Heatmaster HM 60 N, 100 N, 70 N, 150 JUMBO User Manual

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

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

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.

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

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

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

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

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

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