Heatmaster 35 TC Installation, Operating And Servicing Instructions

EN • 1

ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH

664Y2800

Installation, Operating and

Servicing Instructions

EN • 2

ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH

664Y2800

WARINGS 3

Who should read these instructions 3
Symbols 3
Recommendations 3
Applicable standards 3
Warnings 3

INTRODUCTION 4

Description of the specifications 6
Production of hot water 6
Frost protection 6

USERS GUIDE 7

Direction for use 7
Settings parameters 7

TECHNICAL CHARACTERISTICS 8

Natural gas categories 9
Propane categories 9
Domestic hot water features 9

ELECTRICAL CONNECTION 10

Wiring diagram : HeatMaster® 35 TC 10

INSTALLATION INSTRUCTIONS 11

Dimensions 11
Boiler room 11

INSTALLATION 12

Connection to the chimney 12
Connection to the gas 13
Domestic hot water connection 13
Heating connections 14
Installation of a single high temperature circuit with room thermostat ACV 15 control 15
Installation of a weather depending heating circuit high or low temperature 16
Installation of two heating circuit controlled by control unit and ZMC-1 module 18

COMMISSIONING AND MAINTENANCE 20

Commissioning the system 20
Inspection and maitenance 20
Disassembling the burner 21
Disassembling and checking the electrode 21
Cleaning the heat exchanger 21
Temperature sensor resistance tables 21

MCBA PARAMETERS FOR THE SPECIALIST 22

Standby mode 22
Setting the MCBA parameters 23
Request for information on the installation 24
Entering the code 24
MCBA parameters with code restricted access 25
Communication mode 28
Error mode 28
Safety stop [error mode] 29

SPARE PARTS see at the end of this manual

INDEX

EN • 3

ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH

664Y2800

WHO SHOULD READ THESE INSTRUCTIONS

These instructions should be read by:

- the specifying engineer

- the installer

- the user

- the service engineer

SYMBOLS

The following symbols are used in this manual:

• The parts may only be replaced by genuine factory parts. You
will find a list of the spare parts and their reference number
ACV to the end of this document.

• The burners are preset in our factory for use with natural
gas

[equivalent to G20].

• An ajustement of the CO2 is not allowed in Belgium I 2E(s)B.

• It is important to switch the boiler off before carrying out
any work.

• There are no user accessible parts inside the boiler casing.

APPLICABLE STANDARDS

The appliances carry the CE mark in accordance with the
standards in force in the various countries (European Directives
92/42/EC “Efficiency”, 90/396/EC “Gas appliances”). They
also carry the “HR-TOP” label (Gas condensation boilers).

WARNINGS

IF YOU SMELL GAS:

- Immediately shut off the gas intake.

- Open windows for fresh air flowing.

- Do not use any electrical appliances and do not actuate any

switches.

- Immediately notify your gas supplier and/or your installer.

This documentation is part of the information delivered with the
appliance and must be given to the user and stored in a safe
place!

An approved installer must carry out the assembly, commissioning,
maintenance and repair of the system, in accordance with current
standards in force.

ACV shall not accept any responsibility for damage caused by
noncompliantlocation of the system or by use of the parts or
connections not approved by ACV for this application.

The manufacturer reserves the right to change the

technical characteristics and specification of its
products without notice.

The availability of some versions and their accessories

is market dependant.

WARNINGS

RECOMMENDATIONS

• Please, read carefully this manual before installing and
commissioning the boiler.

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

• The product must be installed and serviced by trained
engineers, in compliance with current standards.

• Any failure to follow instructions relating to tests and test
procedures may result in personal injury or risks of pollution.

• To guarantee safe and correct operation of the appliance, it
is important to have it serviced and maintained every year by
an approved installer or maintenance company.

• In case of anomaly, please call your service engineer.

• Despite the strict quality standards imposed by ACV during
the manufacture, inspection and transport of its appliances,
you might notice some errors. Please report immediately any
fault to your approved installer. Remember to note the fault
code displayed on the screen.

Danger of burns

Essential instruction for
the safety of persons
and the environment.

Danger of electrocution.

Essential instruction for
the correct operation of
the installation.

EN • 4

ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH

664Y2800

The HeatMaster® 35 TC combines the
unique ACV Tank-in-Tank concept with
a dual primary circuit resulting in
exceptional performance from a totally
condensing combination boiler.

Tank-in-Tank technology

ACV’s advanced implementation of thermal storage technology is
tried and tested and is remarkably simple, efficient and reliable.
At the heart of the HeatMaster® TC is a stainless steel tank
through which the flue tubes pass.
This is surrounded by a mild steel shell containing the primary
water, which extends down to the combustion chamber and even
around the flue tubes. The burner fires onto the primary water
which indirectly heats the stainless steel tank containing the hot
water. As with all Tank-in-Tanks, this is corrugated over its full
height and is suspended in the HeatMaster® TC by its hot and
cold water connections.
The area of the heat transfer surface is therefore much greater
than that of standard direct fired water heaters. A much larger
heat transfer surface means that Tank-in-Tank units recover much
faster than any other kind of hot water storage device - and keeps
boiler cycling to a minimum. The high storage temperature within
the inner tank also results in exceptional hot water outputs.

Dual primary circuit technology

The HeatMaster® TC primary circuit is split into two sections - a
high temperature upper circuit and a low temperature lower circuit,
divided by a separation plate. The hot water storage tank is located
in the upper circuit which always operates at a temperature of
between 60°C and 90°C. This is ideal for hot water production as
it maintains the stored water at constantly high temperatures,
eliminating bacterial formation such as Legionellae, as well as
resulting in high volume hot water production.
The down-firing flue tubes pass through the upper circuit, through
the separation plate and into the lower circuit. The primary water
here operates at a temperature typically between 30°C and 60°C
for heating (dependent on the heating return temperature), perfect
for condensing when working in heating mode.

Dual coil technology

During hot water mode, the bottom circuit operates at a much
lower temperature, typically 5°C to 20°C depending on the cold
water inlet temperature. The incoming cold water enters the
lower primary circuit via a dual stainless steel coil which preheats
the domestic water prior to it passing into the stainless steel tank
located in the upper circuit. As the coil is wrapped around the
lower flue tubes of the combustion chamber, it is able to absorb
the remaining heat from the flue gases. The result is that during
hot water mode the HeatMaster® TC totally condenses whether
on full or part-load.

INTRODUCTION

Heating

The heating return
enters the lower circuit
of the boiler, which allows
the boiler to operate
in condensing mode.
The upper circuit of the

HeatMaster® TC is kept

at a consistently high
temperature due to the
internal shunt pump which
ensures that the primary
water circulates around
the heat exchanger flue
tubes.

Heating and hot water

Once up to temperature,
the HeatMaster® TC is
capable of producing
heating and hot water
simultaneously.

Hot water

With the upper circuit
maintained at high
temperature, the

HeatMaster® TC is always

ready to supply hot water
on demand. The cold
water enters through
the dual coil at the base
of the heat exchanger
and is pre-heated before
entering the hot water
tank. The low temperature
of the bottom circuit
results in continuous
condensation of the flue
gases in hot water mode.

Operating modes

In both heating and hot water modes, the premix
gas burner fully modulates the power to match
the system demand.

1

3

2

EN • 5

ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH

664Y2800

INTRODUCTION

Separation plate

Drain cock

Stainless steel
Tank-in-Tank
hot water store

Stainless steel
cold water inlet coil

Boiler shunt pump

Stainless steel
heat exchanger

Control panel

Flue connection
concentric 80/125
convertible to parallel connection 80/80

BG 2000 premix gas burner

Heating flow

Hot water outlet

Condenstrap

Heating return

Combustion chamber

Connection frame

(optional)

Gas connection

Cold water inlet

Primary heating circuit

EN • 6

ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH

664Y2800

DESCRIPTION OF THE SPECIFICATIONS

The HeatMaster® TC is an hot water producer combined in
a condensing boiler in accordance to the Belgium "HR-Top"
standard. The boiler is certified compliant with "CE" standards as
a connected appliance C13(x), C33(x), C43(x), C53, C83(x), but it
can also be connected as an open appliance in category B23.

Lining

The boiler is protected by a steel lining that first of all undergoes a
degreasing and phosphation process before being lacquered and
heated at 220°C. The inside of this lining is coated with a layer of
thermal and acoustic insulation, reducing losses to a minimum.

Heat exchanger

The core of the HeatMaster® TC features a new stainless steel
heat exchanger. This piece of technology represents the fruit of
exhaustive research and intensive laboratory testing. It reflects
ACV’s eighty years of experience in using stainless steel for
heating and hot water functions. The particular geometry of the
exchanger pipes is calculated to obtain a very large Reynolds
number throughout its cycles.
The HeatMaster® TC achieves an exceptional output that remains
stable throughout the boiler’s life, given that it causes no oxidation
on the exchanger, which is manufactured entirely from quality
steel.

Burner

ACV uses its BG 2000-M burner for the HeatMaster® TC: this
is an air/gas premix burner providing safe and silent operation
while limiting emissions (NOx and CO) to an incredibly low level.
Although the ACV BG 2000-M boiler is very modern, it uses
proven technology and is manufactured from standard spare
parts that are easily available on the market.

Temperature regulation

The basic version of the HeatMaster® TC is fitted with a
microprocessor controlled regulator (MCBA) which takes over
both the safety functions (ignition, monitoring the flame, limiting
the temperature, etc.) and control of the boiler temperature.
This MCBA also includes a weather-dependent regulator. All you
need to do is connect the outdoor temperature sensor available
as an option to the device. However, this regulator can also
operate with a standard on/off room thermostat In addition,
with the combination of a weather -dependent regulator and a
room thermostat, you can control the temperatures based on
the weather with compensation for the indoor temperature.
There are four user adjustable parameters. By entering a
special maintenance code, qualified ins tallers can access
several other parameters to adapt the boiler to special
requirements. In principle, these parameters are factory set
for all normal applications.

PRODUCTION OF HOT WATER

In addition to its exceptional hot water performances, the ACV
Tank-in-Tank concept provides the follwoing advantages :

- A solution for scale deposits: thanks to the specially designed
corrugations, the hot water tank expands and contracts during
the heating cycle, preventing the formation of scale.

- A guarantee against the risk of Legionnellae Disease and
bacteria: the hot water tank is fully immersed in the primary

circuit and the hot water is constantly kept at a temperature
above 60°C.

- Exceptional resistance against corrosion and aggression:
provided by the stainless steel.

FROST PROTECTION

The boiler is equipped with an integrated frost protection: as soon
as the boiler temperature drops below 7°C, the system activates
the central heating pump. As soon as the NTC1 flow temperature
drops below 3°C, the system automatically ignites the burner until
the temperature rises above 10°C. The pump continues to run
for about 10 minutes.

If an outdoor temperature sensor is connected to the system,
the pump is activated as soon as the outside temperature drops
below the specified threshold.

To provide efficient protection for the whole system, all valves of the
valves on the radiators and the convectors should be completely
open.

INTRODUCTION

FR • 7

ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH

DIRECTIONS FOR USE

Your system must be checked once a year by an approved
installer or maintenance company.

Starting the burner

During operation, the burner starts automatically as soon as
the boiler temperature drops under the required set point and
it stops as soon as the boiler reaches that temperature.

Control panel

SETTINGS PARAMETERS

Setting the domestic hot water temperature:

(Hot water temperature)

- Press Mode: The screen displays PARA.

- Press Step: the first character is 1 and the last two characters

give the current hot water temperature setting.

- To change this temperature, press + or - until the last two

digits show the desired temperature value.

- Press Store to save the new temperature setting.

- Press Mode twice to return to Pilot mode (normal operating

mode).

Enabling or disabling the hot water heating mode:

(hot water)

- Press Mode: The screen displays PARA.

- Press Step twice: the first charact er is 2 and the last two

characters give the current setting:

00 = disabled; 01 = enabled.

- To change this parameter, press + or - until the screen displays

the desired value:

00 = disabled; 01 = enabled.

- Press Store to save.

- Press Mode twice to return to Pilot mode (normal operating

mode).

Enabling or disabling Central Heating mode:

(heating)

- Press Mode: The screen displays PARA.

- Press Step three times: the first character is 3 and the last

two characters give the current setting:

00 = disabled; 01 = enabled.

- To change this parameter, press + or - until the screen displays

the desired value:

00 = disabled; 01 = enabled.

- Press Store to save.

- Press Mode twice to return to Pilot mode (normal operating

mode).

Setting the central heating temperature:

(maximum temperature for the heating circuit)

- Press Mode: The screen displays PARA.

- Press Step four times: the first charact er is 4 and the last

two characters give the current central heating temperature
setting.

- To change this temperature, press + or - until the last two

digits show the desired temperature value.

- Press Store to save the new temperature setting.

- Press Mode twice to return to Pilot mode (normal operating

mode).

Fault:

The temperature setting for the appliance and the safety
functions for its various parts are continuously monit ored by
a regulator controlled by a microprocessor (the MCBA). In the
event of a fault, this MCBA disables the appliance and displays
an error code: the screen flashes displaying E as the first
character, followed by the error code.

To reset the appliance:

- Press "Reset" on the screen.

- Contact your inst aller of the fault happens again.

USERS GUIDE

Heating system

The central heating circuit must be pressurized (see in the
chapter “Installation” how to define the system pressure).
The pressure indicator is located on the right-hand side of the
display.

If your system needs to be refilled more than twice

a year, please contact your installer.

The CH pressure must be a minimum of 1 bar and mus t be
checked by the end user on a regular basis. If the pressure
drops under 0.5 bar, the integrated water pressure switch
blocks the appliance until the pressure in the system returns to
a level above 0.8 bar. The connection for a fill valve is provided
underneath the appliance. The installer can also fit the system
with a separate valve. Make sure that the appliance is powered
off when filling the system. TTo do this, toggle the Start/Stop
switch located on the left of the screen to Off. (see the Control

panel).

For more information, please ask your installer when the system
is delivered.

A safety valve is provided at the underneath of the appliance.
If the system pressure exceeds 3 bars, this valve opens and
drains the water from the system. In this case, please contact
your installer.

bar

2

1O3

4

MCBA display

Pressure gauge

ON/OFF switch

Summer/Winter switch

Pre-cut for an optional
control unit controller

EN • 8

ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH

664Y2800

TECHNICAL CHARACTERISTICS

HeatMaster® 35 TC

Central heating Gas Naturel Propane

Max. [intake] pressure

kW

34,9

Min. [intake] pressure

kW

10,0

Max. output 80/60°C

kW

34,0

Min. output 80/60°C

kW

9,8

Effi ciency [high power] 80/60°C

%

97,4

Domestic hot water mode

%

105,9

Effi ciency [low power] 50/30°C

%

109

Flue gases

CO emissions [high power / min.]

mg/kWh

70

NOx emissions [EN483]

mg/kWh

59

NOx classifi cation 5

Flue gas temperature — high power 80/60°C

°C

60

Flue gas temperature — high power 50/30°C

°C

32

Mass fl ow rate of combustion products

kg/h

55

Flue gas pipe - Max. pressure drop

Pa

130

Concentric fl ue gas channel maximum length Ø 80 / 125

m

20

Gas G20 / G25 G31

Category [varies by country]

I 2E[S]B — I 2Er — I 2H

I 2ELL — I 2L — I 2E

I 3P

Gas pressure

mbar

20 / 25 30 / 37 / 50

G20 gas fl ow rate

m

3

/h

3,7

G25 gas fl ow rate

m

3

/h

4,3

G31 gas fl ow rate

m

3

/h

—

CO

2

[high power]

% CO

2

9,4

CO

2

[low power]

% CO

2

9,0

Hydraulic parameters

Max. operating temperature

°C

90

Total capacity

L

189

Heating circuit capacity

L

108,5

High operating power central heating

bar

3

Heat exchanger pressure drop [ΔT = 20]

mbar

30

Electrical connection

Class

IP

30

Supply voltage

V/Hz

230/50

Electrical power

A

0,8

EN • 9

ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH

664Y2800

TECHNICAL CHARACTERISTICS

Natural gas categories

BE FR NL LU DE

AT - CH - CZ - DK - ES - IT - FI

UK - IE - PT - SE - GR - HU

I 2 E(S)B

[G20] 20 mbar – [G25] 25 mbar

I 2 Er

[G20] 20 mbar – [G25] 25 mbar

I 2 L

[G25] 25 mbar

I 2 E

[G20] 20 mbar

I 2 ELL

[G20] 20 mbar – [G25] 20 mbar

I 2 H

[G20] 20 mbar

Propane categories

DK - NL

NO - IT

BE - CH - ES

FR - UK - IE

PT - FI - SE

IT - GR

AT - CH
CZ - ES
NL - DE
LU - HU

BE - CH
ES - FR

UK - IE

IT - PT

PT

CZ - DK - ES

FI - FR - UK

IE - IT - NL

NO - PT - SE

AT - CH
CZ - DE

FR

I 3 P

[G31] 30 mbar

I 3 P

[G31] 37 mbar

I 3 P

[G31] 50 mbar

I 3 +

[G30 + G31] 28 - 30 / 37 mbar

I 3 +

[G30 + G31] 50 / 67 mbar

I 3 B

[G30] 28 / 30 mbar

I 3 B

[G30] 50 mbar

DOMESTIC HOT WATER FEATURES

HeatMaster

®

35 TC

Operating conditions at 80°C

Peak fl ow at 40°C [ΔT = 30°C]

L/10’

419

Peak fl ow at 40°C [ΔT = 30°C]

L/60’

1312

Constant fl ow at 40°C [ΔT = 30°C]

L/h

1057

Peak fl ow at 45°C [ΔT = 35°C]

L/10’

381

Peak fl ow at 45°C [ΔT = 35°C]

L/60’

1080

Constant fl ow at 45°C [ΔT = 35°C]

L/h

898

Peak fl ow at 60°C [ΔT = 50°C]

L/10’

224

Peak fl ow at 60°C [ΔT = 50°C]

L/60’

692

Constant fl ow at 60°C [ΔT = 50°C]

L/h

578

Pre-heat time

minutes

37

EN • 10

ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH

664Y2800

ELECTRICAL CONNECTION

WIRING DIAGRAM : HeatMaster® 35 TC

1. Power supply 230 V

2. ON/OFF switch

3. Boiler shunt pump

4. Heating pump (optional)

5. Gas valve rectifier

6. 230Volt - 24Volt transformer

7. MCBA

8. Display

9. Water pressure switch

10. Fan PWM control

11. Summer/Winter switch

12. NTC1 flow sensor

13. NTC2 return sensor

14. NTC5 flue gas temperature

15. Room thermostat (optional)

16. NTC3 domestic hot

17. NTC4 outdoor temperature (optional)

18. NTC6 second heating circuit flow sensor (optional)

19. Zero volt of 24V circuit.

20. Safety contact thermostat RAM (optional)

21. Ionisation and ignition cable

123 546

123 546

12345678910111213

12345678910111213

230V

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BUS B

BUS A

X11.

X12.

Br

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X2.12

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X2.9

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X2.7

X2.6

X2.5

X2.4

X2.3

X2.2

X2.1

X3.6

X3.5

X3.4

X3.3

X3.2

X3.1

X4.3

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X5.4

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

1

2

3

4

5

6

8

9

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1010

13

15

14

21

12

11

16

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