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HeatMaster
Installation, Operating and
Servicing Instructions
HM 71
HM 101
excellence in hot water
66401100
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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: Essential instruction for operating the system TECHNICAL SPECIFICATION 4 correctly. Dimensions 4 General fea
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DESCRIPTION CONSTRUCTION FEATURES OPERATING PRINCIPLE Outer body The HeatMaster is a high performance, direct fired hot water storage heater, which has indirect heat transfer due to its Tank-in-Tank The outer body containing the primary fluid is made of carbon steel construction. (STW 22). At the heart of the HeatMaster is a stainless steel cylinder through TANK-IN-TANK heat exchanger which the flue tubes pass. This is surrounded by a mild steel shell The ring-shaped inner tank with its large he
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DESCRIPTION Top cover Flue reduction collar Automatic air vent Central heating flow pipe Domestic cold water inlet Domestic hot water outlet Heating circuit filling valve with removable hose Flue pipes and turbulators and non-return valve Primary expansion vessel Tank-in-Tank heat exchanger Insulation Primary shunt pump Burner Casing front panel Heating return Primary circuit Combustion chamber Burner chamber plate Detector NTC1 and NTC2 Detector NTC3 Low water pressure switch Primary safety val
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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 K A B H C/2 J C D E 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
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TECHNICAL SPECIFICATION MAXIMUM OPERATING CONDITIONS HEATMASTER CONTROL SETTINGS Maximum service pressure (tank full of water) Description - Primary circuit: 3 bar The 71/101 series is fitted with an electronic controller (MCBA) - Secondary circuit: 10 bar which controls burner operation (ignition, safety and modulation), and provides facilities to adapt the controller to the desired application. Test pressure (tank full of water) - Primary circuit: 4.5 bar The MCBA has three levels of settings
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INSTALLATION BOILER ROOM CHIMNEY CONNECTIONS Important •Keep vents free at all times. IMPORTANT • Do not store inflammable products in the boiler room. Boilers must be installed by an approved heating • Do not store corrosive products near the boiler, such as paints, engineer, in accordance with the prevailing local solvents, chlorine, salt, soap and other cleaning products. standards and regulations. • If you smell gas, do not switch on the light or light a flame. Turn off the mains gas tap at
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INSTALLATION Balanced flue boiler connection type: C • C13: concentric horizontal connection • C33: concentric vetical connection • C53: parallel chimney connection • C63: concentric vertical connection without terminal (only in Germany and Luxembourg). C33 120 C13 C53 Maximum length concentric : 6 metres Maximum length parallel : 12 metres Note: a 90 degree bend = 1 metre equivalent length A condensation drain outlet must be fitted close to the boiler to prevent condensation products from the c
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INSTALLATION Example of parallel connection HOT WATER CONNECTIONS Recommended for applications with a high continuous flow. 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 circulat
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INSTALLATION 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. 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 i
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INSTALLATION Alarm - module ELECTRICAL CONNECTION • Connect the flat ribbon cable from the alarm-module “X7” to MCBA connector “X8”. Power supply The volt free relays mounted on the alarm module will now be The boiler operates with a 230 V - 50 Hz single phase supply. actived as described below: 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 1 - Alarm: and before any repairs are carried out on the boiler. T
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INSTALLATION HeatMaster 71/101 and 16 B. Blue burner wiring diagram legend Br. Brown Bk. Black BG 2000-M/101 13 14 15 17 Or. Orange 1. 7-pin burner plug connector L1 N 1 2 3 4 5 V1 V2 V1 V2 C 1 G. Grey 2. 4-pin burner plug connector R. Red 3. On/off switch O-W. Off-white 4. Power and pump connection W. White 5. Central heating pump Y. Yellow 6. HeatMaster shunt pump Gr. Green 7. Room thermostat Y/Gr. Yellow / Green 8. Low water pressure switch 9. Primary temperature detector NTC 1 10. Primary te
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COMMISSIONING BURNER FEATURES FILLING THE HOT WATER AND HEATING CIRCUITS ACV BG 2000-M MODULATING PREMIX GAS BURNERS Description of operation: The BG 2000-M modulating burner continually adjusts output to IMPORTANT demand, improving operating efficiency. The hot water tank must be pressurised before the The burner tube is coated with metal fibre (NIT) which, in addition to heating circuit is filled. its remarkable heat exchange capabilities, gives greater durability. The main components are a ve
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BURNER FEATURES 71/101 Gas 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 % 9.0 9.5 Gas G20 - 20 mbar - I 2E(S)B - I 2 Er - I 2H 3 Flow m /h 2.12 - 7.40 2.64 - 11.32 Gas G25 - 20/25 mbar - I 2L - I 2ELL 3 Flow m /h 2.46 - 8.60 3.80 - 13.17 Gas G31 - 37/50 mbar - I 3P 3 Flow m /h 0.82 - 2.86 0.94 - 4.50 Pressure drop combustion chamber mbar 0.6 1
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MAINTENANCE SERVICE INTERVALS DRAINING THE BOILER ACV recommends that boilers should be serviced at least once a year. Water flowing out of the drain cock may be The burner must be serviced and tested by a competent engineer. extremely hot and could cause severe scalding. If a boiler is subject to heavy use, it may require servicing more than Keep people away from discharges of hot once a year - consult ACV for advice. water. SERVICING THE BOILER 1. Turn OFF the on/off switch on the boiler contr
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USER 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 Summer/winter switch MCBA controller - display On/off switch Combined temperature and pressure
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USER GUIDE CONTROL SETTINGS The boiler is controlled by the MCBA (microprocessor), with the 00 8 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 Changing the MCBA settings: Param
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USER GUIDE 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. 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 codes Error description Fault repai
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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 : ❏ Gas ❏ LPG Name and signature : SERVICE RECORD Date serviced : Flue gas T° : Remarks : % CO2 (min. load) : Efficiency : % CO2 (max. load) : Gas pressure : ❏ Gas LPG Name and signature : ❏ Date serviced : Flue gas T° : Remarks : % CO2 (min. load) : Efficiency : % CO2 (max. load) : Gas pressure : ❏ Gas ❏ LPG
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excellence in hot water INTERNATIONAL ESPAÑA PORTUGAL ACV international n.v ACV ESPAÑA BOILERNOX LDA KERKPLEIN, 39 C/ANTONIO GAUDI, 3 RUA OUTEIRO DO POMAR B-1601 RUISBROEK - BELGIUM E-08349 CABRERA DE MAR - ESPANA CASAL DO CEGO, FRACÇÃO C, TEL.: +32 2 334 82 20 TEL.:+34 937 595 451 PAVILHÃO 3 - MARRAZES FAX: +32 2 378 16 49 FAX:+34 937 593 498 2400-402 LEIRIA - PORTUGAL E-MAIL: international.info@acv-world.com E-MAIL: spain.info@acv-world.com TEL.:+351 244 837 239/40 FAX:+351 244 823 758 E-MAIL:
