Heatmaster 201 User Manual

Page 1
excellence in hot water
Installation, Operating and Servicing Instructions
HeatMaster
®
HeatMaster®201
28/09/2005 - 66402500.B
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Page 3
1
INDEX INTRODUCTION
INTRODUCTION 1
Target group 1 Symbols 1 Certification 1 General information and safety instructions 2
USER GUIDE 2
Using the boiler 2 Setting the parameters 3
DESCRIPTION 4
Operating principle 4 Packing 4 Construction features 4
TECHNICAL SPECIFICATION 6
Effective dimensions 6 General characteristics 6 Maximum operating conditions 7 Domestic hot water performances 7
HeatMaster
®
setting instructions 7
INSTALLATION 8
Boiler room 8 Chimney connections 8 Hot water connections 9 Heating connection 10 Electrical connections 10
COMMISSIONING 12
Filling the hot water and heating circuits 12
BURNER FEATURES 12
ACV BG 2000-M modulating premix gas burner 12
MAINTENANCE 14
Service intervals 14 Servicing the boiler 14 Servicing the safety devices 14 Servicing the burner 14 Draining the boiler 14
MCBA FOR SPECIALISTS: INSTALLER, SERVICE ENGINEER 15
Pilot mode 15 Safety stop (Error mode) 16 Setting the parameters 17 Entering the code 20 Information on the installation 20 Communication mode (with code) 21 Error mode 21
SPARE PARTS 22
Jackets 22 Accessories 22 Setting and electrical accessories 22 Burner 22
SERVICE RECORD 23
Installation details 23 Service notes 23
CERTIFICATION
The appliances carry the “CE” mark, in accordance with the standards in force in the various countries (European Directives 92/42/CEE “Efficiency” and 90/396/CEE “Gas Appliances”). They also carry the labels, “HR+”.
TARGET GROUP
This manual is intended for the use of:
- final users of the appliance;
- the engineer installing and starting up the appliance;
- the engineering and design department;
- the installer responsible for servicing or maintaining the appliance.
SYMBOLS
The following symbols are used in these instructions:
Essential instruction for operating the system correctly.
Risk of scalding.
Danger of electrocution.
Essential instruction for personal safety or environmental protection.
Page 4
2
INTRODUCTION
GENERAL INFORMATION AND SAFETY INSTRUCTIONS
IF YOU SMELL GAS:
- Immediately shut off the gas supply.
- Ventilate the boiler room.
- Do not use electrical appliances and do not switch anything on or off.
- Immediately notify your gas company and/or your installer.
General information
This documentation forms part of the items delivered with the appliance and must be given to the user to keep in a safe place!
This appliance must be serviced and repaired by an approved installer, in accordance with current standards in force.
ACV declines all liability for any damage caused as a result of incorrect installation or as a result of the use of components or connections that are not approved by ACV for this application.
Temperatures
This boiler is designed for central heating systems with a maximum outlet temperature of 90°C. Therefore, the central heating pipelines and the radiators must reach this temperature.
The waste-gas pipe lines must reach temperatures in excess of 100°C.
The hot water can reach temperatures in excess of 60°C.
Installation
Before installing and commissioning the boiler, first
carefully read this manual. Position the HeatMaster®according to the safety rules and standards in force. You must comply with the ventilation requirements for the room where appliances of this type are installed. All air vents must remain unobstructed at all times.
It is prohibited to modify the interior of the appliance in any way, without the manufacturer’s prior written agreement.
Service
In order to ensure the appliance operates safely and correctly, it is important to have it serviced and reconditioned every year by an installer or an approved service company.
Faults
Despite the strict quality standards imposed on its appliances by ACV during production, inspection, and transport, faults may occur. Please immediately inform your approved installer about such faults. Remember to give the fault code as it appears on the screen.
(See
also the list of faults on page 16)
Only genuine factory parts may be used as replacement parts. Please go to page 22 for a list of spare parts and their ACV reference numbers.
Note: ACV reserves the right to change the technical characteristics and specification of its products without notices.
USING THE BOILER
Starting the burner
During operation, the burner starts automatically as soon as the temperature of the boiler is below the set point and goes off when this value is reached.
Control panel
The user must not attempt to gain access to the components inside the control panel.
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. The fill valves A and B are located at the rear of the HeatMaster
®
(
see photo A and B below).
Open both valves and allow thesystem 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.
Main switch
Summer/Winter switch
Thermostat-pressure gauge
Display – MCBA controller
AB
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3
USER GUIDE
Status
SETTING THE PARAMETERS
Setting the temperature of the hot water:
(Temperature of the hot water)
- Press “
Mode
”: “
PARA
” comes up on the screen.
- Press “
Step
”: the first digit is 1 and the last two digits indicate the
current temperature setting for the hot water.
- To change this temperature, press the “
+
” or “-” keys until the temperature indicated by the last two digits is the desired temperature.
- Press “
Store
” to save the setting.
- Press “
Mode
” twice to return to Standby mode (normal operating
mode).
Enabling and disabling hot water mode:
(hot water)
- Press “
Mode
”: “
PARA
” comes up on the screen.
- Press “
Step
” twice: the first digit is 2 and the last two digits
indicate the current setting:
00
= disabled;01= enabled.
- To change this parameter, press the “+” or “-” keys until you reach the desired value:
00
= disabled;01= enabled.
- Press “
Store
” to save the setting.
- Press “
Mode
” twice to return to Standby mode (normal operating
mode).
Enabling and disabling central heating mode:
(heating)
- Press “
Mode
”: “
PARA
” comes up on the screen.
- Press “
Step
” three times: the first digit is 3 and the last two digits
indicate the current setting:
00
= disabled;01= enabled.
- To change this parameter, press the “+” or “-” keys until you reach the desired value:
00
= disabled;01= enabled.
- Press “
Store
” to save the setting.
- Press “
Mode
” twice to return to Standby mode (normal operating
mode).
Setting the temperature of the central heating:
(the maximum temperature for the heating circuit)
- Press “
Mode
”: “
PARA
” comes up on the screen.
- Press “
Step
” four times: the first digit is 4 and the last two digits
indicate the current temperature setting for the central heating.
- To change this temperature, press the “+” or “-” keys until the temperature indicated by the last two digits is the desired temperature.
- Press “
Store
” to save the setting.
- Press “
Mode
” twice to return to Standby mode (normal operating
mode).
Fault:
The temperature setting of the appliance and the safety functions of its parts are constantly monitored by a microprocessor controller (MCBA). In the event of a fault, this MCBA disables the appliance and displays an error code: the screen flashes and the first character is an “
E
followed by the fault code,
(see the list of faults on page 16).
Reset the appliance:
- Press “
Reset
” on the screen.
- If the fault code appears again, contact your installer.
Setting the temperature of the hot water
Setting the temperature of the central heating
Fault Reset the appliance
Enabling and disabling central heating mode
Enabling and disabling hot water mode
Stand by mode
1 X
Mode
1 X
Step
1 X
Store
1 X
Store
2 X
Mode
Stand
by
mode
Stand by mode
1 X
Mode
2 X
Step
1 X
Store
1 X
Store
2 X
Mode
Stand
by
mode
Stand by mode
1 X
Mode
3 X
Step
1 X
Store
1 X
Store
2 X
Mode
Stand
by
mode
Stand by mode
1 X
Mode
4 X
Step
1 X
Store
1 X
Store
2 X
Mode
Stand
by
mode
Reset1
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OPERATING PRINCIPLE
The HeatMaster®is a high performance, direct fired hot water storage heater, which has indirect heat transfer due to its Tank-in­Tank 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 heats the primary water, which indirectly heats the stainless steel tank containing the hot water. As in all Tank-in-Tank systems, the tank 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 HeatMaster
®
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®201 includes the following parts as standard:
- On/off switch
- Summer/Winter switch
- MCBA controller, including
• an electronic controller
• a low-water-level safety device
• a burner modulator
- Primary circulating shunt pump
- Primary expansion vessels
- Primary safety valve
- Pressure and temperature gauge
- Drain valve
- Body completely insulated in rigid polyurethane foam
PACKING
The HeatMaster®is delivered in 4 separate packages.
• Package No. 1: Foam-insulated body, hydraulic accessories,
and control panel.
• Package No. 2: Chimney reducing pipe.
• Package No. 3: The jacket.
• Package No. 4: The burner and its cover, the door insulation
and the sealing cord.
4
DESCRIPTION
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
The HeatMaster®201 range has 15 steel flue ways with an inside diameter of 64 mm. Each flue way has turbulators made of special stainless steel designed to improve the heat exchange and reduce the flue-gas outlet 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.
Burner
Models in the 201 range are always delivered with an ACV BG 2000-M 201 air-gas premix burner.
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5
DESCRIPTION
Thermostat-pressure gauge bulb
Flange of the burner chamber plate
Steam trap
T&P valve
(optional)
Hot water outlet
Chimney reducer
NTC 3 sensor
Cold water inlet
NTC1 and NTC2 sensor
Insulation
Low-water-level pressure switch
Heating return
Boiler drain cock
Heating outlet
Stainless steel pocket
Turbulators
“Tank-in-Tank” type storage exchanger
Primary circuit
Combustion chamber
Flue ways
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6
EFFECTIVE DIMENSIONS
The appliances delivered are factory-tested. Upon receipt, remove the packing and check that there is no damage to the appliances. Refer to the dimensions and weights listed below for transport purposes. The jacket is fitted by the installer on site
(see the assembly instructions in the wooden protective case)
.
TECHNICAL SPECIFICATION
A
G
H
E
C
D
F
506
B
Type HM 201
Fuel Natural gas/propane
Heating Hot water
Maximum Input kW 60 - 220 60 - 240
Maximum Output kW 56.4 - 200.2 56.4 - 218.4
Maintenance loss at 60°C as rated value % 0.3
Total capacity L 641
Primary circuit capacity L 241
Heating connection Ø 2”
Hot water connection Ø 2”
Chimney connection Ø mm 250
Hot water tank heat exchange surface m
2
5.30
Weight empty Kg 550
Pressure drop primary circuit mbar 240
GENERAL CHARACTERISTICS
A mm B mm C mm D mm E mm F mm G mm H mm
HeatMaster®201 2085 300 1020 1320 1020 600 1383 590
250
302
338
250
190
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7
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
DOMESTIC HOT WATER PERFORMANCES
HEATMASTER®SETTING INSTRUCTIONS
Description
The HeatMaster®201 range is equipped with an electronic controller (MCBA) which controls the burner (start-up, safety, and modulation) and allows the controller to be adapted to the selected application.
The MCBA system includes a controller with 3 levels for setting the parameters: manufacturer, installer, and user. It includes 3 temperature sensors located in the primary and secondary circuits.
There are two operating modes:
1. Heating mode
The T° is set by the user in the range 60 to 90°C.
• Differential “ON” starts the burner.
• Differential “OFF” stops the burner.
• PI controller (Proportional Integral) in “Heating” mode.
• The controller compares the primary temperature with the setting and the module.
The room thermostat detects the demand for heat.
2. Hot water mode
(with priority to the hot water)
The T° is set by the user in the range 60 to 90°C.
The sensor located in the secondary tank detects the demand for hot water. As soon as the draw-off is detected, the controller goes to “demand for hot water” mode:
• Differential “ON” starts the burner.
• Differential “OFF” stops the burner.
• PI controller (Proportional Integral) in “Hot water” mode.
• The controller compares the primary temperature with the setting and the module.
• The charging pump starts up.
• The heating circulator pump is no longer supplied.
• The burner starts and the controller controls the modulation based on the primary pump.
Parameters accessible by the user
1. “Hot water” temperature, which can be set to 20 - 90°C.
2. Hot water mode ON/OFF.
3. Heating mode: ON/OFF.
4. “Heating” temperature, which can be set to 60 - 90°C.
Parameters accessible for “service”
Main basic characteristics:
- Hot water priority active.
- Demand for heat detected by the room thermostat.
- Only one heating circuit.
An access code is required to access “Service” parameters.
Please see pages 17 to 19 for further details.
HM 201
Peak delivery at 40°C L/10’ 1745
Peak delivery at 45°C L/10’ 1489
Peak delivery at 60°C L/10’ 971
Peak delivery at 70°C L/10’ 763
Peak delivery at 80°C L/10’ 586
Peak delivery at 40°C L/60’ 6690
Peak delivery at 45°C L/60’ 5667
Peak delivery at 60°C L/60’ 3534
Peak delivery at 70°C L/60’ 2554
Peak delivery at 80°C L/60’ 1723
Continuous delivery at 40°C L/h 6117
Continuous delivery at 45°C L/h 5039
Continuous delivery at 60°C L/h 2914
Continuous delivery at 70°C L/h 2128
Continuous delivery at 80°C L/h 1468
N.B.:
The outputs above are given for a hot water temperature of 90°C and a cold water temperature of 10°C.
Page 10
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 350 mm
Ventilation
The boiler room must have both low- and high-level ventilation, in accordance with the local standards and provisions force.
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.
The duct size may not be smaller than the boiler outlet duct.
Typical boiler connection: 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.
INSTALLATION
Ventilation 201
Min. fresh air requirement m3/h 436
Bottom dm
2
2.45
To p dm
2
7.30
Chimney / minimum flue diameter 201
E = 5 m Ø F min. mm 350
E = 10 m Ø F min. mm 300
E = 15 m Ø F min. mm 270
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.
Connecting the boiler to an air vent type: C
• C53: parallel connection
total loss of pressure (air intake + flue-gas discharge) may not exceed 250 Pa. See the table below showing the pressure drops for the various components.
A condensation drain outlet must be fitted close to the boiler to prevent condensation products from 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.
A. Top vent B. Bottom vent C. Draught regulator D. Inspection window E. Height of lined chimney F. Chimney diameter
Air Flue gas
Ø 100 mm Ø 250 mm
Pipe, L. 1000mm 18.0 1.0
90° bend 70.0 3.0
45° bend 28.0 -
Condensates trap - 5.0
Terminal 50.0 3.0
When connecting the flue gas outlet to an existing chimney, do not take into account the pressure drop on the “flue gas side”.
F
C53
E
A
A
C53
D
B23
C
B
A
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9
INSTALLATION
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)
DANGER! As a safety measure, we strongly advise installing a thermostatic mixer to prevent the risk of burns.
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.
12
6
2
3
7
4
8
10
11
5
9
Page 12
10
ELECTRICAL CONNECTIONS
Electrical supply
The boiler operates on a single-phase supply of 230V/50Hz. You should install a control box with a double-pole switch and a 6 A fuse or a 6A circuit breaker externally to the boiler to allow the boiler to be isolated from the power supply for servicing and repairs.
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.
HeatMaster®201 wiring diagram key
01. Main switch
02. Module AM3-11
03. Module AM3-2
04. MCBA
05. 24V transformer
06. Display
07. Room thermostat
(optional)
08. Low-water-level safety device
09. NTC1 primary temperature sensor
10. NTC2 primary temperature sensor
11. NTC3 hot water temperature sensor
12. NTC4 outdoor sensor
(optional)
13. Summer/Winter switch
14. NTC6 heating outlet sensor
(optional)
15. Heating circulator pump
(not supplied)
16. Heating circulator pump
(not supplied)
for use with 4-way power-
operated valve
17. Charging pump
18. Charging pump
19. Charging pump Booster
20. 4-way power-operated valve
21. Alarm switch
22. Outside gas valve/burner operation switch
23. Hot water mode operating switch
24. Fan (BG 2000-M / 201)
25. Gas valve (BG 2000-M / 201)
26. Gas pressure switch (BG 2000-M / 201)
(optional)
27. Charging circulator pump control relay
Note: The switches have zero voltage.
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.
WARNING The power supply to the heating pump for the MCBA is limited to 250W. In the event of a higher wattage, provide a relay between the pump and the MCBA.
Expansion
The HeatMaster®201 models are equipped with 4 8-litre expansion vessels. These expansion vessels are sized for hot water operation 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
expansion vessels)
.
Example of a single circuit connection
1. 4-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. MCBA controller, module AM3-11
9. Surface-mounted sensor
(optional)
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.
WARNING In the case of heating at low temperature, the use of the kit
(code: 10800099)
is required.
8
1
4
9
7
423
5
6
Page 13
11
INSTALLATION
HeatMaster
®
201 wiring
B. Blue
Br. Brown
Bk. Black
Or. Orange
G. Grey
R. Red
W. White
Y. Ye l l o w
V. Violet
2
X1.1
X1.2
X2.1
X2.2
X3.1
AM3 - 11
X3.2
X1.1
2
14 x 0,25mm
X7 X7
X1.2
X2.1
X2.2
3
X3.1
AM3 - 2
X3.2
X3
010203
V
X2.8
X7
X1.1
X1.2
9
14
8
7
t
040605
G
X2.10
4
X1.3
X1.4
10
P
X2.9
MCBA
X1.5
11
0708091011121314151617
Bl
Or
Br
R
X3.1
X3.2
X3.3
X3.5
X10
X1.6
12
BUS B
BUS A
O Volt
6
18
19
Bl
2
13
G
Bk
V
BrBlW
Bk
Or
Bk
X3.4
X5.4
X5.3
X4.3
X2.1
X2.4
X2.3
X2.2
X2.11
X2.5
X4.2
X5.1
X5.2
X7
X2.6
X2.12
14 x 0,25mm
2 x 2 fils
5
5
1
X1
Bk
Bk
Bl Bl
Br
Bl
010203
L
BkBrBl
R
V
Or
WG
Bl
Bl
Bk
V
W
R
Or
V
G
Bk
W
Or Or
Bl
04
03
R
Bl
M
M1MM2
15
R
Bl
Bk
Bl
1
3
27
2
4
V
Bl
G
Bl
10
08
Y/Gr
09
R
Bl
M
M3MM4
17
11
12
Y/Gr
07
05
06
R
Bl
Y/Gr
16
W
Bl
Bk
5
13
A1A2
6
14
W
Bl
W
Bl
13
14
15
R
Bl
Y/Gr
18
Bl
W
Bl
17
18
16
R
Bl
M
M5
Y/Gr
19
R
W
V
Bk
Bl
02
01
X2
N
W
Bk
W
R
R
WW
BlRRWBkGV
2120221923
24
25
Y/Gr
21
N
M
M6
Or
Or
V
G
Bk
BlWVRBk
Or
N
L1
T1
T2
S3
X4
28
27
26
3 x 0,75
22
23
2132154
321
BG 2000-M/201
24
B4
4 x 0,75
54321
20
Br
Bl
G
Or
T6T7T8
B5
X5
Br
Bl
2 x 0,75
P
25
26
Page 14
12
COMMISSIONING
FILLING THE HOT WATER AND HEATING CIRCUITS
IMPORTANT Hot water tank must be pressurised before the heating circuit is filled.
1. Close the primary circuit filling valves (A and B)
2. Open the stop valve (1) and the draw-off tap (8). Fill the tank
with the water from the tap; close the draw-off tap (8).
3. Fill the primary (heating) circuit by opening the valves (A and B)
and pressurising to 1 bar.
ACV BG 2000-M MODULATING PREMIX GAS BURNER
Description and operating method:
The BG 2000-M modulating burner's output is constantly adjusted to suit the fluctuating demand for heat, thus optimising operating efficiency. The gas tube is covered with a metal fibre (NIT), which, in addition to its outstanding heat-exchange properties, increases its life.
The main parts are a venturi and a valve, a unit developed specially by Honeywell for low NOx air/gas premix burners with automatic ignition and flame detection by ionisation. 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 blockage in the chimney 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-M burner on the HeatMaster
®
201 is controlled by an MCBA controller (Honeywell), which controls the safety of operation of the burner and its modulation according to the temperature.
The BG 2000-M burners are factory-set for natural gas.
Air/gas mixture control system
Air
Venturi Fan
Air/gas mixture
Gas flow adjuster
screw
Offset adjuster
screw
Gas
BURNER FEATURES
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 = 10 m and 2 bar = 15 m.
6. Check that the electrical connection and boiler room ventilation conform to the relevant standards.
7. Switch the on/off switch to the ON position.
8. Set the temperature values
(see page 17)
.
9. Check the gas supply pressure
(see page 13)
.
10. When the burner is on, check that the flue gas discharge pipes are completely gas tight.
11. After operating for five minutes, turn off the boiler and drain the heating circuit again, maintaining a pressure of 1 bar.
12. Turn the appliance back on and check the combustion
(see
page 13)
.
AB
6
12
2
3
7
4
5
8
10
11
9
Page 15
BE FR AT DK ES UK IT PT IE SE NL LU DE
I 2Er X
I 2E(R)B x
I 2H XXXXXXXX
I 3P XX XX XX
I 2L X
I 2ELL X
I 2E X
13
BURNER FEATURES
201 gas burner characteristics
Gas category
Type Heating Hot water
Input Kw 60 - 220 60 - 240
Nominal output Kw 56.4 - 200.2 56.4 - 218.4
Combustion efficiency - natural gas % 96.6 - 91.5 96.6 - 91.5
Natural gas CO2 % 99
Pressure loss of the flue-gas circuit mbar 2.4 2.9
Net T° of combusted gases °C 180 190
Mass flow rate of combustion products g/sec. 110.3 120.3
Gas G20 - 20 mbar -
I 2E(R)B - I 2 Er - I 2H - I 2E - I 2ELL
Flow m3/h 6.35 - 23.28 6.35 - 25.40
Gas G25 - 20 mbar -
I 2ELL /
25 mbar -
I 2L
Flow m3/h 7.38 - 27.08 7.38 - 29.54
Gas G31 - 30/37/50 mbar -
I 3P
Flow m3/h 2.45 - 9.00 2.45 - 9.81
CO2 % 11.0 - 11.2 11.0 - 11.2
BG 2000-M/201
Tube
Gas valve
Ignition electrode
Ø 5/4” gas supply flange
Flame inspection window
Fan
Venturi
Burner adjustment (Prohibited in Belgium).
With the burner operating at full power, the CO
2 must be in the
range 8.8 to 9.2 % (natural gas) or 10.5 to 10.6 % (propane).
If necessary, adjust the CO
2 by
turning the screw clockwise to reduce it and counter-clockwise to increase it.
(see photo
opposite)
.
Increase
Reduce
Page 16
14
Draining the boiler’s primary circuit
1. Put the main switch on the control panel to OFF, cut the outside power supply and close the gas-supply valve to the boiler.
2. Close the isolating valves (4) or manually set the 4-way valve (1) to “0”.
3. Connect a flexible tube to the drain cock (7). Make sure it is properly connected.
4. Open the drain cock and allow the hot water to flow into the drain.
Drain the hot water circuit.
1. Put the main switch on the control panel to OFF, cut the outside power supply and close the gas-supply valve to the boiler.
2. Release the pressure in the heating circuit until the pressure gauge reads zero.
3. Close the cocks (1 and 8).
4. Open valve (9) and then (10).
5. Allow the hot water to flow into the drain.
The drain cock (9) must be at ground level for the circuit to drain fully.
MAINTENANCE
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.
Vertical flue-gas outlet reducer
3. Take down and remove the flue lining to release the top of the boiler.
4. Loosen the nuts and remove the chimney reducer.
5. Take out the turbulators from the flue ways to clean them.
6. Dismantle the chamber plate and remove the burner.
7. Brush the flue ways.
8. Clean the combustion chamber and the burner.
9. Replace the turbulators, the chimney reducer, and the flue lining; check that the seal on the chimney reducer is in good condition. Replace the seal if necessary.
Horizontal flue-gas outlet reducer
3. Loosen the nuts and remove the chimney reduction.
5. Take out the turbulators from the flue ways to clean them.
6. Dismantle the chamber plate and remove the burner.
7. Brush the flue ways.
8. Clean the combustion chamber and the burner.
9. Replace the turbulators, the chimney reducer, and the flue lining; check that the seal between the chimney reducer and the chimney is in good condition. Replace the seal if necessary.
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
- Check that the insulation and the seal on the chamber plate are in
good condition; replace them if necessary.
- Check and clean the burner and the electrodes. Replace the
electrodes if necessary
(1 x per year in normal usage conditions)
- Check that the safety devices are in good working order.
- Check the combustion
(CO2, CO, and gas pressure)
and record the
values and any other comments on page 23 of the service record.
DRAINING THE BOILER
Water flowing out of the drain cock may be extremely hot and could cause severe scalding. Keep people away from discharges of hot water.
8
5
1
7
4
9
423
6
6
12
2
3
7
4
8
10
11
5
9
Page 17
15
MCBA FOR SPECIALISTS:
INSTALLER, SERVICE ENGINEER
PILOT MODE
Pilot mode
After you power down the appliance the screen displays Pilot mode, as shown in the figure above.
This is the standard MCBA mode. The MCBA automatically returns to this mode after 20 minutes if no keys have been pressed on the screen. Any parameters that were modified are then enabled.
The first character shows the current status of the boiler depending on the condition of both the boiler and the burner. The last 2 characters indicate the start temperature.
If the burner is blocked for one of the reasons mentioned above, the screen display alternates between a 9 followed by the temperature (two last digits) and b with the error code.
Pilot, no demand for heat
Fan first, fan after
Ignition
Operation of the boiler burner for the heating
Operation of the boiler burner for the domestic hot water
Air pressure limit or obtaining the number of start revolutions.
The burner goes out when the specified value is reached. A demand for heat is present nonetheless.
Pump over-run time after the demand for domestic hot water
Pump over-run time after the demand for central heating
Burner blocked:
:T1 > 95°C
:T2 > 95°C
: T2 - T1 > 10.20 or 40°C after a time of xx
: dT1/dt > maximum gradient T1
: water pressure switch not off
: no fan signal
: erroneous fan signal
: T1 - T2 > max Delta
• : NTC3 short-circuit
• : NTC3 interrupt
: wait for the fan to start
Status Boiler function
Internal check — three-way valve
Boiler burner in hot water ready function
Test function: Central heating high power
Test function: Central heating low power
Test function: Boiler with fixed number of revolutions
Status Boiler function
Once the cause of the blockage has been resolved, the burner starts automatically within 150 seconds at most.
Page 18
16
MCBA FOR SPECIALISTS: INSTALLER, SERVICE ENGINEER
SAFETY STOP (ERROR MODE)
If a fault occurs while the appliance is running, the system locks and the screen starts to flash. The first character is an E and the next two characters give the code for this fault, as illustratedin the table below.
Table of error codes and how to resolve them
To unlock the system:
• Press RESET on the screen.
• Contact your installer if the fault happens again.
Codes Description of the fault Resolution of the fault
Abnormal flame signal
- Check the wiring
(short-circuit in the 24V wiring)
- Check the electrode/ replace the MCBA
(water damage).
No flame signal after five attempts at firing the boiler
- Check the ignition cable, the electrode and the position of the electrode.
- Check that there is gas at the burner.
Persistent lock - Press RESET
EPROM error
-If the problem persists after two RESET attempts, replace the MCBA.
Max input, thermostat open or 24V fuse gone.
- Check the wiring and check the 24V fuse on the MCBA.
Internal error
- If the problem persists after two RESET attempts,
replace the MCBA.
T1 > 110°C
- Check the NTC wiring and replace if necessary.
T2 > 110°C - Check the NTC wiring and replace if necessary.
T1 gradient too high
- Check that the pump is turning. If there is
no problem with the pump, drain the system.
No fan signal present
- If the fan is working:
• Check the fan control connection and the fan wiring
• if the problem persists after 2 RESET attempts, replace the
fan
• if the problem persists, replace the MCBA.
- If the fan is not working:
• Check that the fan 230V connection. If the problem persists,
replace the fan.
NTC 1 short-circuit
- Check the connection and the NTC1 wiring
If the problem persists, replace the NTC1.
NTC 2 short-circuit
- Check the connection and the NTC2 wiring
If the problem persists, replace the NTC2.
NTC 3 short-circuit
- Check the connection and the NTC3 wiring
If the problem persists, replace the NTC3.
NTC 1 connection open
- Check the connection and the NTC1 wiring
If the problem persists, replace the NTC1.
NTC 2 connection open
- Check the connection and the NTC2 wiring
If the problem persists, replace the NTC2.
NTC 3 connection open
- Check the connection and the NTC3 wiring
If the problem persists, replace the NTC3.
Internal error
- If the problem persists after two RESET attempts,
replace the MCBA.
Error while reading the parameters Press RESET. If the error persists, replace the MCBA.
Problem with the power supply to the fan
Check the MCBA power supply voltage. If it is OK, replace the fan.
To
Page 19
17
MCBA FOR SPECIALISTS:
INSTALLER, SERVICE ENGINEER
SETTING THE PARAMETERS
Parameter mode
To access Parameter mode when the system is in Pilot mode, press MODE once.
To scroll through the list of parameters, simply press “step”.To modify a parameter value, use the + or - keys. Then press “Store” to save the value you just changed. The screen flashes once to confirm the data has been saved.
To activate the parameters you changed, press “Mode” once more (which brings you into Info mode). However, if you do not press a key, the system returns to Pilot mode after 20 minutes and automatically enables the changes.
MODE
Adjusting the hot water temperature
STEP
STEP
STEP
STEP
Minimum central heating temperature when using an outdoor sensor
STEP
Minimum outdoor temperature (adjust the heating curve)
STEP
Maximum outdoor temperature (adjust the heating curve)
STEP
Frost protection temperature
STEP
Correction based on the outdoor temperature
STEP
Blockage T 0 = Disabled
90
01
01
90
60
0
20
- 15
00
00
STEP
Key Display Description of parameters Factory setting
Key Screen Description of parameters Factory setting
Key Display
Parameters for the specialist: only accessible by using the Code
Booster 00 = Stop (minute)
STEP
00
Production of hot water
00 = Stop 01 = Start 02 = Stop + pump continuously on 03 = Start + pump continuously on
Turn on/Turn off the heating
00 = Stop 01 = Start 02 = Stop + pump continuously on 03 = Start + pump continuously on
Maximum temperature in Central Heating mode
Page 20
18
MCBA FOR SPECIALISTS: INSTALLER, SERVICE ENGINEER
Night-time heating temperature reduction (°C)
STEP
Fan speed in heating mode (rpm x 100)
STEP
10
52
Key Display Description of the parameters Factory setting
Max. fan speed in heating mode (rpm x 100)
STEP
00
Max fan speed in hot water mode (rpm x 100)
STEP
57
Max. fan speed in hot water mode (rpm x 100)
STEP
00
Min. fan speed (rpm x 100)
STEP
15
Min. fan speed (rpm x 100)
STEP
00
Fan speed at ignition (rpm x 100)
STEP
37
Heating pump time delay 0 = 10 sec (minute) 00
STEP
Hot water pump time delay 10.2 = 10 sec (minute) 16
00
01
01
03
STEP
Burner interlock hysteresis (heating)
STEP
Burner trigger hysteresis (heating)
STEP
Burner interlock hysteresis (hot water)
STEP
Burner trigger hysteresis (hot water)
STEP
04Hot water mode interlock hysteresis
STEP
Hot water mode trigger hysteresis
STEP
01
Page 21
19
MCBA FOR SPECIALISTS:
INSTALLER, SERVICE ENGINEER
Heating lock time (sec x 10.2)
STEP
Hot water lock time (sec x 10.2)
STEP
Lock time to switch from hot water mode to heating mode (sec x
10.2)
STEP
Difference T1 - T2 for modulation
STEP
BUS address (-1 = disabled)
STEP
Increase the primary temperature value to generate hot water (relative to the hot water temperature)
STEP
1st digit: heating circuit (AM3-11 – 4-way valve) 0 = disabled 5 = enabled
2nd digit: the demand for heat comes from: 0 = room thermostat
STEP
00
00
00
05
- 01
05
00
Key Display Description of the parameters Factory setting
1st digit: Hot water circulator pump (= 1)
2nd digit: tank with NTC3 sensor (= 2)
STEP
Manual fan speed (- 01 = modulation)
12
- 01
11
00
60
30
01
00
STEP
1st digit: PWM pump operating speed
2nd digit: PWM pump speed during time-delay
STEP
Holding temperature
STEP
Maximum temperature for the heating circuit outlet (AM3-11 – 4-way valve)
STEP
Minimum temperature for the heating circuit outlet (AM3-11 – 4-way valve)
STEP
Hysteresis of the heating circuit outlet temperature (AM3-11 – 4-way valve)
STEP
1st digit: Special pump (0 = disabled)
2nd digit: Minimum disable cycle (0 = disabled)
STEP
Page 22
20
MCBA FOR SPECIALISTS: INSTALLER, SERVICE ENGINEER
INFORMATION ON THE INSTALLATION
Info mode
To switch from Pilot mode to Info mode, press “Mode” twice.
ENTERING THE CODE
Code mode
You can access the following parameters by entering the service code:
• Parameters 5 - 42
• Communication mode
• Fan Speed mode
• ERROR mode
MODE
MODE
Start temperature T1 in °C
STEP
Return temperature T2 in °C
STEP
Hot water temperature T3 in °C
STEP
Outdoor temperature T4 in °C
STEP
Not used
STEP
Start temperature calculated in °C
STEP
Rate of increase in the start temperature in °C/s
STEP
Rate of increase in the return temperature in °C/s
STEP
Rate of increase in the hot water temperature in °C/s
STEP
Heating circuit outlet temperature (AM3-11 – 4-way valve)
STEP
Press “STEP” until the system displays the information you need. The point located behind the first position flashes to indicate that the boiler is in “INFO” mode.
Key Display Description of parameters
Key Display
STEP
STORE
MODE STEP
+
or
-
Press “STEP” once and the system displays “C”
in position 1, followed by arbitrary
characters in positions 3 and 4.
Press “STORE”, the screen flashes
briefly to indicate that the code has been accepted.
Press “MODE” until
the system displays the correct mode.
Press “+” or “-” to change the code.
Only ACX authorised installers know the access code.
For further information, please contact our after-sales department.
To access Code mode, press
MODE and STEP simultaneously
(only from Pilot mode!).
Page 23
21
MCBA FOR SPECIALISTS:
INSTALLER, SERVICE ENGINEER
COMMUNICATION MODE (WITH CODE)
When in this mode, the system displays the communication between the boiler and the control module, the optional interface kit or the optional programmable room thermostat.
FAN MODE (WITH CODE)
ERROR MODE (WITH CODE)
ERROR” mode indicates the most recent error, as well as the status of the boiler and its readings at the time this error occurred.
Fan speed
MODE
The current fan speed is 5,500 rpm.
STEP
Key Display Description of parameters
MODE
Code mode
(See the table on page 16 for a full list)
STEP
Status of the boiler at the time of the error
(See the table on page 16)
STEP
Start temperature T1 at the time of the error
MODE
Return temperature T2 at the time of the error
STEP
Hot water temperature T3 at the time of the error
STEP
Outdoor temperature T4 at the time of the error
STEP
Key Display
Key Display Description of parameters
MODE
No communication
Communication between the boiler module and the optional control modules only (RMCI)
STEP
Communication between all the devices connected
Key Display
Key Display Description of parameters
Temp. °C R Temp. °C R
-20 98200 40 6650
-15 75900 45 5520
-10 58800 50 4610
-5 45900 55 3860 0 36100 60 3250 5 28600 65 2750
10 22800 70 2340 15 18300 75 1940 20 14700 80 1710 25 12000 85 1470 30 9800 90 1260 35 8050 95 1100
100 950
Temperature sensor resistance tables
Page 24
22
SPARE PARTS
No. Jackets Codes HeatMaster®201
A01 Right side 21471415 A02 Left side 21471415 A03 Right side rear corner 21478415 A04 Left side rear corner 21473415 A05 Rear panel 21474415 A06 Right side front corner 21472415 A07 Left front side 21479415 A08 Upper front panel 2147A415 A09 Lower front panel 2147B415 A10 Burner cover 21476415 A11 Rear top cover 21475415 A12 Front top cover 21475416 A13 Rear half-base 2147S415 A14 Unequipped control panel 21477416 A15 Body + accessories (package No. 1) 27300047
No. Accessories
B01 Low-water-level pressure switch 557D3011 B02 Wilo circulator pump 557A4007 B03 3 bar / Ø 3/4” - 1” safety valve 557A1048 B04 Burner chamber insulating cover 51700041 B05 8-l expansion vessel 55301200 B06 Steam trap, Ø 1/2” 557A3001 B07 Drain cock, Ø 3/4” 557A1000 B08 Fill set, Ø 1/2” 55426018 B09 Type A, high-level turbulators 507F2009 B10 Type B, low-level turbulators 507F2010
No. Setting and electrical accessories
C01 MCBA 537D8016 C02 Transformer 547D3021 C03 NTC Duplo (NTC1 - NTC2) 5476G002 C04 NTC Single (NTC3) 5476G003 C05 Module AM3-11 10800080 C06 Module AM3-2 10800060 C07 Full control panel 24614133 C08 Display 537D3020 C09 Display case 537D3023 C10 Pressure gauge-thermometer 54441008 C11 ON/OFF switch 54766016 C12 Summer/Winter switch 54766017 C13 Control panel self-adhesive 617G0105
No. Burner
D01 Full burner 237D0118 D02 Fan 537D3034 D03 Venturi 537D4042 D04 110 x 3.5mm O-ring 557A0045 D05 Plate fan seal 557A0040 D06 Burner chamber plate seal 557A0020 D07 Ø 98mm burner tube + NIT 537DZ019 D08 Chamber plate sealing cord 51700025 D09 Ignition electrode 537DZ020 D10 Ignition cable 25760046 D11 Burner chamber plate insulating stone 51700040 D12 Burner chamber plate 2147P416 D13 Gas valve 537D4041 D14 Valve flange 537D8021
Page 25
23
SERVICE RECORD
Service date:
% CO2
(min. load)
:
% CO2
(max. load)
:
Gas
Propane
Model:
Serial number:
Heating system pressure setting:
Name and signature:
Flue gas T°:
Efficiency:
Gas pressure:
INSTALLATION DETAILS
Service date:
% CO2
(min. load)
:
% CO2
(max. load)
:
Gas
Propane
Comments:
Name and signature:
Flue gas T°:
Efficiency:
Gas pressure:
SERVICE NOTES
Service date:
% CO2
(min. load)
:
% CO2
(max. load)
:
Gas
Propane
Comments:
Name and signature:
Flue gas T°:
Efficiency:
Gas pressure:
Service date:
% CO2
(min. load)
:
% CO2
(max. load)
:
Gas
Propane
Comments:
Name and signature:
Flue gas T°:
Efficiency:
Gas pressure:
Service date:
% CO2
(min. load)
:
% CO2
(max. load)
:
Gas
Propane
Comments:
Name and signature:
Flue gas T°:
Efficiency:
Gas pressure:
Service date:
% CO2
(min. load)
:
% CO2
(max. load)
:
Gas
Propane
Comments:
Name and signature:
Flue gas T°:
Efficiency:
Gas pressure:
Page 26
24
SERVICE RECORD
Service date:
% CO2
(min. load)
:
% CO2
(max. load)
:
Gas
Propane
Comments:
Name and signature:
Flue gas T°:
Efficiency:
Gas pressure:
Service date:
% CO2
(min. load)
:
% CO2
(max. load)
:
Gas
Propane
Comments:
Name and signature:
Flue gas T°:
Efficiency:
Gas pressure:
Service date:
% CO2
(min. load)
:
% CO2
(max. load)
:
Gas
Propane
Comments:
Name and signature:
Flue gas T°:
Efficiency:
Gas pressure:
Service date:
% CO2
(min. load)
:
% CO2
(max. load)
:
Gas
Propane
Comments:
Name and signature:
Flue gas T°:
Efficiency:
Gas pressure:
Service date:
% CO2
(min. load)
:
% CO2
(max. load)
:
Gas
Propane
Comments:
Name and signature:
Flue gas T°:
Efficiency:
Gas pressure:
Service date:
% CO2
(min. load)
:
% CO2
(max. load)
:
Gas
Propane
Comments:
Name and signature:
Flue gas T°:
Efficiency:
Gas pressure:
Page 27
Page 28
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