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

HeatMaster

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

excellence in hot water

66400501

INDEX
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

INTRODUCTION

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.

1

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.

2

DESCRIPTION

Features of HeatMaster 70 N / 100 N

Top cover

Automatic air vent

Domestic cold water inlet

Heating circuit filling valve with removable hose and non-return valve

Primary expansion vessel

Primary shunt pump

Casing front panel

Primary circuit

Burner chamber plate

Flue reduction collar

Central heating flow pipe

Domestic hot water outlet

Flue pipes and turbulators

Tank-in-Tank heat exchanger

Insulation

Burner

Heating return

Combustion chamber

Safety features of the HeatMaster 60 N	Control panel HeatMaster 60 N
Thermal reset high
limit thermostat
	Combined temperature		Manual reset high
Manual reset high	and pressure gauge		limit thermostat
limit thermostat
	Burner
	lockout		Time clock
Low water	indicator
pressure switch

Primary safety valve
Primary circuit low
water pressure
indicator		Control	ON / OFF
Control thermostat		thermostat	switch
High limit cutoff
indicator			Summer / Winter switch

3

DESCRIPTION

Safety features of the HeatMaster 70 N and 100 N

Thermal reset high limit thermostat

Manual reset high limit thermostat

Low water pressure switch

Control thermostat

Primary safety valve

Safety features of the HeatMaster 150 Jumbo

Primary safety valve

Thermal reset high limit thermostat

Manual reset high limit thermostat

Low water pressure switch

Control thermostat

Control panel HeatMaster 70 N and HeatMaster 100 N

Combined temperature	Manual reset high
and pressure gauge	limit thermostat

Burner

lockout Summer / Winter switch indicator

Time clock

Primary circuit low water pressure indicator

Control	ON / OFF
thermostat	switch

High limit cutoff indicator

Control panel HeatMaster 150 Jumbo

			Mains power
			electrical connection
			(multi-pin plug)
Combined temperature
and pressure gauge			Primary circuit low
		bar	water pressure indicator
Relay base	.. ....
	. .
	..
	. .
	. .
	.	.
		. .
Time clock
			ON / OFF switch
Fuse			Manual reset high
			limit thermostat
Control thermostat
			Thermal reset high
			limit thermostat
Servicing socket
(230 V ˜ 50 Hz)

4

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

TECHNICAL SPECIFICATION

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.

5xØ6.5(M8)		Ø28
Ø130
60
60
	60			60

DOMESTIC HOT WATER PERFORMANCES

		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	9	9	16	16	13	13	17

GENERAL FEATURES

		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	11/2”	11/2”	11/2”	DN 50
Hot water connection	Ø	3/4”	1”	1”	2”
Hot water tank heat exchange surface	m2	2.46	3.14	3.95	5.30
Weight empty	Kg	220	270	320	530
Pressure drop primary circuit	mbar	54	46	83	120

5

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 purposes, 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

F

G

A

A

B

H K

C/2

J

C		C
D	D	E

6

TECHNICAL SPECIFICATION

HeatMaster 70 N and HeatMaster 100 N

Without burner	With ACV BG 2000-S				G
	premix gas burner				F

K

A

A

B

H

C/2

J

C		C
D	D	E

HeatMaster 150 Jumbo

F

562

A	H

K

C

D

G

J

E

7

INSTALLATION

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.

Ventilation		60 N	70 N	100 N	150
					Jumbo
Min. fresh air
requirement	m3/h	126	126	194	278
Bottom	dm2	2.11	2.11	3.20	4.8
Top	dm2	2.0	2.0	2.0	2.0

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.

A.Top vent

B.Bottom vent

C.Draught regulator

D.Inspection window

E.Height of lined chimney

F.Chimney diameter

A

B

F

E

C

D

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

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.

8