Casablanca Fan Company HM 101 User's Manual
Contents
1. 107 22 110 Maximum Output kW 63 0 96 8 Maintenance loss at 60 C of rated value K 0 5 0 4 Total capacity 239 0 330 0 Primary circuit capacity 108 0 130 0 Hot water connection it il Heating connection 11 2 11 2 Flue connection mm 150 150 Hot water tank heat exchange surface m 3 14 3 95 Weight empty Kg 282 335 Pressure drop primary circuit mbar 46 83 TECHNICAL SPECIFICATION MAXIMUM OPERATING CONDITIONS HEATMASTER CONTROL SETTINGS 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 e Chlorures lt 150 mg l 304 lt 2000 mg l Duplex MEIER 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 ah 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 L2. Internal control Burner on for holding boiler warm Setting for T1 Burner high function Testmode max RPM in CH mode Variation of T1 C s lt lt eg gt Burner low function Testmode min RPM in CH mode Variation of T2 C s Burner on for manual fanspeed servicing O mMInI I DaJa AJ UJN Variation of T3 C s If the burner is turned off because of an extra protection the display shows boiler sequence 9 and the flow temperature This alternates with the error code eg b26 16 Safety shutdown If an operating error develops the system locks and the display flashes the first digit shows the sequence the burner was in when the error occurred the last two digits show the error code see table below the first digit and the next two flash alternately LS To reset the system Press the RESET button on the MCBA display If an error occurs again call an approved heating engineer Table of error codes and corrective action USER GUIDE codes Error description Fault repair 00 No flame detected check wiring change electrode change MCBA 02 No ignition after 5 attempts check ignition electrode and its positioning 03 07 Internal error if the problem persists after 2 resets change the MCBA 11 Eprom error if the problem persists after 2 resets change t
3. KERKPLEIN 39 B 1601 RUISBROEK BELGIUM TEL 32 2 334 82 40 FAX 32 2 334 82 59 E MAIL belgium info acv world com CHILE ALBIN TROTTER Y ACV LTDA SAN PABLO 3800 QUINTA NORMAL SANTIAGO CHILE TEL 56 2 772 01 69 FAX 56 2 772 92 62 63 E MAIL chile info acv world com CZECH REPUBLIC ACV CR SPOL s r o NA KRECKU 365 CR 109 04 PRAHA 10 CZECH REPUBLIC TEL 420 2 720 83 341 FAX 420 2 720 83 343 E MAIL ceskarepublika info acv world com DEUTSCHLAND ACV WARMETECHNIK GMBH amp CO KG GEWERBEGEBIET GARTENSTRASSE D 08132 MULSEN OT JACOB DEUTSCHLAND TEL 49 37601 311 30 FAX 49 37601 311 31 E MAIL deutschland info acv world com ESPANA ACV ESPANA C ANTONIO GAUDI 3 E 08349 CABRERA DE MAR ESPANA TEL 34 937 595 451 FAX 34 937 593 498 E MAIL spain info acv world com FRANCE ACV FRANCE sa 31 RUE AMPERE Z I MI PLAINE F 69680 CHASSIEU FRANCE TEL 33 4 72 47 07 76 FAX 33 4 72 47 08 72 E MAIL france info acv world com ITALIA ACV ITALIA VIA MALPIGHI 6 1 48018 FAENZA RA ITALIA TEL 39 0546 62 25 15 FAX 39 0546 62 25 05 E MAIL italia info acv world com NEDERLAND ACV NEDERLAND bv POSTBUS 350 NL 2980 AJ RIDDERKERK NEDERLAND TEL 31 180 42 10 55 FAX 31 180 41 58 02 E MAIL nederland info acv world com POLAND ACV POLSKA sp z 0 0 UL WITOSA 3 87 800 WWOCWAWEK POLAND TEL 48 54 412 56 00 FAX 48 54 412 56 01 E MAIL polska info acv world com
4. PORTUGAL BOILERNOX LDA RUA OUTEIRO DO POMAR CASAL DO CEGO FRACGAO C PAVILH O 3 MARRAZES 2400 402 LEIRIA PORTUGAL TEL 351 244 837 239 40 FAX 351 244 823 758 E MAIL boilernox mail telepac pt RUSSIA ACV RUSSIA 1 9 MALY KISELNYI 103031 MOSCOW RUSSIA TEL 7 095 928 48 02 7 095 921 89 79 FAX 7 095 928 08 77 E MAIL russia info acv world com SLOVAK REPUBLIC ACV SLOVAKIA s r o PLUHOVA 49 831 04 BRATISLAVA SLOVAK REPUBLIC TEL 421 2 444 62 276 FAX 421 2 444 62 275 E MAIL slovakia info acv world com UK ACV UK Ltd ST DAVID S BUSINESS PARK DALGETY BAY FIFE KY11 9PF TEL 44 1383 82 01 00 FAX 44 1383 82 01 80 E MAIL uk info acv world com USA TRIANGLE TUBE PHASE III FREEWAY CENTER 1 TRIANGLE LANE BLACKWOOD NJ 08012 USA TEL 1 856 228 8881 FAX 1 856 228 3584 E MAIL sales triangletube com ARGENTINA TECNOPRACTICA ALFEREZ BOUCHARD 4857 1605 CARAPACHAY BUENOS AIRES TEL 54 11 47 65 33 35 FAX 54 11 47 65 43 07 E MAIL jchas tecnopractica com BRAZIL SIMETAL INDUSTRIA E COMERCIO DE FERRAMENTAS LTDA RUA GERSON ANDREIS 535 95112 130 CAXIAS DO SUL BRAZIL TEL 55 54 227 12 44 FAX 55 54 227 12 26 E MAIL export simetall com br BULGARIA PROXIMUS ENGINEERING LTD 7 BIAL KREM STR 9010 VARNA BULGARIA TEL 359 52 500 070 FAX 359 52 301 131 E MAIL info proximus bg com CHINA BEIJING HUADIAN HT POWER TECHNOLOGY DEVELOPMENT CO LTD R
5. engineer in accordance with the prevailing local standards and regulations k 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 een B Bottom vent C Draught regulator F D Inspection opening ec E Lined chimney height F Chimney diameter A Chimney minimum flue diameter 71 101 E 5n FP min mm 189 234 E 10m F min mm 159 178 E 15m OF min mm 150 150 ES Note Regulations vary from country to country therefore the table above is intended only as a guide A 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 Balanced flue boiler connection type C e C13 concentric horizontal connection C33 concentric vetical connection C53 parallel chimney connection C63 concentric vertical connection without terminal only in Germany and Luxembourg C33 C13 2m min Maximum lengt
6. 40 233 20 62 00 E MAIL office eurotherm ro SLOVENIA Z MAJ doo CESTA OF 49 1420 TRBOVLJE SLOVENIA TEL 386 356 32 830 FAX 386 356 32 831 E MAIL jjeraj zmaj si SWEDEN WARMEPRODUKTER KLIPPAN AB TEMPLAREGATAN 7 26435 KLIPPAN SWEDEN TEL 46 435 184 10 FAX 46 435 184 02 E MAIL warmeprodukter se telia com TUNISIE SOCOME CHAUMAX BO TE POSTALE N 44 1002 TUNIS TUNISIE TEL 216 71 78 15 91 FAX 216 71 78 87 31 UKRAINE UKRTEPLOSERVICE LTD PR LAGUTENKO 14 83086 DONETSK UKRAINE TEL 38 062 382 60 47 48 FAX 38 062 335 16 89
7. starts automatically whenever the boiler temperature falls below the set temperature Understanding the control panel Summer winter switch MCBA controller display On off switch Combined temperature and pressure gauge There are no user parts inside the control panel Heating system pressure EN 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 both valves Replace the casing top front panel Restore the power supply and switch the boiler on Safety Valves If water discharges fro
8. 60 715 1241 Continuous delivery at 80 C L 60 675 903 Reheat time to 60 C min 16 13 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 e Differential OFF burner stops Pl 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 Parameter
9. HeatMaster Installation Operating and Servicing Instructions HM 71 HM 101 excellence in hot water INDEX INTRODUCTION INTRODUCTION 1 INTENDED USERS OF THESE INSTRUCTIONS Intended users of these instructions 1 These instructions are intended for Symbols 1 specifying engineers Applicable standards 1 installing engineers Warnings 1 end users servicing engineers DESCRIPTION 2 SYMBOLS Operating principle 2 Construction features 2 The following symbols are used in these instructions TECHNICAL SPECIFICATION 4 VS Essential instruction for operating the system correctly Dimensions 4 General features 4 Maximum operating conditions 5 IAN Essential instruction for personal safety or Domestic hot water performances 5 environmental protection HeatMaster control settings 5 INSTALLATION 6 J Danger of electrocution Boiler room 6 Chimney connections 6 Hot water connections 8 Heating connection 9 A 8 Electrical connection 10 Risk of scalding Wiring diagram 11 COMMISSIONING 12 Filling the hot water and heating circuits 12 APPLICABLE STANDARDS The products have received the CE certificate in accordance with BURNER FEATURES 12 the standards prevailing in different countries European Directives A 92 42 EEC efficiency 90 396 EEC gas appliances These ACV BG 2000 M moduling premix gas burners 12 products have also received the Belgian HR gas boiler
10. NT The hot water tank must be pressurised before the heating circuit is filled Close the primary circuit filling valves 11 2 Open the stop valve 1 and the drawoff tap 8 When water flows out of the tap the hot water tank is full and the drawoff tap 8 should be closed 3 Fill the primary heating circuit by opening the valves 11 and pressurising to 1 bar Y 4 Open the automatic air vent located on top of the boiler IMPORTANT the screw cap must be left loose to allow future automatic venting to take place 5 After venting the air from the system bring the pressure up to the static head plus 0 5 bar 1 5 bar 10m and 2 bar 15 m 6 Check that the electrical connection and boiler room ventilation conform to the relevant standards 7 Switch the on off switch to the ON position 8 Set the temperature settings see pages 15 16 Check the gas supply pressure see page 13 10 When the burner operates check the chimney connection for leaks 11 After 5 minutes of operation turn the boiler off and vent the heating circuit system again maintaining the water pressure at 1 bar 12 Then restart the unit and check the combustion see page 13 Burner troubleshooting See page 15 17 Spare parts Refer to the specific document available from ACV or your distributor BURNER FEATURES ACV BG 2000 M MODULATING PREMIX GAS BURNERS Description of operation The BG 2000 M modulating burner cont
11. OOM B 912 TOWER B COFCO PLAZA N 8 JANGUOMENNE AVENUE BEIJING 100005 PEOPLE S REPUBLIC OF CHINA TEL 86 10 652 30 363 393 EXT 101 FAX 86 10 652 27 071 E MAIL li zheng acv world com DENMARK VARMEHUSET FRICHSVEJ 40 A 8600 SILKEBORG DENMARK TEL 45 86 82 63 55 FAX 45 86 82 65 03 E MAIL vh varmehuset dk ESTONIA TERMOX AS TAHE 112A 51013 TARTU ESTONIA TEL 372 736 73 39 FAX 372 736 73 44 E MAIL termox termox ee GREECE ESTIAS MARASLI STREET 7 54248 THESSALONIKI GREECE TEL 30 23 10 31 98 77 30 23 10 32 03 58 FAX 30 23 10 31 97 22 E MAIL info genikithermanseon gr ILE MAURICE SOTRATECH 29 RUE MELDRUM BEAU BASSIN ILE MAURICE TEL 230 46 76 970 FAX 230 46 76 971 E MAIL stech intnet mu LITHUANIA UAB GILIUS IR KO SAVARNORIU PR 192 3000 KAUNAS LITHUANIA TEL 370 37 308 930 FAX 370 37 308 932 MAROC CASATHERM PLACE EL YASSIR 20300 CASABLANCA MAROC TEL 212 22 40 15 23 FAX 212 22 24 04 86 MOLDAVIA STIMEX PRIM S R L STR BUCURESTI 60A 2012 CHISINAU MOLDAVIA TEL 37 32 22 46 75 FAX 37 32 27 24 56 E MAIL stimex slavik mldnet com OSTERREICH PROTHERM HEIZUNGSTECHNIK Gmbh TRAUNUFERSTRASSE 113 4052 ANSFELDEN OSTERREICH TEL 43 7229 804 82 FAX 43 7229 804 92 E MAIL protherm nextra at ROMANIA SC TRUST EURO THERM SA D N PIATRA NEAMT ROMAN km 2 C P 5 O P 3 jud Neamt 5600 PIATRA NEAMT ROMANIA TEL 40 233 20 62 06 FAX
12. at the factory for natural gas Conversion to propane A Not applicable for Belgium Conversion kit included with burner comprising Cap s Nameplate s Sticker with settings Mounting instructions Air gas mixture control system Venturi Fan Air gt Air gas l a mixture Gas flow regulating screw 12 71 101 Gas burner features BURNER FEATURES Type HM 71 HM 101 Input Kw 22 0 69 9 25 0 107 22 0 110 Output Kw 18 4 63 0 23 0 96 3 20 2 99 0 Combustion efficiency natural gas 92 0 92 1 Natural gas CO2 Ki 9 0 9 5 Gas G20 20 mbar I 2E S B 1 2 Er I 2H Flow m h 2 12 7 40 2 64 11 32 Gas G25 20 25 mbar I 2L I 2ELL Flow m h 2 46 8 60 3 80 13 17 Gas G31 37 50 mbar I 3P Flow m h 0 82 2 86 0 94 4 50 Pressure drop combustion chamber mbar 0 6 1 4 Flue gas temperature net C 172 165 Mass flow rate of combustion products grammes per second 9 2 32 1 11 5 49 2 propane Gas category BE FR AT DK ES UK IT PT IE SE NL LU DE l 2Er X 2E S B X 12H X X X Xx X X X X 13P X X X Xx X Xx 12L X 2ELL X X BG 2000 M 71 Burner tube Air collector Gas valve Gas inlet BG 2000 M 101 Burner tube Air collector Gas inlet 13 MAINTENANCE SERVICE INTERVALS DRAINING THE BOILER ACV recommends that boiler
13. ating circuit filling valve with removable hose and non return valve Primary expansion vessel Primary shunt pump Casing front panel Primary circuit Burner chamber plate Detector NTC1 and NTC2 Low water pressure switch Primary safety valve Ceaeaeaeeaeeaeeaeeaeeaeeaes vv e e e e e e e e e e We e DESCRIPTION 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 Detector NTC3 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 delivery and after unpacking check the equipment for damage For transport purposes refer to the weights and dimensions given below G F a i __ 1 e ITU G 1 l fe K 1 A B H l C 2 a G l O Ge J L ee C D E A mm B mm C mm D mm E mm Fmm G mm Hmm Jmm Kmm 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 HM 71 HM 101 Fuel type Natural gas propane Natural gas propane Maximum Input kW 20 69 9 25
14. f a heat request is present and the fan is running 3 Domestic Hot Water pump This contact closes if a Domestic Hot water heat request is present Technical data Ambient temperature Contact ratings 0 60 C lous lt 1A 230 V 10 15 50 Hz VS If inductive loads are connected take precautions over these loads against peak voltages e g RC network X8 Ribbon cable connection for alarm module option X7 Display connection GASMODUL 10 INSTALLATION HeatMaster 71 101 and B e burner wiring diagram legend Br Brown d i Bk Black 7 pin burner plug connector Or Orange 4 pin burner plug connector G Grey On off switch R Red Power and pump connection O W Off white Central heating pump W White HeatMaster shunt pump Y Yellow Room thermostat Gr Green Low water pressure switch Y Gr Yellow Green ONDA Primary temperature detector NTC 1 Primary temperature detector NTC 2 Hot water temperature detector NTC 3 Summer winter switch Fan power supply 230 volts Fan PWM Gas valve rectifier Gas valve rectifier HM 101 Gas pressure switch optional BG 2000 M 71 101 LENET F CERME a gt a 5 HEATMASTER 71 101 fe ACV MCBA 1 lelsl4 s e ij HANE 230V 50 Hz 11 COMMISSIONING FILLING THE HOT WATER AND HEATING CIRCUITS A IMPORTA
15. h concentric 6 metres Maximum length parallel 12 metres Note a 90 degree bend 1 metre equivalent length k A condensation drain outlet must be fitted close to the boiler to prevent condensation products from the chimney running into the boiler A To avoid condensation water running out of the terminal all horizontal flue runs must fall back towards the boiler INSTALLATION HOT WATER CONNECTIONS Pressure reducing valve If the mains water pressure is greater than 6 bar a pressure reducing valve must be fitted Expansion relief valve The tank expansion relief valve must be ACV approved and calibrated to a maximum of 7 bar The valve discharge must be connected to the drain Hot water expansion vessel A hot water expansion vessel must be installed Hot water circulation If the tank is situated a long way from the point of use then installing a recirculation loop can provide a faster supply of hot water to the outlets Temperature and pressure relief valve If using the HeatMaster as an unvented hot water unit in some countries a temperature and pressure relief valve must be fitted consult your ACV stockist for assistance Example of hot water connection with thermostatic mixer Stop cock Non return valve Pressure reducing valve Expansion relief valve Hot water expansion vessel Hot water secondary pump if fitted Thermostatic mixing valve Drawoff tap Drain cock 10 Stop cock fo
16. he MCBA 12 Low water pressure or 24V fuse failure top up the primary circuit see Using The Boiler Heating System Pressure call engineer to check fuse 13 17 Internal error if the problem persists after 2 resets change the MCBA 18 Primary temperature 1 gt 110 C check that sensor NTC1 is propely housed in its pocket if so change sensor NTC1 19 Primary temperature 2 gt 110 C check that sensor NTC2 is propely housed in its pocket if so change sensor NTC2 25 Primary temperature 1 gradient too high check that the shunt pump is operating and if so vent the boiler 28 No fan signal if the fan is turning check the PWM connection if the problem persists after 2 resets change the fan if the problem persists after 2 resets change the MCBA if the fan is not turning e check the 230 Volt power to the fan 31 Short circuit in temperature 1 sensor change sensor NTC1 32 Short circuit in temperature 2 sensor change sensor NTC2 33 Hot water temperature sensor change sensor NTC3 36 Temperature 1 sensor circuit open check the connection of sensor NTC1 to the terminal strip if the problem persists change sensor NTC1 37 Temperature 2 sensor circuit open check the connection of sensor NTC2 to the terminal strip if the problem persists change sensor NTC2 38 Hot water temperature sensor circuit open check the connection of sensor NTC3 to the terminal strip if the problem persists change sensor NTC3 44 Internal e
17. inually adjusts output to demand improving operating efficiency The burner tube is coated with metal fibre NIT which in addition to its remarkable heat exchange capabilities gives greater durability The main components are a venturi and one model 71 or two model 101 gas valves technology specially developed by Honeywell for low Nox premix air gas burners with automatic ignition and ionisation flame detection The pressure at the gas valve outlet is equal to the air pressure in the neck of the venturi less the offset The fan sucks combustion air through the venturi into which the gas inlet emerges As it passes through the air produces a pressure differential in the constriction of the venturi and sucks the gas into the venturi outlet A perfect mix of air and gas then passes through the fan to the burner tube This design ensures very quiet and safe operation e If there is an air blockage the pressure differential in the venturi falls the gas flow diminshes the flame goes out and the gas valve closes the burner is in safety shutdown mode If there is a blockage in the chimney outlet the air flow diminishes and the same reactions as those described above cause the burner to shut down in safety mode e The BG 2000 M burner fitted to the HeatMaster 71 and 101 is regulated by a MCBA controller Honeywell which controls burner operating safety as well as temperature modulation VS BG 2000 M burners are preset
18. m any of the safety valves switch the boiler off and call a service engineer 15 USER GUIDE CONTROL SETTINGS The boiler is controlled by the MCBA microprocessor with the control panel housed behind a flap on the front of the boiler see picture on page 16 Standby Mode Standby Mode is the normal operation display setting The first digit shows the boiler sequence This sequence relates to current boiler status The last two digits show the boiler temperature Sequence Boiler status 0 Stand By no heat request 1 Pre purge post purge Ignition Burning in CH mode Burning in DHW mode jJ AJOON Waiting for opening of Air pressure switch max 1 Min Waiting for closing of Air pressure switch max 2 x 1 Min Burner off because the set value has been reached Overrun time pump in CH mode Overrun time pump in DHW mode Step Store Changing the MCBA settings Parameter mode Proceed as follows Press the MODE button once the display will show PARA Press the STEP button once the first digit is 1 and the last two show the setting for the first parameter To change these last two press to increase and to decrease Save the new setting selected with the STORE button To access the next parameter press STEP Press the MODE button twice to return to standby mode List of accessible parameter
19. mary 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 p
20. r cleaning 11 Primary circuit filling valves 12 Temperature relief valve UK only OMNOORWND Y Wyss DANGER As a safety measure against scalding we strongly recommend installing a thermostatic mixing valve O Example of parallel connection Recommended for applications with a high continuous flow Example of series connection Preferable for high temperature applications with up to three units Example of heating storage connection Recommended for applications requiring a high peak flow HEATING CONNECTION The HeatMaster has two connections at the rear that can be used to connect a central heating circuit Connecting a heating system may reduce the domestic hot water performance A WARNING The maximum pump motor load for the MCBA is 250 Watt If a larger pump is required install a relay between the pump and the MCBA Expansion HeatMaster 71 101 models are fitted with two 10 litre expansion vessels which are sized for hot water operation only If a heating sys tem is connected to the primary circuit calculate the expansion capa city necessary for the total volume of the heating system Refer to the technical instructions from a relevant manufacturer of expansion vessels Example of a single circuit connection 1 3 way valve 2 Heating pump 3 Non return valve 4 Isolating valve 5 Safety valve set to 3 bar with pressure gauge 6 Expansion vessel 7 Drain cock 8 Prima
21. rimary 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 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 e 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 e 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 Top cover Automatic air vent Domestic cold water inlet He
22. rror if the problem persists after 2 resets change the MCBA 17 SERVICE RECORD INSTALLATION DETAILS Date installed Flue gas T Model CO2 min load Efficiency Serial number CO2 max load Gas pressure Heating system pressure setting L Gas LJ LPG Name and signature SERVICE RECORD Date serviced Flue gasT Remarks CO2 min load Efficiency CO2 max load Gas pressure LI Gas LI LPG Name and signature Date serviced Flue gasT Remarks CO2 min load Efficiency CO2 max load Gas pressure LI Gas LI LPG Name and signature Date serviced Flue gasT Remarks CO2 min load Efficiency CO2 max load Gas pressure LI Gas LI LPG Name and signature Date serviced Flue gasT Remarks CO2 min load Efficiency CO2 max load Gas pressure LI Gas LI LPG Name and signature Date serviced Flue gasT Remarks CO2 min load Efficiency CO2 max load Gas pressure L Gas LJ LPG Name and signature 18 17 02 2003 excellence in hot water INTERNATIONAL ACV international n v KERKPLEIN 39 B 1601 RUISBROEK BELGIUM TEL 32 2 334 82 20 FAX 32 2 378 16 49 E MAIL international info acv world com BELGIUM ACV BELGIUM nv sa
23. ry circuit filling valve 9 Controller AS WARNING The pimary safety valve is supplied with a plastic tube connected to the discharge outlet this is for test purposes only and should be removed The safety valve should be connected to a drain using a metallic pipe eg copper INSTALLATION INSTALLATION ELECTRICAL CONNECTION Power supply The boiler operates with a 230 V 50 Hz single phase supply A double pole isolator with a 6 amp fuse or a 6 amp MCB must be fitted outside the boiler to allow power to be shut off during servicing and before any repairs are carried out on the boiler Conformity Boiler installation must comply with the prevailing local standards and legislation Safety The stainless steel tank must be earthed separately A The power to the boiler must be switched off before any work is carried out Internal MCBA connections X1 Connection MCBA 230 Volt X2 24 Volt connector X3 NTC connector X4 NTC 5 analogue in connector X5 Communication NTC 4 connector Connection for transformer MCBA Alarm module Alarm module e Connect the flat ribbon cable from the alarm module X7 to MCBA connector X8 The volt free relays mounted on the alarm module will now be actived as described below 1 Alarm This contact closes if the MCBA is in lock out 2 External gas valve burner run indication This contact closes i
24. s Wl o Sn oo Burner off because of protection automatic restart occurs when the condition has cleared b08 airflowsensor did not close b18 T1 gt 95 b19 TA gt 95 C b24 T2 T1 gt 10 20 or 40 C after 19 minutes b25 dT1 dt gt Maximum Gradient T1 b26 Minimum gas pressure switch not closed b28 no fan signal b29 fan signal incorrect fan rotation b30 T1 T2 gt Max delta b33 NTC3 short circuit b35 NTC5 short circuit b38 NTC3 open circuit e b40 NTC5 open circuit b52 TS gt T5max b61 airflowsensor closed b65 wait for fanstart Parameter N Description Range 1 hot water setting 20 90 C 2 Hot water system status O O0FF 1 0N 3 Heating system status O OFF 1 ON 4 Heating setting 60 90 C Temperature measurement display Info mode Proceed as follows e Press the MODE button twice the display will show INFO e Press the STEP button once the first digit is the measurement number and the last two its value e Press the STEP button to display the next measurement To return to standby mode press the MODE button once List of measurements available Measurement N Description 1 Temperature T1 primary Temperature T2 primary Temperature T3 secondary
25. s marks MAINTENANCE 14 Service Intervals 14 Servicing the boiler 14 Servicing the safety devices 14 Servicing the burner 14 Draining the boiler 14 WARNINGS USER GUIDE 15 These instructions are an integral part of the equipment to which they refer and must be supplied to the user Using the boiler 15 Control Settings 16 The product must be installed and serviced by qualified engineers in compliance with the prevailing standards SERVICE RECORD 18 ACV accepts no liability for any damage resulting from incorrect installation or from the use of components or fittings not specified by ACV A 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 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 pri
26. s 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 INSTALLATION BOILER ROOM CHIMNEY CONNECTIONS Important Keep vents free at all times Do not store inflammable products in the boiler room e 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 150mm above 700 mm Ventilation The boiler room must be fitted with top and bottom vents according to the prevailing local standards and regulations The table below gives an example conforming to the Belgian standards Ventilation 71 101 Min fresh air requirement m h 126 194 Bottom vent dm 2 4 3 20 Top vent dm 2 0 210 Other countries should refer to their own standards Base The base on which the boiler rests must be made of non combustible materials IE IMPORTANT Boilers must be installed by an approved heating
27. s should be serviced at least once a year The burner must be serviced and tested by a competent engineer If a boiler is subject to heavy use it may require servicing more than once a year consult ACV for advice SERVICING THE BOILER 1 Turn OFF the on off switch on the boiler control panel and isolate external electrical supply Turn off the gas supply to the boiler Remove the flue to gain access to the top of the boiler Remove the casing top panel and lift off the flue reduction collar by undoing the fastening bolts Remove the turbulators from the flue pipes for cleaning Unscrew the burner chamber plate and remove the burner Brush the flue pipes Clean the burner chamber and the burner Re assemble turbulators flue reduction collar and flue checking that the gasket on the flue reduction collar is in good condition Replace gasket if necessary POR CONDA Chimney flue Casing top panel Flue reduction collar Flue pipe and turbulators Burner chamber px e a ER EI OO eae Me ye px Se ey ee ee e yy Burner chamber SERVICING THE SAFETY DEVICES Check that all thermostats and safety devices are working properly Test the safety valves on the central heating and hot water circuits SERVICING THE BURNER Check that the insulation and gasket on the burner chamber plate are in good condition replace if necessary Check and clean the burner and electrodes Replace electrodes if necessar
28. y under normal use once a year Check that the safety components are working properly Check the combustion CO2 CO and gas pressure and record the values and any remarks in the Service Record on page 18 Water flowing out of the drain cock may be extremely hot and could cause severe scalding Keep people away from discharges of hot water Draining the heating circuit 1 Turn OFF the on off switch on the boiler control panel isolate external electrical supply and turn off the gas supply to the boiler 2 Close the isolating valves 4 3 Connect a hose to the drain cock 7 4 Open the drain cock to drain the primary circuit Draining the hot water circuit 1 Turn OFF the on off switch on the boiler control panel isolate external electrical supply and turn off the gas supply to the boiler 2 Release the pressure in the heating circuit until the pressure gauge indicates zero bar Close stop cock 1 and turn off tap 8 Open valve 9 then valve 10 Let the water empty into the drain OT e w Y ES For the tank to be emptied valve 9 must be situated at ground level 14 USER GUIDE USING THE BOILER ER 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
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