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66401100
excellence in hot water
Installation, Operating and
Servicing Instructions
HeatMaster
HM 71
HM 101
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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.
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 4
Dimensions 4
General features 4
Maximum operating conditions 5
Domestic hot water performances 5
HeatMaster control settings 5
INSTALLATION 6
Boiler room 6
Chimney connections 6
Hot water connections 8
Heating connection 9
Electrical connection 10
Wiring diagram 11
COMMISSIONING 12
Filling the hot water and heating circuits 12
BURNER FEATURES 12
ACV BG 2000-M moduling premix gas burners 12
MAINTENANCE 14
Service Intervals 14
Servicing the boiler 14
Servicing the safety devices 14
Servicing the burner 14
Draining the boiler 14
USER GUIDE 15
Using the boiler 15
Control Settings 16
SERVICE RECORD 18
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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-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 71/101 has the following items as standard :
- On/off switch
- Summer/Winter switch
- MCBA controller, incorporating
• electronic control and high limit thermostats
• burner modulation
- primary circulating shunt pump
- primary expansion vessels
- primary safety valve
- pressure and temperature gauge
- drain valve
- body completely insulated in rigid polyurethane foam
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DESCRIPTION
CONSTRUCTION FEATURES
Outer body
The outer body containing the primary fluid is made of carbon steel
(STW 22).
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
HeatMaster 71/101 models contain 8 steel flue pipes with an
internal diameter of 64 mm. Each pipe is fitted with a
turbulator of stainless steel designed to improve heat
exchange and to 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 casing which has been scoured and
phosphated before being stove enamelled at 220 °C.
Burner
71 and 101 models are always delivered with ACV BG 2000-M 71
and 101 air/gas premix burners.
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DESCRIPTION
Flue reduction collar
Top cover
Automatic air vent
Central heating flow pipe
Flue pipes and turbulators
Insulation
Burner
Detector NTC3
Heating return
Combustion chamber
Burner chamber plate
Primary circuit
Primary safety valve
Low water pressure switch
Detector NTC1 and NTC2
Casing front panel
Primary expansion vessel
Domestic cold water inlet
Heating circuit filling
valve with removable hose
and non-return valve
Primary shunt pump
Domestic hot water outlet
Tank-in-Tank heat exchanger
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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 delivery and after unpacking, check the equipment for damage.For transport pur poses, refer to the weights and dimensions given below.
TECHNICAL SPECIFICATION
D
G
F
E
J
H
BAK
C
C/2
HM 71 HM 101
Fuel type Natural gas / propane Natural gas / propane
Maximum Input kW 20 - 69.9 25 - 107 / 22 - 110
Maximum Output kW 63.0 96.8
Maintenance loss at 60 °C of rated value % 0.5 0.4
Total capacity L 239.0 330.0
Primary circuit capacity L 108.0 130.0
Hot water connection Ø 1” 1”
Heating connection Ø 11/2”11/2”
Flue connection Ø mm 150 150
Hot water tank heat exchange surface m
2
3.14 3.95
Weight empty Kg 282 335
Pressure drop primary circuit mbar 46 83
A mm B mm C mm D mm E mm F mm G Ø mm H mm J mm K mm
HM 71 1743 1630 680 937 680 390 150 1289 285 1720
HM 101 2093 2030 680 937 680 390 150 1693 285 2120
GENERAL FEATURES
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HEATMASTER CONTROL SETTINGS
Description
The 71/101 series is fitted with an electronic controller (MCBA)
which controls burner operation (ignition, safety and modulation),
and provides facilities to adapt the controller to the desired application.
The MCBA has three levels of settings : manufacturer, installer and
user.There are three temperature detectors located in the primary
and secondary circuits.
It provides two operating modes.
1. Heating mode
Temperature set by the user at between 60 and 90 °C.
• Differential “ON”, burner starts.
• Differential “OFF”, burner stops.
• PI (Proportionnel Integral) regulator in “heating” mode.
• The regulator compares the primary temperature with the setting
and modulates.
The room thermostat detects the heating demand
2. Hot water mode
(with hot water priority)
The detector located in the secondary tank detects the hot water
demand.
When a draw-off is detected the controller goes to “hot water
demand” mode:
• The primary shunt pump starts.
• The heating pump switches off.
• The burner starts and the controller uses the data from the
primary detector to control modulation.
User-accessible parameters
1. “Hot water” setting adjustable from 20 to 90 °C.
2. “Hot water” mode: ON/OFF.
3. “Heating” mode: ON/OFF.
4. “Heating” setting adjustable from 60 to 90 °C.
Parameters accessible in servicing
Main default settings:
- Hot water priority active.
- Heating demand detection by room thermostat.
- A single heating circuit.
An access code is required for “service” access.
For more technical information, contact your ACV dealer.
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
HM 71 HM 101
Peak delivery at 40 °C L/10’ 646 905
Peak delivery at 45 °C L/10’ 543 777
Peak delivery at 60 °C L/10’ 346 514
Peak delivery at 70 °C L/10’ 268 385
Peak delivery at 80 °C L/10’ 203 290
Peak delivery at 40 °C L/60’ 2133 3172
Peak delivery at 45 °C L/60’ 1794 2680
Peak delivery at 60 °C L/60’ 1219 1813
Peak delivery at 70 °C L/60’ 971 1378
Peak delivery at 80 °C L/60’ 710 1003
Continuous delivery at 40 °C L/60’ 1835 2776
Continuous delivery at 45 °C L/60’ 1573 2379
Continuous delivery at 60 °C L/60’ 1067 1665
Continuous delivery at 70 °C L/60’ 715 1241
Continuous delivery at 80 °C L/60’ 675 903
Reheat time to 60 °C min 16 13
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