cylinder expands and contracts during use and this, together
with the fact that cold water does not come into contact with the
intense heat of the burner flame, means that limescale buildup is
prevented.
This scale resistant feature, along with the corrosion resistance of
stainless steel, eliminates the need for sacrifical anodes.
The HeatMaster has one very major advantage over other direct
fired water heaters - because it heats the DHW with a primary
circuit, this primary water can be used to provide central heating as
well.
By connecting two, three, four or more HeatMasters together in a
module, most hot water and heating demands can be met.
Indeed, when used in conjunction with HR and Jumbo hot water
storage tanks the Heatmaster can supply even the largest hot water
requirement.
Standard equipment
The HeatMaster 60 N / 70 N / 100 N and 150 Jumbo has the following
items as standard :
- On/off switch
- Summer/Winter switch
- Timeclock
- primary circulating shunt pump
- primary expansion vessels
- primary safety valve
- pressure and temperature gauge
- drain valve
- body completely insulated in rigid polyurethane foam
CONSTRUCTION FEATURES
Outer body
The outer body containing the primary fluid is made of thick STW 22
steel.
TANK-IN-TANK heat exchanger
The ring-shaped inner tank with its large heating surface for producing
domestic hot water is built of Chrome/Nickel 18/10 stainless steel.It
is corrugated over its full height by an exclusive production process
and entirely argon arc welded by the TIG (Tungsten Inert Gas)
method.
Combustion gas circuit
The combustion gas circuit is paint-protected and comprises:
• Flue pipes
Depending on output, HeatMaster models contain several
steel flue pipes with an internal diameter of 64 mm. Each
pipe is fitted with a baffle of special steel designed to
improve heat exchange and reduce flue gas temperature.
• Combustion chamber
The combustion chamber on HeatMaster models is
entirely water cooled.
Insulation
The boiler body is fully insulated by rigid polyurethane foam with a
high thermal insulation coefficient, sprayed on without the use of
CFCs.
Casing
The boiler is covered by a steel jacket which has been scoured and
phosphated before being stove enamelled at 220 °C.
The jacket of the HM 150 Jumbo is delivered separately and must
be assembled on site following the instructions supplied with it.
Burner
All HeatMaster models can be fitted with pressure jet gas burners or
oil burners.The HeatMaster 60, 70 and 100 can also be fitted with the
low-NOx pre-mix BG 2000 gas burner.
Page 4
3
DESCRIPTION
Thermal reset high
limit thermostat
Manual reset high
limit thermostat
Primary safety valve
Low water
pressure switch
Control thermostat
Domestic cold water inlet
Combustion chamber
Top cover
Insulation
Features of HeatMaster 70 N / 100 N
Safety features of the HeatMaster 60 N
Domestic hot
water outlet
Burner chamber plate
Primary shunt pump
Primary expansion vessel
Heating circuit filling valve
with removable hose and
non-return valve
Automatic air vent
Heating return
Burner
Tank-in-Tank
heat exchanger
Flue pipes and
turbulators
Flue reduction collar
Central heating
flow pipe
Casing front panel
Primary circuit
Control panel HeatMaster 60 N
Manual reset high
limit thermostat
Burner
lockout
indicator
Combined temperature
and pressure gauge
Time clock
Control
thermostat
ON / OFF
switch
Primary circuit low
water pressure
indicator
High limit cutoff
indicator
Summer / Winter switch
I
O
Page 5
4
DESCRIPTION
Thermal reset high
limit thermostat
Manual reset high
limit thermostat
Primary safety valve
Low water
pressure switch
Control thermostat
Thermal reset high
limit thermostat
Manual reset high
limit thermostat
Primary safety valve
Low water
pressure switch
Control thermostat
Safety features of the HeatMaster 70 N and 100 N
Safety features of the HeatMaster 150 Jumbo
bar
1
8
1
7
1
6
1
5
1
4
1
3
1
2
1
1
1
0
9
8
7
6
5
4
3
2
1
2
4
2
3
2
2
2
1
2
0
1
9
GRASSLINGRASSLIN
I
O
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
Manual reset high
limit thermostat
Burner
lockout
indicator
Combined temperature
and pressure gauge
Time clock
Servicing socket
(230 V ˜ 50 Hz)
Control
thermostat
ON / OFF
switch
Primary circuit low
water pressure
indicator
Fuse
Control thermostat
Relay base
Time clock
Combined temperature
and pressure gauge
Thermal reset high
limit thermostat
ON / OFF switch
Manual reset high
limit thermostat
Primary circuit low
water pressure indicator
Mains power
electrical connection
(multi-pin plug)
Summer / Winter switch
High limit cutoff
indicator
Control panel HeatMaster 150 Jumbo
Control panel HeatMaster 70 N and HeatMaster 100 N
I
O
Page 6
5
TECHNICAL SPECIFICATION
MAXIMUM OPERATING CONDITIONS
Maximum service pressure (tank full of water)
- Primary circuit: 3 bar
- Secondary circuit: 10 bar
Test pressure (tank full of water)
- Primary circuit: 4.5 bar
- Secondary circuit: 13 bar
Operating temperature
- Maximum temperature: 90 °C
Water quality
• Chlorures: < 150 mg/l (304)
< 2000 mg/l (Duplex)
• 6 ≤ ph ≥ 8
BURNER CHAMBER PLATE
The burner chamber plate has 4 threads (M 10 x 20) for attaching
the burner.It is protected from heat by a blanket insulation.
Ø130
Ø28
5x
Ø
)
60
60
60
60
HM 60 N HM 60 N HM 70 N HM 70 N HM 100 N HM 100 N HM 150
BM 101 BG 2000-S/60 BM 101 BG 2000-S/70 BM 101 BG 2000-S/100 JUMBO
Peak delivery at 40 °C L/10’ 474 474 646 646 905 905 1504
Peak delivery at 45 °C L/10’ 378 378 543 543 777 777 1289
Peak delivery at 60 °C L/10’ 245 245 346 346 514 514 870
Peak delivery at 70 °C L/10’ 193 193 268 268 343 343 700
Peak delivery at 80 °C L/10’ 135 135 207 207 258 258 540
Peak delivery at 40 °C L/60’ 1942 1942 2133 2133 3172 3172 4828
Peak delivery at 45 °C L/60’ 1656 1656 1794 1794 2680 2680 4138
Peak delivery at 60 °C L/60’ 1106 1106 1219 1219 1813 1813 2864
Peak delivery at 70 °C L/60’ 681 681 971 971 1226 1226 2131
Peak delivery at 80 °C L/60’ 499 499 636 636 893 893 1362
Continuous delivery at 40 °C L/h 1835 1835 1835 1835 2776 2776 3989
Continuous delivery at 45 °C L/h 1573 1573 1573 1573 2379 2379 3419
Continuous delivery at 60 °C L/h 1101 1101 1067 1067 1665 1665 2393
Continuous delivery at 70 °C L/h 791 791 918 918 1104 1104 1718
Continuous delivery at 80 °C L/h 455 455 580 580 804 804 987
Reheat time at 60 °C min 991616 13 13 17
HM 60 N HM 70 N HM 100 N HM 150
JUMBO
Maximum Input kW 69.9 69.9 107.0 154.0
Maximum Output kW 62.5 63.0 96.8 139.1
Maintenance loss at 60 °C as rated value % 0.57 0.60 0.65 0.52
Total capacity L 162 239 330 645
Primary circuit capacity L 82 108 130 245
Heating connection Ø 1
1/2”11/2”11/2” DN 50
Hot water connection Ø 3/4” 1” 1” 2”
Hot water tank heat exchange surface m
2
2.46 3.14 3.95 5.30
Weight empty Kg 220 270 320 530
Pressure drop primary circuit mbar 54 46 83 120
GENERAL FEATURES
DOMESTIC HOT WATER PERFORMANCES
6.5(M8
Page 7
6
TECHNICAL SPECIFICATION
DIMENSIONS
The units are delivered fully assembled, tested and packed on a timber base with shockproof edges and protected by heat-shrunk plastic film.
On reception and after unpacking, check the equipment for damage.For transport pur poses, refer to the weight
(page 5) and dimensions given
below.
A mm B mm C mm D mm E mm F mm G Ø mm H mm J mm K mm
HM 60 N 1698 1583 538 625 540 390 150 1098 281 1665
HM 60 N BG 2000-S 60 1698 1583 538 801 540 390 150 1098 281 1665
HM 70 1743 1630 678 797 680 390 150 1289 285 1720
HM 70 N BG 2000-S 70 1743 1630 680 937 680 390 150 1289 285 1720
HM 100 N 2093 2030 680 797 680 390 150 1693 285 2120
HM 100 N BG 2000-S 100 2093 2030 680 937 680 390 150 1693 285 2120
HM 150 Jumbo 2124 2117 1020 1440 1020 600 250 1383 590 2250
HeatMaster 60 N
Without burner With ACV BG 2000-S
premix gas burner
A
C
D
D
C
F
G
BA K
H
J
E
C/2
Page 8
7
TECHNICAL SPECIFICATION
A
K
H
J
E
C
D
F
G
562
HeatMaster 150 Jumbo
HeatMaster 70 N and HeatMaster 100 N
Without burner With ACV BG 2000-S
premix gas burner
A
C
D
D
G
F
K
A
B
H
C/2
J
C
E
Page 9
8
BOILER ROOM
Important
•Keep vents free at all times.
• Do not store inflammable products in the boiler room.
• Do not store corrosive products near the boiler, such as paints,
solvents, chlorine, salt, soap and other cleaning products.
• If you smell gas, do not switch on the light or light a flame.Turn off
the mains gas tap at the meter and inform the appropriate
services immediately.
Access
The boiler room must be large enough to allow good access to the
boiler.The following minimum distances are required around the boiler:
- front 500 mm
- side 100 mm
- behind 150 mm
- above 700 mm
Ventilation
The boiler room must be fitted with top and bottom vents sized
according to the table below or to current regulations.
The table below gives an example conforming to the Belgian standards.
Other countries should refer to their own standards.
Base
The base on which the boiler rests must be made of non-combustible
materials.
CHIMNEY CONNECTIONS
IMPORTANT
Boilers must be installed by an approved heating
engineer, in accordance with the prevailing local
standards and regulations.
Flue size should not be less then the outlet size of the
boiler.
Chimney connection type: B23
The boiler is connected to the chimney by a metal pipe rising at an
angle from the boiler to the chimney.
A flue disconnection piece is required.
This must be easy to remove to give access to the flue pipes when
servicing the boiler.
Note:
Regulations vary from country to country therefore
the table above is intended only as a guide.
Due to the high efficiency of our boilers, the flue gasses
exit at low temperature. Accordingly, there is risk that
the flue gasses could condense, which could damage
the chimney. In order to avoid this risk, it is strongly
recommended that the chimney be lined.
INSTALLATION
Ventilation 60 N 70 N 100 N 150
Jumbo
Min. fresh air
requirement m3/h 126 126 194 278
Bottom dm22.11 2.11 3.20 4.8
Top dm22.0 2.0 2.0 2.0
Chimney 60 N 70 N 100 N 150
minimum flue diameter Jumbo
E = 5 m Ø F min. mm 189 189 234 286
E = 10 m Ø F min. mm 159 159 178 250
E = 15 m Ø F min. mm 150 150 150 250
A. Top vent
B. Bottom vent
C. Draught regulator
D. Inspection window
E. Height of lined chimney
F. Chimney diameter
F
A
B
C
E
D
Page 10
9
INSTALLATION
Balanced flue boiler connection type: C
• C13:concentric hor izontal connection
• C33:concentric vetical connection
• C53:parallel chimney connection
• C63: concentric vertical connection without terminal (only in
Germany and Luxembourg).
Maximum length concentric : 6 metres
Maximum length parallel : 12 metres
Note: a 90 degree bend = 1 metre equivalent length
A condensation drain outlet must be fitted close to the boiler to prevent condensation products fr om
the chimney running into the boiler.
To avoid condensation water running out of the terminal, all horizontal flue runs must fall back
towards the boiler.
C33
120
150 min.
C13
C53
2 m min.
Page 11
10
INSTALLATION
Example of heating + storage connection
Recommended for applications requiring a high peak flow.
Example of series connection
Preferable for high temperature applications with up to three units.
Example of parallel connection
Recommended for applications with a high continuous flow.
DANGER!
As a safety measure against scalding, we
strongly recommend installing a thermostatic
mixing valve.
HOT WATER CONNECTIONS
Pressure reducing valve
If the mains water pressure is greater than 6 bar, a pressure reducing
valve must be fitted.
Expansion relief valve
The tank expansion relief valve must be ACV approved and
calibrated to a maximum of 7 bar. The valve discharge must be
connected to the drain.
Hot water expansion vessel
A hot water expansion vessel must be installed.
Hot water circulation
If the tank is situated a long way from the point of use, then
installing a recirculation loop can provide a faster supply of hot water
to the outlets.
Temperature and pressure relief valve
If using the HeatMaster as an unvented hot water unit, in some countries, a temperature and pressure relief valve must be
fitted - consult your ACV stockist for assistance.
Example of hot water connection with thermostatic mixer
1. Stop cock
2. Non-return valve
3. Pressure reducing valve
4. Expansion relief valve
5. Hot water expansion vessel
6. Hot water secondary pump (it fitted)
7. Thermostatic mixing valve
8. Drawoff tap
9. Drain cock
10. Stop cock for cleaning
11. Temperature relief valve
(UK-only)
12
3
4
5
6
2
7
10
11
I
O
8
I
O
I
O
I
O
I
O
I
O
I
O
9
I
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Page 12
11
INSTALLATION
HEATING CONNECTION
The HeatMaster has two connections at the rear that can be used to
connect a central heating circuit. Connecting a heating system may
reduce the domestic hot water performance.
Expansion
The HM 60 is fitted with an 8 litre expansion vessel. HM 70/100
models are fitted with two 10 litre expansion vessels, and the
HM 150 Jumbo is fitted with four 8 litre expansion vessels. These
expansion vessels are sized f or hot water oper ation only. If a heating
system is connected to the primary circuit, calculate the expansion
capacity necessary for the total volume of the heating system.
(Refer
to the technical instructions from a relevant manufacturer of e xpansion vessels)
.
Example of a single circuit connection
1. 3-way valve
2. Heating pump
3. Non-return valve
4. Isolating valves
5. Safety valve set to 3 bar with pressure gauge
6. Expansion vessel
7. Drain cock
8. Controller
WARNING
The pimary safety valve is supplied with a plastic tube
connected to the discharge outlet - this is for test
purposes only and should be removed. The safety
valve should be connected to a drain using a metallic
pipe eg. copper.
OIL SUPPLY CONNECTIONS - ACV BM BURNERS
(If another make of buner is fitted please refer to that manufacturers technical
manual)
Installation without return
Installation with return
H
max 4m
L1
L1
L1
H
H
max 4m
L (m) (L = H + L1)
H (m) Ø int. 8 mm Ø int. 10 mm
0.5 10 20
120 40
1.5 40 80
260 100
L (m) (L = H + L1)
H (m) Ø int. 8 mm Ø int. 10 mm
035 100
0.5 30 100
125 100
1.5 20 90
215 70
28 30
3.5 6 20
142
I
O
3
5
8
4
6
7
Page 13
12
ELECTRICAL CONNECTIONS
Power supply
The boiler operates with a 230 V - 50 Hz single phase supply.
A double pole isolator with a 6 amp fuse or a 6 amp MCB must
be fitted outside the boiler to allow power to be shut off during
servicing and before any repairs are carried out on the boiler.
Conformity
Boiler installation must comply with the prevailing local standards
and legislation.
Safety
The stainless steel tank must be earthed separately.
The power to the boiler must be switched off before
any work is carried out.
WIRING DIAGRAM
HeatMaster wiring diagram legend
60 N, 70 N, 100 N (page 13) and 150 Jumbo (page 14)
1. 230 V power connection plug
2. On/off switch
3. Temperature high limit cutoff indicator (except HM 150 Jumbo)
4. Manual reset high limit thermostat
5. Primary circuit low water pressure indicator
6. Low water pressure switch
7. Time clock
8. Summer/winter switch (except HM 150 Jumbo)
9. Hot water priority link (except HM 150 Jumbo)
10. Bur ner lockout indicator (except HM 150 Jumbo)
11. Room ther mostat connection (option)
12. Central heating pump
13. HeatMaster shunt pump
14. Bur ner plug connector
15. Water flow switch connection
(option)
16. Ther mal reset high limit thermostat 95 °C
17. Control ther mostat
18. 230 V servicing socket
(only HM 150 Jumbo)
19. Relay (only HM 150 Jumbo)
INSTALLATION
Electrical connection HeatMaster 60 N, 70 N and 100 N
B. Blue
Bk. Black
Br. Brown
G. Grey
Gr. Green
Or. Orange
Pk. Pink
R. Red
V. Violet
W. White
Y. Yellow
Y/Gr. Yellow / Green
Y/Gr
Br
Y/Gr
Y/Gr
Or
Or
W
W
Pk
Pk
R
B
B
Or
BB
B
Y
G
Gr
Y/Gr
Y/Gr
Br
B
Y
G
Gr
Y/Gr
Or
G
G
GG
B
B
Or Or
B
B
B
B
Br
B
B
G
Y/Gr
B
Br
Y/Gr
Br
B
Or
Or Br Bk
B
B
B
Bk
W
Pk
Bk
W
PkW
8
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
L1 N T1 T2 S3 B4
L1 N T1 T2 S3 B4
11
21
9
C
5
7
6
4
12 13
4
3
21
C
103 °C
12
P
14
15
10
95 °C
12
16
C
5
0 - 90 °C
3
I
2
O
12
17
C
L1 N
L1 N
1
Page 14
13
INSTALLATION
Electrical connection HeatMaster 150 Jumbo
Y/Gr
Br
W
Pk
G
B
Or
Br
Bk
B
BR
R
Or
W
W
W
V
Or
V
Bk
Bk
B
B
Bk
Bk
B
Y/Gr
B
B
B
Br
Br
Br
Br
B
Br
B
R
Y/Gr
RBr
B
Or
B
Or
B
B
Br
R
Bk
B
B
W
Bk
Or
Y/Gr
Br
W
B
Or
Br
Y/Gr
Y/Gr
W
R
R
B
Bk
B
B
B
Y/Gr
Bk
Bk
W
W
W
Br
W
W
Bk
Pk
Br
B
B
Br
W
W
Br
Br
R
B
Br
Or
Bk
Br
Br
G
B
B
W
B. Blue
Bk. Black
Br. Brown
G. Grey
Gr. Green
Or. Orange
Pk. Pink
R. Red
V. Violet
W. White
Y. Yellow
Y/Gr. Yellow / Green
Boiler run
230V signal connections
Burner lock out
High temperature
A2
A1
103 °C
4
C
2
1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
15
14
L1 N T1 T2 S3 B4
13
19
6
11
4
5
9
1
95 °C
16
C
10 - 100 °C
17
1 3 5
12
C
A1
1
A2
7
5
42
21
2
18
12
6,3 A
L1 N T1 T2 S3
220/240V
~ 50 Hz
ph
n
1
11
6
C
Page 15
FILLING THE HO T WATER AND HEA TING CIRCUITS
IMPORTANT
Hot water tank must be pressurised before the heating
circuit is filled.
1. Close the primary circuit filling valves (A)
2. Open the stop valve (B) and the drawoff tap (C).
When water flows out of the tap, the hot water tank is full and
the drawoff tap (C) should be closed.
3. Fill the primary (heating) circuit by opening the valves (A) and
pressurising to 1 bar.
4. Open the automatic air vent located on top of the boiler.
IMPORTANT - the screw cap must be left loose to allow future
automatic venting to take place.
5. After venting the air from the system, bring the pressure up to
the static head plus 0.5 bar: 1.5 bar = 10m and 2 bar = 15 m.
6. Check that the electrical connection and boiler room ventilation
conform to the relevant standards.
7. Set the thermostat between 60 and 90 °C.
8. Switch the on/off switch to the ON position.
9. For gas burner, check the gas supply pressure on starting up.
10. For the oil burner, check the oil supply (and return). Proceed
with the necessary venting, measurements and settings.
11. Set the heating control to heat demand. When the burner
operates, check the flue gas discharge pipes for leaks.
12. After 5 minutes of operation, vent the primary circuit again
maintaining the water pressure at 1 bar.
13. Then restart the unit and check the combustion.
14
COMMISSIONING
HeatMaster 60 N
HeatMaster 70 N and 100 N
HeatMaster 150 Jumbo
GRASSLIN
B
C
A
I
O
B
I
O
C
B
A
umbo
Kerkplein 39
1601 Sint-Pieters-Leeuw(Ruisbroek) Belgium
Num.
Code
Typ.
Anno
Max. Temp.
Chauffage-CV-Heizung
Eau sanitair. water-Brauchwasser
Débit-Debiet-Abflussmenge
bar
Agréation-Keuring-Prüfnummer
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
1
8
1
7
9
1
1
6
0
2
1
5
1
2
1
4
2
2
I
1
3
3
2
1
4
2
2
1
1
1
O
1
2
0
3
9
GRASSLIN
4
8
5
7
6
C
A
Page 16
15
BURNER FEATURES
ACV BG 2000-S PREMIX GAS BURNERS
Description
The burner tube is coated with metal fibre (NIT) which, in addition to
its remarkable heat exchange capabilities, gives greater durability.
The main components are a venturi and one (model 60 and 70) or
two (model 100) gas valves, technology specially developed by
Honeywell for low No x premix air/gas b urners with automatic ignition
and ionisation flame detection.
The pressure at the gas valve outlet is equal to the air pressure in
the neck of the venturi, less the offset.The fan sucks combustion air
through the venturi, into which the gas inlet emerges.
As it passes through, the air produces a pressure differential in the
constriction of the venturi and sucks the gas into the venturi outlet.
A perfect mix of air and gas then passes through the fan to the
burner tube.
This design ensures very quiet and safe operation:
• If there is an air blockage, the pressure differential in the venturi
falls, the gas flow diminshes, the flame goes out and the gas
valve closes:the burner is in safety shutdown mode.
• If there is a b lockage in the chimne y outlet, the air flow diminishes,
and the same reactions as those described above cause the
burner to shut down in safety mode.
• The BG 2000-S burner fitted to the HeatMaster 60, 70 and 100
is controlled by a Honeywell module which controls burner
operating safety.
BG 2000-S burners are preset at the factory
for natural gas.
Conversion to propane:
Not applicable for Belgium.
Conversion kit included with burner comprising:
- Cap(s)
- Nameplate(s)
- Sticker with settings.
- Mounting instructions.
ACV BG 2000-S premix gas burners dimensions
Air
Gas flow
regulating screw
Offset regulation
screw
Gas
Air-gas mixture control system
248
342
342
228
248
248
375
375
375
BG 2000-S / 60
BG 2000-S / 70
BG 2000-S / 100
CBAType
Air - gas
mixture
Venturi Fan
AB
C
Page 17
16
B. Blue
Bk. Black
Br. Brown
G. Grey
Gr. Green
Y. Yellow
Y/Gr. Yellow / Green
Electrical connections
B. Blue
Bk. Black
Br. Brown
G. Grey
Gr. Green
Y. Yellow
Y/Gr. Yellow / Green
Electrical connections
Burner electrical connection BG 2000-S/60 and BG 2000-S/70
Burner electrical connection BG 2000-S/100
Br
B
Br
Bk
Br
Gr
Y
B
Br
Y
Y/Gr
Br
Bk
G
Gr
B
B
Br
Y/Gr
G
Br
B
B
Y/Gr
Br
Br
B
Br
Bk
Br
Gr
Y
Y
Y/Gr
Br
Bk
G
Gr
B
B
Br
Y/Gr
G
B
Y/Gr
Br
BURNER FEATURES
123456789101112
123456789101112
Page 18
17
BURNER FEATURES
Ignition electrode
Burner tube
Gas valve
Venturi
Ionisation probe
Burner chamber plate insulation
Ignition electrode
Burner tube
Gas valve
Venturi
Ionisation probe
Burner chamber plate insulation
Chamber plate
Relay
Burner plug connector
Fan power plug
Gas inlet
Fan
Potentiometer setting
Chamber plate
Relay
Burner plug connector
Fan power plug
Gas inlet
Fan
Potentiometer setting
ACV premix gas burner BG 2000-S/60 and BG 2000-S/70
ACV premix gas burner BG 2000-S/100
Page 19
18
BURNER FEATURES
HeatMaster 60, 70 and 100 Gas burner features - BG 2000
HM 60 N HM 70 N HM 100 N HM 100 N HM 150 Jumbo
+ BG 2000-S/60 + BG 2000-S/70 + BG 2000-S/100 + gas pressure + gas pressure
jet burner jet burner
Input kW 69.9 69.9 85.0 96.8 154
Output kW 63.0 63.0 77.4 90.0 139.1
Combustion efficiency - natural gas % 91.2 91.5 92.9 92.9 91.5
Natural gas CO2 % 9.5 9.0 9.0 9.0 9.0
Gas G20 - 20 mbar - I 2E(S)B - I 2 Er - I 2H
Flow m3/h 7.40 7.40 8.99 10.24 16.30
Gas G25 - 20/25 mbar - I 2L - I 2ELL
Flow m3/h 8.60 8.60 10.46 11.91 18.95
Gas G31 - 37/50 mbar - I 3P
Flow m3/h 2.86 2.86 3.47 3.95 6.29
Pressure drop combustion chamber mbar 0.6 0.6 1.4 1.4 0.6
Flue gas temperature (net) °C 186 172 145 165 181
Mass rate of combustion
products
(grammes per second) 32.1 32.1 39.1 44.5 70.8
Gas category
BE FR AT DK ES UK IT PT IE SE NL LU DE
I 2Er
I 2E(S)B
I 2H
I 3P
I 2L
I 2ELL
Page 20
19
BURNER FEATURES
ACV BM 101 AND BM 151 OIL BURNERS
Description
The use of new technology enables our medium output burners to
meet current performance and emissions quality requirements.
These burners are fitted with high quality components including a
two-stage oil pump that permits soft start.
Components:
- Landis & Gyr relay
- A.E.G. motor
- Suntec pump
- May & Christe transformer
- Landis & Gyr oil preheater
Features
- Easy to install – fitted with safety closure and new burner
suspension system.
- The burner air pressure adjusts to the pressure in the burner
chamber.
- An automatic damper shuts off the air flow when the burner is
turned off, preventing the boiler from cooling.
- Quiet and extremely reliable.
- Adjustable to the depth of the boiler burner chamber thanks to
the adjustable bracket at the mouth of the burner chamber.
- Three air adjustment points to ensure the best air/oil mixture.
• upstream air presetting
• primary setting
• combustion head setting
BM oil burners dimensions
A mm B mm C mm D mm E mm F mm G Ø L Ø LK Ø Kg
BM 101 260 300 250 310 60 - 150 M 8 90 95 125 - 180 14
BM 151 280 340 280 350 60 - 190 M 8 115 120 156 - 200 20
Oil burner specification and perfomances
HM 60 N HM 70 N HM 100 N HM 150 JUMBO
Burner type BM 101 BM 101 BM 151 BM 151
Input kW 69.9 69.9 107.0 154.0
Nozzle flow US Gal/h 1.50 1.50 2.00 3.00
Nozzle angle 60° 60° 60° 60°
Oil flow Kg/h 5.9 5.9 8.92 13.0
Pump pressure bar 10.5 10.5 13.5 12.5
Pressure drop combustion chamber mbar 0.6 0.6 1.4 0.6
Flue gas temperature (net) °C 175 170 170 181
CO2 % 12.5 12.5 12.5 12.5
Mass rate combustion
products (grammes per second) 29.6 29.6 44.8 64.7
LK
L
F
G
3°
C
E D
A
B
Page 21
20
SERVICE INTERVALS
ACV recommends that boilers should be serviced at least once a year.
The burner must be serviced and tested by a competent engineer.
If a boiler is subject to heavy use, it may require servicing more than
once a year - consult ACV for advice.
SERVICING THE BOILER
1. Turn OFF the on/off switch on the boiler control panel and isolate
external electrical supply.
2. Turn off the gas or oil supply to the boiler.
3. Remove the flue to gain access to the top of the boiler.
4. Remove the casing top panel and lift off the flue reduction collar
by undoing the fastening bolts.
5. Remove the turbulators from the flue pipes for cleaning.
6. Unscrew the burner chamber plate and remove the burner.
7. Brush the flue pipes .
8. Clean the burner chamber and the burner.
9. Re-assemble turbulators, flue reduction collar and flue, checking
that the gasket on the flue reduction collar is in good condition.
Replace gasket if necessary.
MAINTENANCE
Casing top panel
Chimney flue
Flue reduction collar
Burner chamber
Burner chamber plate
Flue pipe and turbulators
Page 22
21
MAINTENANCE
SERVICING THE SAFETY DEVICES
- Check that all thermostats and safety devices are working properly.
- Test the safety valves on the central heating and hot water circuits.
SERVICING THE BURNER
Oil burner
- Check and if necessary clean the main filter on the oil line.
- Check the alignment of the nozzle: check, clean or change the
nozzle and its filter, check that the electrodes and flame holder
are clean and correctly adjusted.
- Reassemble and check that the safety components are working
properly.
- Set the combustion parameters.
- Check the combustion (CO
2, CO and burner pressure) and record
the values and any remarks in the Service Record on page 24.
Gas burner
- Check that the insulation and gasket on the burner chamber plate
are in good condition - replace if necessary.
- Check and clean the burner and electrodes. Replace electrodes if
necessary
(under normal use once a year).
- Check that the safety components are working properly.
- Check the combustion (CO2, CO and gas pressure) and record
the values and any remarks in the Service Record on page 24.
DRAINING THE BOILER
Water flowing out of the drain cock may be
extremelyhot and could cause severe scalding.
Keep people away from discharges of hot
water.
Draining the heating circuit
1. Turn OFF the on/off switch on the boiler control panel, isolate
external electrical supply, and turn off the gas or oil supply to the
boiler.
2. Close the isolating valves (4).
3. Connect a hose to the drain cock (7).
4. Open the drain cock to drain the primary circuit.
Draining the hot water circuit
1. Turn OFF the on/off switch on the boiler control panel, isolate
external electrical supply, and turn off the gas or oil supply to the
boiler.
2. Release the pressure in the heating circuit until the pressure
gauge indicates zero bar.
3. Close stop cock (1) and turn off tap (8).
4. Open valve (9) then valve (10) (first 9 then 10).
5. Let the water empty into the drain.
For the tank to be emptied, valve (9) must be situated
at ground level.
SPARE PARTS
Please refer to the specific document available from ACV or your
distributor.
3
12
4
6
2
7
11
5
I
O
9
8
10
142
I
O
8
3
5
4
6
7
Page 23
22
USER GUIDE
USING THE BOILER
Your system should be serviced at least once a year
by a qualified engineer.
If the boiler is subject to heavy use, it may require
servicing more than once a year - consult your service
engineer for advice.
Starting the burner:
In normal operation, the burner starts automatically
whenever the boiler temperature falls below the set
temperature.
Understanding the control panel
There are no user parts inside the control panel.
1. On/Off switch
This turns the HeatMaster on or off.
2. Control thermostat - 60 to 90 °C
When using the HeatMaster as a hot water generator only, the
temperature can be set between 60 °C and 90 °C.
If the HeatMaster is used for both hot water and central heating, the
control thermostat would normally be set at 80 °C to achieve optimum
operating conditions.
3. Summer/Winter switch
This turns the heating pump (if fitted) on or off.
4. Manual reset high limit thermostat
If the boiler temperature exceeds 103 °C this safety device will
activate and the high temperature indicator will light up.To reset first allow the boiler to cool to below 60 °C, unscrew the cap and
press the reset button using a pencil or similar pointed device,
replace the cap. If the fault persists, turn the boiler off and call an
engineer.
5.Time clock
This allows the HeatMaster to be timed on and off and operates on
a 24 hour sequence. Around the outside of the clock there are a
number of white tabs, these allow 15 minute switching periods. To
set the time clock simply push outwards the number of tabs required
for ON period.
Remember: TAB IN = HeatMaster OFF
TAB OUT = HeatMaster ON
6.Temperature and pressure gauge
This gauge indicates both the temperature of the HeatMaster and
the pressure within the primary circuit.
The temperature should not exceed 90 °C - if it does, switch the
boiler off and check the thermostat setting. If the fault persists, call
an engineer.
The pressure should not fall below 1bar , if it does the please see the
'Heating System Pressure' paragraph later in this section.
7. Low primary water pressure indicator
If this indicator lights up, the primary circuit of the HeatMaster requires
topping up with water. Please see the 'Heating System Pressure'
paragraph later in this section.
Control panel HeatMaster 60 N
Manual reset high
limit thermostat
Burner
lockout
indicator
Combined temperature
and pressure gauge
Time clock
Control
thermostat
ON / OFF
switch
Primary circuit low
water pressure
indicator
High limit cutoff
indicator
Summer / Winter switch
bar
1
8
1
7
1
6
1
5
1
4
1
3
1
2
1
1
1
0
9
8
7
6
5
4
3
2
1
2
4
2
3
2
2
2
1
2
0
1
9
GRASSLINGRASSLIN
I
O
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
.
Servicing socket
(230 V ˜ 50 Hz)
Fuse
Control thermostat
Relay base
Time clock
Combined temperature
and pressure gauge
Thermal reset high
limit thermostat
ON / OFF switch
Manual reset high
limit thermostat
Primary circuit low
water pressure indicator
Mains power
electrical connection
(multi-pin plug)
Control panel HeatMaster 150 Jumbo
Manual reset high
limit thermostat
Burner
lockout
indicator
Combined temperature
and pressure gauge
Time clock
Control
thermostat
ON / OFF
switch
Primary circuit low
water pressure
indicator
Summer / Winter switch
High limit cutoff
indicator
Control panel HeatMaster 70 N and HeatMaster 100 N
I
O
I
O
Page 24
B
A
HeatMaster 150 Jumbo
23
USER GUIDE
Heating system pressure
From time to time you may need to top up the heating
system pressure.This pressure is indicated by the combined
temperature and pressure gauge on the boiler control
panel.
The minimum pressure when the boiler is cold should be
1 bar.The precise operating pressure required depends on
the height of the building, and your installer will have
informed you of this value at the time of installation
(see
Commissioning Section - Filling the hot water and heating circuits)
.
If the pressure falls below 1 bar, the boiler water pressure
switch will turn the boiler off until pressure is restored.
To re-pressurise, the system needs to be topped up with
water.
First, switch the boiler OFF on the on/off switch and isolate
the external electrical supply. Then remove the casing top
front panel by pulling it forward.The filling valves “A” and
“B” can now be seen. Open both valves and allow the
system to fill. When the combined temperature and
pressure gauge shows the required pressure, close both
valves. Replace the casing top front panel. Restore the
power supply and switch the boiler on.
Safety Valves
If water discharges from any of the safety valves, switch the boiler
off and call a service engineer.
B
A
HeatMaster 70 N and 100 N
B
A
HeatMaster 60 N
Page 25
24
USER GUIDE
RESETTING THE PRESSURE JET OIL OR GAS
BURNER
• HM 60 N and HM Jumbo 150
➠ the lockout indicator is situated on the burner.
• HM 70 N and 100 N
➠ the lockout indicator is situated on the burner and on the
control panel.
The red warning light indicates an operating fault.Wait five minutes
before resetting the burner.To reset :press the button located on the
burner.
If the burner does not relight, call the service engineer after ensuring
that the fault is not due to a power cut or low oil in the tank.
RESETTING THE BG 2000-S PREMIX GAS BURNER
• HM 60 N BG 2000-S/60
➠ the lockout indicator is situated on the burner.
• HM 70 N BG 2000-S/70 and HM 100 N BG 2000-S/100
➠ the lockout indicator is situated on the burner and on the
control panel.
1. Remove the burner cover.
2. Press the red button to restart the burner.
3. If the burner lights, replace the cover.
4. If the fault persists, call a service engineer.
BURNER TROUBLESHOOTING
For all burners - please refer to the relevant servicing and
troubleshooting instructions in your burner's technical manual.
Page 26
25
SERVICE RECORD
Date installed :
% CO
2 (min. load) :
% CO2 (max. load) :
Gas LPG
Oil
Model :
Serial number :
Heating system pressure setting :
❏❏
❏
Name and signature :
Flue gas T° :
Efficiency :
Gas pressure :
INSTALLATION DETAILS
Date serviced :
% CO2 (min. load) :
% CO2 (max. load) :
Gas LPG
Oil
Remarks :
❏❏
❏
Name and signature :
Flue gas T° :
Efficiency :
Gas pressure :
SERVICE RECORD
Date serviced :
% CO2 (min. load) :
% CO2 (max. load) :
Gas LPG
Oil
Remarks :
❏❏
❏
Name and signature :
Flue gas T° :
Efficiency :
Gas pressure :
Date serviced :
% CO2 (min. load) :
% CO2 (max. load) :
Gas LPG
Oil
Remarks :
❏❏
❏
Name and signature :
Flue gas T° :
Efficiency :
Gas pressure :
Date serviced :
% CO2 (min. load) :
% CO2 (max. load) :
Gas LPG
Oil
Remarks :
❏❏
❏
Name and signature :
Flue gas T° :
Efficiency :
Gas pressure :
Date serviced :
% CO
2
(min. load) :
% CO
2
(max. load) :
Gas LPG
Oil
Remarks :
❏❏
❏
Name and signature :
Flue gas T° :
Efficiency :
Gas pressure :
Page 27
26
SERVICE RECORD
Date serviced :
% CO2 (min. load) :
% CO2 (max. load) :
Gas LPG
Oil
Remarks :
❏❏
❏
Name and signature :
Flue gas T° :
Efficiency :
Gas pressure :
Date serviced :
% CO
2 (min. load) :
% CO2 (max. load) :
Gas LPG
Oil
Remarks :
❏❏
❏
Name and signature :
Flue gas T° :
Efficiency :
Gas pressure :
Date serviced :
% CO2 (min. load) :
% CO2 (max. load) :
Gas LPG
Oil
Remarks :
❏❏
❏
Name and signature :
Flue gas T° :
Efficiency :
Gas pressure :
Date serviced :
% CO2 (min. load) :
% CO2 (max. load) :
Gas LPG
Oil
Remarks :
❏❏
❏
Name and signature :
Flue gas T° :
Efficiency :
Gas pressure :
Date serviced :
% CO
2
(min. load) :
% CO2 (max. load) :
Gas LPG
Oil
Remarks :
❏❏
❏
Name and signature :
Flue gas T° :
Efficiency :
Gas pressure :
Date serviced :
% CO2 (min. load) :
% CO2 (max. load) :
Gas LPG
Oil
Remarks :
❏❏
❏
Name and signature :
Flue gas T° :
Efficiency :
Gas pressure :
Page 28
27
SERVICE RECORD
Date serviced :
% CO2 (min. load) :
% CO2 (max. load) :
Gas LPG
Oil
Remarks :
❏❏
❏
Name and signature :
Flue gas T° :
Efficiency :
Gas pressure :
Date serviced :
% CO
2 (min. load) :
% CO2 (max. load) :
Gas LPG
Oil
Remarks :
❏❏
❏
Name and signature :
Flue gas T° :
Efficiency :
Gas pressure :
Date serviced :
% CO2 (min. load) :
% CO2 (max. load) :
Gas LPG
Oil
Remarks :
❏❏
❏
Name and signature :
Flue gas T° :
Efficiency :
Gas pressure :
Date serviced :
% CO2 (min. load) :
% CO2 (max. load) :
Gas LPG
Oil
Remarks :
❏❏
❏
Name and signature :
Flue gas T° :
Efficiency :
Gas pressure :
Date serviced :
% CO
2
(min. load) :
% CO2 (max. load) :
Gas LPG
Oil
Remarks :
❏❏
❏
Name and signature :
Flue gas T° :
Efficiency :
Gas pressure :
Date serviced :
% CO2 (min. load) :
% CO2 (max. load) :
Gas LPG
Oil
Remarks :
❏❏
❏
Name and signature :
Flue gas T° :
Efficiency :
Gas pressure :
Page 29
28
SERVICE RECORD
Date serviced :
% CO2 (min. load) :
% CO2 (max. load) :
Gas LPG
Oil
Remarks :
❏❏
❏
Name and signature :
Flue gas T° :
Efficiency :
Gas pressure :
Date serviced :
% CO
2 (min. load) :
% CO2 (max. load) :
Gas LPG
Oil
Remarks :
❏❏
❏
Name and signature :
Flue gas T° :
Efficiency :
Gas pressure :
Date serviced :
% CO2 (min. load) :
% CO2 (max. load) :
Gas LPG
Oil
Remarks :
❏❏
❏
Name and signature :
Flue gas T° :
Efficiency :
Gas pressure :
Date serviced :
% CO2 (min. load) :
% CO2 (max. load) :
Gas LPG
Oil
Remarks :
❏❏
❏
Name and signature :
Flue gas T° :
Efficiency :
Gas pressure :
Date serviced :
% CO
2
(min. load) :
% CO2 (max. load) :
Gas LPG
Oil
Remarks :
❏❏
❏
Name and signature :
Flue gas T° :
Efficiency :
Gas pressure :
Date serviced :
% CO2 (min. load) :
% CO2 (max. load) :
Gas LPG
Oil
Remarks :
❏❏
❏
Name and signature :
Flue gas T° :
Efficiency :
Gas pressure :
Page 30
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MOLDAVIA
STIMEX - PRIM S.R.L.
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Z*MAJ d.o.o.
CESTA OF 49
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TUNISIE
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13/05/2003
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