Heatmaster 60N, 70N, 100N Installation And Operating Instructions Manual
EN • 1
ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH
664Y0500.A
Installation, operating and
servicing instructions
HeatMaster® 60N / 70N / 100N
HeatMaster® 60N / 70N / 100N
With ACV BG 2000-S premix gas burner
HeatMaster
®
60N / 70N / 100N
With ACV BM oil burner
HeatMaster
®
EN • 2
ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH
664Y0500.A
WARNINGS 3
Who should read these instructions 3
Symbols 3
Recommendations 3
Applicable standards 3
Warnings 3
DESCRIPTION 4
Operating principle 4
Construction features 4
USERS GUIDE 6
Using the boiler 6
Resetting the pressure jet oil or Gas burner 7
Ressetting the BG 2000-S premix gas burner 7
Burner troubleshooting 7
TECHNICAL CHARACTERISTICS 8
Maximum operating conditions 8
Burner chamber plate 8
General features 8
Domestic hot water features 8
ELECTRICAL CONNECTION 9
Wiring diagram 9
INSTALLATION 10
Dimensions 10
Boiler room 11
Connection to the chimney 11
Domestic hot water connection 12
Heating connections 13
Oil supply connections - ACV BM burners 13
Connection to the gas 13
COMMISSIONING 14
Filling the domestic hot water and heating circuits 14
BURNER FEATURES 15
ACV BG 2000-S premix gas burners 15
ACV BM 102 and BM 152 oil burners 18
MAINTENANCE 19
Servicing intervals 19
Servicing the boiler 19
Servicing the safety devices 19
Servicing the burner 19
Draining the boiler 19
SPARE PARTS See at the end of this manual
INDEX
ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH
EN • 3
664Y0500.A
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 ACV reference
number at the end of this document.
• The gas burners are preset in our factory for use with natural
gas
[equivalent to G20].
• Specific regulation applicable in Belgium [for the gas burners]:
The CO2 level, the air and gas flows and the gas / air ratio
are factory set . Any field adjustments of those settings is
not allowed in Belgium.
• 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+” label (Gas boilers) and “OPTIMAZ” label
(Oil boilers).
WARNINGS
IF YOU SMELL GAS:
- Immediately isolate the gas supply.
- Open windows and doors to ventilate the area.
- Do not use any electrical appliances and do not operate 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
non-compliant location 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, carefully read 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.
Risk of scalding
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
664Y0500.A
OPERATING PRINCIPLE
The HeatMaster® is a high performance, direct fired hot water
storage heater, which has indirect heat transfer due to its Tankin-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 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® 60 N, 70 N and 100 N 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 gases within the boiler
The combustion gas circuit is paint-protected and comprises:
• Flueways
Depending on output, HeatMaster® models contain several
steel flueways with an internal diameter of 64 mm. Each
flueway is fitted with a baffle of special steel designed to improve
heat exchange and reduce flue gas temperatures.
• 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
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.
DESCRIPTION
ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH
EN • 5
664Y0500.A
DESCRIPTION
Safety features of the HeatMaster® 60 N Safety features of the HeatMaster® 70 N and 100 N
1. Automat ic air vent
2. Dom es ti c co ld w at er inlet
3. Br ass p oc ke t
4. Pol yurethane foa m insulation
5. Heating circui t filling valve with removable hose and
non-return valve
6. Ca sin g fr on t pan el
7. P r i m a r y e x p a n s i o n v e s s e l
8. Cont rol p ane l
9. Boiler shunt pump
10. Burner cover
11. Burner chamber plate insulation
12. To p c a s ing
13. Flue reduc tion collar
14. He a tin g f l ow
15. Domestic hot water ou tlet
16. St ainlees steel Tank-in-Tank hot wa ter s tore
17. Flue pipes and turbulators
18. Primary heating cir cuit
19. Hea t i n g r e t u r n
20. Combustion chamber
21. Burner
A. Thermal reset high limit thermostat
B. Manual rese t high li mit thermostat
C. Low water pressure switch
D. Primary safety valve
E. Contro l ther mostat
1
2
3
4
8
12
19
13
14
17
18
6
5
7
9
10
11
20
21
16
15
A
C
D
E
B A
C
D
E
B
EN • 6
ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH
664Y0500.A
USERS 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.
• ON/OFF switch
This turns the HeatMaster® on or off.
• 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.
• Summer/Winter switch
This turns the heating pump (if fitted) on or off.
• 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.
• 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
• 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 set ting. If the fault persist s,
call an engineer.
The pressure should not fall below 1 bar, if it does the please
see the ‘Heating System Pressure’ paragraph later in this
section.
• Low primary water pressure indicator
If this indicator lights up, the primar y circuit of the HeatMaster
®
requires topping up with water. Please see the ‘Heating System
Pressure’ paragraph later in this section.
1. Burner lockout indicator
2. Primary circui t low wa ter pressure indicator
3. High limit cutoff indicator
4. Combined t emper ature and pr essure gauge
5. Co nt ro l therm os ta t
6. Ti me cl ock
7. M a n u a l r e s e t h i g h l i m i t t h e r m o s t at
8. O N / OF F sw it ch
9. Summer / Winter switch
I
O
Control panel HeatMaster® 60 N
I
O
1
4
53
2
76
8 9
Control panel HeatMaster® 70 N and 100 N
1
4
53
2
76
8 9
ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH
EN • 7
664Y0500.A
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
bothvalves. 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.
RESETTING THE PRESSURE JET OIL OR
GAS BURNER
• HeatMaster® 60 N / 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 butt on
located on the burner.
If the burner does not relight, call the service engineer after
ensuring that the faul t is not due to a power cut or low oil in
the tank.
USERS GUIDE
HeatMaster® 70 N and 100 N
A
B
HeatMaster® 60 N
A
B
RESETTING THE BG 2000-S PREMIX
GAS BURNER
• HeatMaster® 60 N with BG 2000-S/60
HeatMaster® 70 N with BG 2000-S/70
HeatMaster® 100 N with 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 but ton 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.
EN • 8
ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH
664Y0500.A
TECHNICAL CHARACTERISTICS
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 M8 for attaching the
burner. It is protected from heat by a blanket insulation.
Ø130
Ø28
4x(M8)
60
60
60 60
DOMESTIC HOT WATER FEATURES
Operating conditions at 80°C
HeatMaster® 60 N HeatMaster® 70 N HeatMaster® 100 N
Peak fl ow at 40°C [ΔT = 30°C]
L/10’
474 646 905
Peak fl ow at 45°C [ΔT = 35°C]
L/10’
378 543 777
Peak fl ow at 60°C [ΔT = 50°C]
L/10’
245 346 514
Peak fl ow at 70°C [ΔT = 60°C]
L/10’
193 268 343
Peak fl ow at 80°C [ΔT = 70°C]
L/10’
135 207 258
Peak fl ow at 40°C [ΔT = 30°C]
L/60’
1942 2133 3172
Peak fl ow at 45°C [ΔT = 35°C]
L/60’
1656 1794 2680
Peak fl ow at 60°C [ΔT = 50°C]
L/60’
1106 1219 1813
Peak fl ow at 70°C [ΔT = 60°C]
L/60’
681 971 1226
Peak fl ow at 80°C [ΔT = 70°C]
L/60’
499 636 893
Constant fl ow at 40°C [ΔT = 30°C]
L/h
1835 1835 2776
Constant fl ow at 45°C [ΔT = 35°C]
L/h
1573 1573 2379
Constant fl ow at 60°C [ΔT = 50°C]
L/h
1101 1067 1665
Constant fl ow at 70°C [ΔT = 60°C]
L/h
791 918 1104
Constant fl ow at 80°C [ΔT = 70°C]
L/h
455 580 804
Pre-heat time
minutes
91613
GENERAL FEATURES
HeatMaster
®
60 N HeatMaster® 70 N HeatMaster® 100 N
Maximum Input
kW
69,9 69,9 107,0
Maximum Output
kW
62,9 62,9 96,3
Maintenance loss at 60°C as rated value
%
0,57 0,60 0,65
Total capacity
L
162 239 330
Primary circuit capacity
L
82 108 130
Heating connection [F]
Ø
1”1/2 1”1/2 1”1/2
Domestic hot water connection [M]
Ø
3/4” 1” 1”
Domestic hot water tank heat exchanger surface
m
2
2,46 3,14 3,95
Pressure drop primary circuit
mbar
54 46 83
Pressure drop in the combustion chamber
mbar
0,6 0,6 1,4
ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH
EN • 9
664Y0500.A
ELECTRICAL CONNECTION
WIRING DIAGRAM : HeatMaster® 60 / 70 / 100
1. 230 V power connection plug
2. ON/OFF switch
3. Temperature high limit cutoff indidicator
4. Manuel reset high limit thermostat
5. Primary circuit low water pressure indicator
6. Low water pressure switch
7. Time clock
8. Summer / Winter switch
9. Hot water priority link
10. Burner lockout indicator
11. Room thermostat (optional)
12. Central heating pump
13. HeatMaster
®
loading pump
14. Burner plug connector
15. Water flow switch connection (optional)
16. Termal reset high limit thermostat 95°C
17. Control thermostat
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
1234567891011121314151617181920
11
9
L1 N T1 T2 S3 B4
L1 N T1 T2 S3 B4
L1 N
L1 N
O
I
1
2
3
4
5
6
7
8
10
12 13
14
15
16
17
21
C
12
P
12
C
12
C
5
4
3
103 C
95 C
0 - 90 C
21
C
Br
Y/Gr
B
Y
G
Gr
Y/Gr
Br
B
Y
G
Y/Gr
Y/Gr
Y/Gr
Gr
Or
B
R
Pk
W
Bk
W
Pk
Or
B
B
B
GG
G
G
G
Y/Gr
Or
B
Or
Or
B
B
Or
B
Br
Bk
Pk
Bk
W
W
B
B
B
B
G
B
Or Br
Br
B
Br
B
Y/Gr
B
The wiring shown is designed for
blown gas or oil burners.
It is important to move the link
from points (12 - 15) to (15 - 16)
when using the BG 2000-S burner.
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