ACV HeatMaster 120 TC Installation, Operation And Maintenance Instructions Download

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A1003474 - 664Y7000 • B

INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS

for the Installer and the User

HeatMaster

Summary of Contents for HeatMaster 120 TC

Page 1: ...A1003474 664Y7000 B EN FR NL ES IT DE PL RU INSTALLATION OPERATION AND MAINTENANCE INSTRUCTIONS for the Installer and the User 25 C HeatMaster...

Page 2: ...Addendum Royal Decree A1007429 ADD0180 Addendum Declaration of Conformity i a w Royal Decree BE APPLICABILITY 664Y6900 Rev E HeatMaster 25 35 45 70 85 120 TC 664Y7000 Rev B HeatMaster 25C...

Page 3: ...Gewogen Ponderado Pesata Gewichtet rednio HeatMaster 25 TC mg kWh 26 3 35 TC mg kWh 24 6 45 TC mg kWh 29 5 70 TC mg kWh 33 2 85 TC mg kWh 33 1 120 TC mg kWh 29 3 HeatMaster 25 C mg kWh 31 1 Prestige 2...

Page 4: ...mplete assembly on the boiler If the assembly is incomplete replace the entire assembly Make sure that the condensate drain assembly is filled with water before starting up the boiler and check regula...

Page 5: ...x PP 80 537D6448 HeatMaster 25 C HeatMaster 25 35 45 TC WaterMaster 25 35 45 C13 C33 PP Galva 80 125 RoofTerminal 537D6184 Wall terminal kit 537D6185 Wall terminal Kit 10800301 Lengths 250 mm 537D6186...

Page 6: ...120 B23P C53 SST 150 RoofTerminal flue 150 537D6211 Wall terminal kit flue 150 537D6212 Wall terminal kit air 100 537D6213 Lengths flue 150 250 mm 537D6214 500 mm 537D6215 1000 mm 537D6216 Length air...

Page 7: ...nsatsestremplid eauavantded marrer lachaudi reetv rifierr guli rementleniveaud eau Leremplird eausin cessaire La ventilation de la chaufferie est obligatoire Les dimensions de l ouverture haute ou bas...

Page 8: ...0 100 mm 80 125 mm 537D6405 HeatMaster 25 C HeatMaster 25 35 45 TC WaterMaster 25 35 45 C93 PP Flex 80 Set C93 80 125 537D6287 Tube flexible PPS 80 25 m 537D6275 Fourreau de raccord ement pour concen...

Page 9: ...90 537D6220 Air 100 45 537D6221 Air 100 90 537D6222 Tube de mesure avec r cup rateur de condensats fum es 150 537D6223 Solin r glable 25 45 537D6209 Fixation 150 mm 537D6210 Solin toit plat 430 mm 53...

Page 10: ...lmatig het waterniveau Vul met water indien nodig Deventilatievandestookruimteisverplicht Deafmetingenvandebovenverluchting of onderverluchting zijn afhankelijk van het vermogen van de ketel en het vo...

Page 11: ...PP 80 537D6448 HeatMaster 25 C HeatMaster 25 35 45 TC WaterMaster 25 35 45 C13 C33 PP Galva 80 125 Dakdoorvoer 537D6184 Muurdoorvoer met muurplaten 537D6185 Lengte 250 mm 537D6186 500 mm 537D6187 100...

Page 12: ...aster 70 85 120 TC WaterMaster 70 85 120 B23P C53 SST 150 Dakdoorvoer rook 150 537D6211 Muurdoorvoer rook 150 537D6212 Muurdoorvoel lucht 100 537D6213 Lengte rook 150 250 mm 537D6214 500 mm 537D6215 1...

Page 13: ...Addendum HeatMaster WaterMaster Chimney Connections A1005390 ADD0080...

Page 14: ...1 1 X100 6 V B Y Gr W B Y Gr Br B Y Gr Br B Y Gr B Or STEPPER PUMP PWM 8 9 R Bk Y Y R R W W W W Or Br R Br B Br B Y Gr V 1 2 3 4 5 1 2 3 4 5 10 A B C D 2 1 1 NTC 5 11 2 1 1 NTC 2 12 2 1 1 NTC 1 13 C M...

Page 15: ...s connected to the earth Check that the gas type and pressure from the distribution network are compatible with the appliance settings V rifier que le type de gaz et la pression du r seau de distribut...

Page 16: ...ance UK Only 26 INSTALLATION 28 Safety Instructions for the Installation 28 Package contents 29 Tools Required for the Installation 30 Boiler preparation 30 Hydraulic Connections 30 DHW Connection 30...

Page 17: ...ures of its products without prior notice In spite of the strict quality standards that ACV applies to its appliances during production inspection and transport faults may occur Please immediately not...

Page 18: ...mmendation for the correct operation of the appliance or the system General remark Safety valve connected to the sewage system Connection to the sewage system Symbols on the packaging Meaning Fragile...

Page 19: ...DE PL RU en 5 USER S GUIDE The part number Code and serial number N of the appliance are indicated on its rating plate and must be provided to ACV in case of warranty claim Failure to do so will make...

Page 20: ...menus of the ACVMAX controller to set up the system 4 Arrow keys and OK key to browse through the screens of the ACVMAX controller set up the boiler increase and decrease the displayed values and val...

Page 21: ...ty over central heating calls Priority Timeout Central heating and domestic hot water calls are being received simultaneous ly The domestic hot water priority time limit has been exceeded Priority wil...

Page 22: ...ed in a hot boiler the boiler can be damaged definitively If the system needs to be refilled repeatedly with water please contact your installer Check thatthereisnowateronthefloorundertheboiler Ifther...

Page 23: ...2 Default 60 C Select CH Demand prompts the installer to select how a CH Demand is generated There are three Select CH Demand options among which the installer must make a selection Thermostat Setpoin...

Page 24: ...CH1 heating call when an Outdoor Reset option is chosen in Select CH Demand Outdoor curve presets are available to cover most applications The outdoor curve can also be adjusted to any desired settin...

Page 25: ...tional changes can be made in the Installer Menu if required Press OK to return to EZ Setup Menu EZ Setup Complete Heating EZ setup is complete Additional changes can be made in the Installer Menu if...

Page 26: ...to enter the fixed boiler setpoint temperature during a hot water call when the Thermostat option is selected Press on LEFT or RIGHT button to adjust the required temperature setpoint then press OK to...

Page 27: ...eep current settings EZ Setup Reset allows to reset all EZ setup settings back to the original factory defaults Follow the on screen instructions to reset all EZ setup settings Display Easy Setup Disp...

Page 28: ...the Installer s Handbook of the HeatMaster boilers Lockout History records the last eight lockouts Six lines are displayed on the Lock out History screen at one time Each line contains a lockout desc...

Page 29: ...air gas premix burner with low NOx emissions During operation the burner starts automatically as soon as the boiler temperature gets lower than the preset temperature and stops as soon as the preset t...

Page 30: ...o be connected to the sewage system 2 Gas connection M 3 Grommets for electrical wires low voltage con trol 4 Domestic Hot Water outlet M 5 Heating supply connection F 6 Connection for provided heatin...

Page 31: ...mm 1610 L mm 1405 M aux circulation loop mm N mm 446 O mm 273 Heating Connection F 1 DHW Connection M 1 Auxiliary connection F Gas connection M 3 4 min of flue pipe mm 80 Drained weight Kg 174 Boiler...

Page 32: ...w rate G20 G25 20 mbar m h 2 66 25 mbar m h 2 96 Max gas flow rate G31 30 37 50 mbar m3 h 0 98 Kg h 1 9 Temp of flue gases Normal C 57 7 57 7 Max C 120 120 Min C 32 9 32 9 Average temp of combus tion...

Page 33: ...air and discharging combustion products that is approved and sold separately Prohibited in some countries e g Belgium refer to local regulations and standards in force Terminals for the supply of com...

Page 34: ...cated in the table on previous page Example of verification of the flue pipe length L in a concentric flue pipe system 80 125 The method is detailed through an example Figure 1 The assembly is compris...

Page 35: ...efer to your ACV representative HeatMaster 25 C cascade in a C43 chimney connection configuration HeatMaster 25 C cascade in a B23 chimney connection configuration Elbow type 150 L Eq 45 M 1 7 90 M 4...

Page 36: ...items Pump P3 and P4 terminals Flame terminal versatile connection according to configuration 8 Modulating pump PWM 9 Burner PWM plug 10 NTC5 flue gas temperature sensor 11 NTC2 return sensor 12 NTC1...

Page 37: ...Y Gr V 1 2 3 4 5 6 7 8 8 7 6 5 4 3 2 1 1 2 3 4 5 6 F00 X100 V ON OFF 3 230 V 50Hz 1 N L N L N L 2 6 25 B Y Gr Br B Y Gr Br Br B Bk B Y Gr Y Gr Y Gr Y Gr Y Gr Y Gr Y Gr V B Y Gr W B Y Gr Br B Y Gr B O...

Page 38: ...ircuit 8 6 bar Maximum Operating temperatures Maximum temperature primary 87 C Maximum temperature DHW 75 C Water Quality See Recommendations for the Prevention of Corrosion and Scaling in Heating Sys...

Page 39: ...is recommended to install a hydrocyclone or magnetic filter on the installation side 2 Limit the fill frequency Limit fill operations In order to check the quantity of water that has been added into...

Page 40: ...6 The discharge pipe D2 from the tundish should a have a vertical section of pipe at least 300mm long below the tundish before any elbows or bends in the pipework and b be installed with a continuous...

Page 41: ...ommon temperature relief valve outlet sizes UK Worked example of discharge pipe sizing Figure on the left shows a G1 2 temperature relief valve with a discharge pipe D2 having 4 No elbows and length o...

Page 42: ...es not damage the heating body Only use ACV flue systems to connect this appliance to ensure that the pipe and connection diameters all match Hot water can cause scalding In the event of small amounts...

Page 43: ...er removal of packaging check the package contents and that the appliance is free of damages Contents Boiler Installation Operation and Maintenance Instructions Installer s Handbook manual on electron...

Page 44: ...t be fitted in the heating circuit if there is no built in expansion vessel or if the built in expansion vessel size is not sufficient Cold water Hot water Typical installation with internal DHW tank...

Page 45: ...ster 25 C A1003474 664Y7000 B EN FR NL ES IT DE PL RU en 31 INSTALLATION For additional system configurations refer to Configuration and system set up on page 34 and to the Installer s Handbook Access...

Page 46: ...connection the boiler room air vent system the tightness of flue gas outlet pipes and of the burner chamber plate Control the gas pressure and consumption at appliance start up Check the boiler CO2 a...

Page 47: ...screws for reinstallation 5 Remove the gas valve 1 from the venturi 3 by releasing 3 screws 4 Retain the screws for reinstallation 6 Install the orifice in the center of the O ring 6 Make sure you po...

Page 48: ...r B Y Gr Br Br B Bk B Y Gr Y Gr Y Gr Y Gr Y Gr Y Gr Y Gr V B Y Gr W B Y Gr B Or X101 18 20 19 21 22 23 W V 24 X18 5AT Fuse 5AT Fuse 5AT Fuse R Bk Y Y R R W W Bk Bk R Bk W Y Y Y Y Y Y Y Y Y Y W W W W W...

Page 49: ...Y Y Y Y Y Y W W W W W W 2 1 1 NTC 1 12 R Bk 13 1 2 3 1 2 1 2 3 4 1 2 3 4 5 6 X7 X4 X6 X5 Bus A Bus Ground Bus B 0 10 Volt Ground 0 10 Volt Input NTC 3 NTC 4 1 2 Bk R EBV Clip in wiring CASCADE CONFIGU...

Page 50: ...is totally evacuated from the system close the draw off tap 2 3 Check all the connections for leaks Heating circuit filling procedure 1 Open boiler front panel refer to applicable procedure in the ma...

Page 51: ...table read out the supply and return temperatures Check that the difference between the supply and return temperature is equal or less than 20k If the Delta T is higher than 20k check the pump setting...

Page 52: ...NANCE TASKS Tasks Frequency Periodic inspec tion 1 year 2 years End user Professional 1 Make sure that the system water pressure is at least 1 bar when cold Top up the system if necessary adding small...

Page 53: ...onnection open a draw off tap located higher in the system 6 Close the drain valve 2 and the draw off tap 3 once the DHW tank of the boiler is empty Cold water Hot water 1 1 2 1 2 3 1 2 3 HeatMaster 2...

Page 54: ...nger on page 41 7 If not removed previously remove check and reinstall the electrode refer to Removal Check and Installation of the Burner Electrode on page 39 Installation procedure 1 Reinstall the b...

Page 55: ...y be present in the heat exchanger 3 Remove and clean the condensate trap 4 Reinstall the condensate trap refer to Boiler preparation on page 30 Follow on tasks 1 Reinstall the burner according to pro...

Page 56: ...eck the gas valve and wiring harness 2 If the problem persists replace the ACVMax circuit board E 12 Internal Fault EEPROM misconfiguration 1 Turn unit off and on to resume normal operation 2 If the p...

Page 57: ...ture sensor and wiring harness for a short circuit 2 If necessary replace the sensor or the wire harness 3 After fixing the problem reset the appliance and resume normal operation E 44 Return Sensor O...

Page 58: ...or circuit 1 Check system temperature sensor and wiring for a short circuit 2 If necessary replace the sensor or the wire harness 3 After fixing the problem reset the appliance and resume normal opera...

Page 59: ...HeatMaster 25 C A1003474 664Y7000 B EN FR NL ES IT DE PL RU en 45 SERVICE LOG Service date CO2 Flue gas T Efficiency Remarks Name Signature SERVICE LOG...

Page 60: ...HeatMaster 25 C A1003474 664Y7000 B en 46 EN FR NL ES IT DE PL RU DECLARATION OF CONFORMITY...

Page 61: ...Combination heater Useful heat output at 30 of rated heat output P1 kW 7 9 at rated output and high temp regime P4 kW 24 3 Useful efficiency at 30 of rated heat output 1 98 2 at rated output and high...

Page 62: ...n condensation condensation declared load profile for water heating XXL XXL XXL XXL XXL XXL XXL Seasonal space heating energy efficiency class A A A A A A A Water heating efficiency class B A A A A A...

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ACV HeatMaster 120 TC, Installation, Operation And Maintenance Instructions

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