ACV HeatMaster 25 TC Installation, Operation And Maintenance Instructions
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Also See for HeatMaster 25 TC:
- Installation operation & maintenance (77 pages) ,
- Installation, operating and servicing instructions (32 pages) ,
- Installer's handbook (107 pages)
Related Manuals for ACV HeatMaster 25 TC
Summary of Contents for ACV HeatMaster 25 TC
- Page 1 INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS for the Installer and the User HeatMaster 25 - 35 - 45 - 70 - 85 - 120 A1003129 - 664Y6900 • C...
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Page 2: Table Of Contents
Control Panel and Display .................................6 CONFIGURATION AND SYSTEM SET-UP ..............40 Stand-by Screen ....................................7 Basic Configuration - HeatMaster 25 TC V15: High Temperature Heating Circuit Controlled by Room Lockout Screen ....................................7 Thermostat and Optional Outdoor Sensor........................40 Status Messages ....................................7 Cascade Configuration, Controlled by EBV Controller .................... -
Page 3: General Recommendations
The manufacturer reserves the right to change the technical characteristics and features 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 notify your approved installer of any faults. -
Page 4: User's Guide
USER’S GUIDE MEANING OF SYMBOLS Symbols on the packaging Meaning Symbols in the manual Meaning Fragile Essential recommendation for safety (of persons and equipment) Keep dry Essential recommendation for electrical safety (electrical hazard) Keep standing, up Essential recommendation for the correct operation of the appliance or the system Danger of tipping over General remark... -
Page 5: Boiler Marking
Back panel 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 the claim void. HeatMaster 25 TC... -
Page 6: Nl Control Panel And Display
USER’S GUIDE CONTROL PANEL AND DISPLAY Main Icons of ACVMAX display Central Heating - indicates information related to the CH circuit. DHW - indicates information related to the Domestic Hot Water circuit. Home - to go back to the main menu screen. Back - to go back to the previous screen. -
Page 7: Stand-By Screen
USER’S GUIDE STAND-BY SCREEN STATUS MESSAGES This screen is displayed at start-up. It indicates that the HeatMaster is ready to respond when a demand is received. Stand-by Indicates that the HeatMaster is ready to respond when a demand is received. CH Demand A central heating call has been received. -
Page 8: What To Check On A Regular Basis
ACVMax controller. The EZ setup function allows the user/installer to quickly setup the appliance for im- mediate operation according to the system configuration*. ACV recommends to check the system at least every 6 months as follows: • Check that the system water pressure is at least 1 bar when cold. If the pressure drops General remarks below 0.7 bar, the built-in pressure sensor blocks the appliance until the pressure... - Page 9 USER’S GUIDE Heating Easy setup (no outdoor sensor connected) • To navigate on the screen, use the UP, DOWN, LEFT and RIGHT keys, Use the OK key to validate a selection. • To increase/decrease values, use the UP and DOWN keys, or LEFT and RIGHT, according to the situation •...
- Page 10 USER’S GUIDE Heating Easy Setup (outdoor sensor connected) EZ Setup Select CH Demand prompts the installer to select how a CH Demand is generated. There are several Select CH Demand options, Heating EZ Setup Select CH Demand among which the installer must make a selection. Thermostat &...
- Page 11 USER’S GUIDE EZ Setup Heating EZ Setup Warm Weather Shutdown Select CH Demand CH1 Setpoint CH2 Setpoint EZ Setup Complete 82°C 60°C Thermostat & Outd. Curve Heating EZ setup is complete. Constant & Outdoor Curve Additional changes can be made in Refer to page 9 for screen descriptions Constant &...
- Page 12 USER’S GUIDE DHW Setup EZ Setup Select DHW Demand prompts the installer to select how a DHW Demand is generated. There are two Select DHW Demand options, DHW EZ Setup Select DHW Demand among which the installer must make a selection. Thermostat When Thermostat is selected in Select DHW Demand, a domestic hot water call from an aquastat or dry contact switch will enable Sensor...
- Page 13 USER’S GUIDE Starting from the Home screen : Easy Setup Reset HeatMaster EZ Setup 84°C 61°C EZ Setup Reset allows to reset all EZ EZ Setup Reset EZ Setup Reset Target = 85°C setup settings back to the original factory Boiler Protection defaults.
- Page 14 USER’S GUIDE CH/DHW Operation CH/DHW Operation provides a simple way to enable/disable either the CH or the DHW function of the Heat- CH / DHW Operation Heating enabled DHW enabled Master. Press on LEFT or RIGHT button to select the object (CH or DHW icon), then press OK to toggle between the enabled/disabled status.
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Page 15: Appliance Description
"Tank-in-Tank" concept with a double primary circuit to reach the high performance of a TOTAL CONDEN- SATION, double-circuit boiler. All the HeatMaster® TC models are equipped with a high efficiency charging pump and with an ACV 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 temper- ature is reached. -
Page 16: Heatmaster® 70 - 85 - 120 Tc Overview
APPLIANCE DESCRIPTION HEATMASTER® 70 - 85 - 120 TC OVERVIEW Concentric flue gas/air inlet box Flue gas exhaust tube Combustion chamber Stainless steel heat exchanger Stainless steel “Tank-in-Tank” hot water production tank Primary circuit separation disc Indirect water pre-heater Condensate recovery dish + NTC5 sensor (flue gas) High efficiency circulator pump NTC2 sensor (CH return) Pressure sensor... -
Page 17: Connections - At The Back
APPLIANCE DESCRIPTION CONNECTIONS - AT THE BACK Discharge for built-in DHW safety valve / (T & P re- Connection for provided heating safety valve (to lief valve - UK only) outlet to be connected to the be installed). sewage system Connection for low temperature heating circuit Gas connection [M] return (HM 70 - 85 - 120 TC only) -
Page 18: Technical Characteristics
TECHNICAL CHARACTERISTICS DIMENSIONS Boiler Dimensions HM 25 - 35 - 45 TC HM 70 - 85 TC HM 120 TC 1755 2170 2170 1670 2080 2080 1717 2126 2126 1610 2030 2030 1405 1750 1750 M (aux. circulation loop) – Heating Connection [F] “... -
Page 19: Clearance
TECHNICAL CHARACTERISTICS CLEARANCE GAS CATEGORIES (All models) Boiler Clearance HeatMaster® 25 - 35 - 45 - 70 - 85 - 120 TC Gas type Recommended Pressure (mbar) A (mm) Minimum Recommended Country code Category B (mm) Minimum II 2H3P Recommended C (mm) II 2H3P Minimum... -
Page 20: Combustion Characteristics
TECHNICAL CHARACTERISTICS COMBUSTION CHARACTERISTICS HM 70 TC HM 85 TC HM 120 TC HM 25 TC HM 35 TC HM 45 TC Main Characteristics Main Characteristics G20/G25 G20/G25 G20/G25 G20/G25 G20/G25 G20/G25 max. 69.9 69.9 85.0 85.0 115.0 115.0 25.0 25.0 35.0 35.0... -
Page 21: Chimney Connection Characteristics
The appliance is also connected through a second duct fitted with a terminal, that supplies the burner with fresh outdoor air. Please contact your ACV representative for the meters of flue pipes that can be used to connect the appliance(s). -
Page 22: Pl Calculation Of The Flue Pressure Drop In The Flue Pipes
TECHNICAL CHARACTERISTICS CALCULATION OF THE FLUE PRESSURE DROP IN THE FLUE PIPES When connecting the flue pipes, make sure not to exceed the maximum flue pressure drop value, recommended for the product, otherwise the system pressure might decrease. The flue pipe dimensions can be calculated using the method shown below. Please refer to the tables below indicating the pressure drop values, applied to each of the connection components. Then compare the calculation result to the recommended maximum flue pressure drop indicated in the table on previous page. -
Page 23: Cascade : Calculation Of The Maximum Length Of Flue Pipes
— * This table is for systems comprised of boilers with identical power. For any other configuration, please refer to your ACV representative. **Dn 150/200 : Hor. = 150 mm, Vert.=200 mm HeatMaster 25 - 35 - 45 - 70 - 85 - 120 TC : A1003129 - 664Y6900 • C... -
Page 24: Electrical Characteristics Heatmaster ® 25-35-45 Tc
TECHNICAL CHARACTERISTICS ELECTRICAL CHARACTERISTICS HEATMASTER 25-35-45 TC ® 230 V power supply plug HeatMaster TC Ground Main Characteristics ON/OFF master switch Rated voltage Gas valve rectified Burner power supply Rated frequency Terminal block for optional items Max. Electrical consumption 230 VAC OUTPUT ! : Alarm (ERR) Min. - Page 25 10 11 10 11 12 X103 Harness code: A1002113 Bus A Bus - Ground Bus B Y/Gr X103 ACV Max NTC 3 NTC 4 Y/Gr 0-10 Volt - Input 0-10 Volt - Ground Y/Gr ON / OFF X101 230 V ~ 50Hz...
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Page 26: Electrical Characteristics Heatmaster ® 70-85 Tc
TECHNICAL CHARACTERISTICS ELECTRICAL CHARACTERISTICS HEATMASTER 70-85 TC ® 230 V power supply plug HeatMaster TC Ground Main Characteristics ON/OFF master switch Rated voltage Gas valve Burner power supply Rated frequency Terminal block for optional items Max. Electrical consumption 230 VAC OUTPUT ! : Alarm (ERR terminal) Min. - Page 27 10 11 10 11 12 Harness code: A1002113 Bus A Bus - Ground X103 Bus B Y/Gr X103 ACV Max NTC 3 NTC 4 Y/Gr 0-10 Volt - Input 0-10 Volt - Ground Y/Gr ON / OFF X101 230 V ~ 50Hz...
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Page 28: Electrical Characteristics Heatmaster ® 120 Tc
TECHNICAL CHARACTERISTICS ELECTRICAL CHARACTERISTICS HEATMASTER 120 TC ® 230 V power supply plug HeatMaster TC Ground Main Characteristics ON/OFF master switch Rated voltage Gas valve Burner power supply Rated frequency Terminal block for optional items Max. Electrical consumption 230 VAC OUTPUT ! : Alarm (ERR terminal) Min. - Page 29 10 11 12 Harness code: A1002114 X103 Bus A Y/Gr Bus - Ground Bus B X103 Y/Gr ACV Max NTC 3 NTC 4 0-10 Volt - Input 0-10 Volt - Ground Y/Gr ON / OFF X101 230 V ~ 50Hz...
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Page 30: Ru Hydraulic Characteristics
TECHNICAL CHARACTERISTICS HYDRAULIC CHARACTERISTICS DHW PERFORMANCE Domestic hot water performance* (cold drink water at 10°C) HEATMASTER TC Operating conditions at 80°C HM 25 TC HM 35 TC HM 45 TC Main Characteristics 40 °C [∆T = 30 K] 1,104 1,390 Capacity (primary) Constant flow at 45 °C [∆T = 35 K]... -
Page 31: Recommendations For The Prevention Of Corrosion And Scaling In Heating Systems
A deaerator (on the boiler flow line) combined with a dirt separator (upstream of the boiler) must be installed according to the manufacturer's instructions. - ACV recommends using additives that keep the oxygen in solution in the water, such as Fernox (www.fernox.com) and Sentinel (www.sentinel-solutions.net) products. -
Page 32: G3 Requirements And Guidance - Uk Only
TECHNICAL CHARACTERISTICS G3 REQUIREMENTS AND GUIDANCE - UK ONLY 3.55 Any discharge should be visible at the tundish. In addition, where discharges from safety devices may not be apparent, e.g. in dwellings occupied by people with im- paired vision or mobility, consideration should be given to the installation of a suitable safety Discharge pipe from safety valves device to warn when discharge takes place, e.g. - Page 33 TECHNICAL CHARACTERISTICS 3.63 The discharge would consist of high temperature water and steam. Asphalt, roofing Worked example of discharge pipe sizing felt and non-metallic rainwater goods may be damaged by such discharges. Figure on the left shows a G1/2 temperature relief valve with a discharge pipe (D2) having 4 No.
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Page 34: Installation
• Only use ACV flue systems to connect this appliance to ensure that the pipe and For UK specific requirements for the discharge from safety valves, refer to «G3 Require- connection diameters all match. -
Page 35: Package Contents
INSTALLATION PACKAGE CONTENTS The HeatMaster® 25 - 35 - 45 - 70 - 85 - 120 TC boilers are delivered assembled and packaged. At product reception and after removal of packaging, check the package contents and that the appliance is free of damages. Contents •... -
Page 36: Hydraulic Connections
INSTALLATION HYDRAULIC CONNECTIONS TOOLS REQUIRED FOR THE INSTALLATION General remark • The circuit illustrations are basic principle diagrams only. Essential recommendations for safety • The hot water output may reach temperatures in excess of 60°C, which can cause scalding! It is therefore necessary to install a thermostatic mixing valve after the appliance. -
Page 37: Heating Connection
Cold water INSTALLATION Hot water Typical connection - low temperature HEATING CONNECTION Description Typical connection - high temperature Isolating valve 3-way mixing valve Description Heating pump Isolating valve Safety valve Heating pump Filling valve Filling valve Check valve Check valve Expansion vessel Safety valve Drain valve... -
Page 38: Removal And Installation Of The Front And Top Panels
INSTALLATION REMOVAL AND INSTALLATION OF THE FRONT AND TOP PANELS GAS CONNECTION Essential recommendations for safety Set-up conditions • The gas connection must comply with all applicable local standards and • External power supply isolated regulations, and the circuit will be equipped with a gas pressure regulator as required. -
Page 39: Conversion To Propane
INSTALLATION CONVERSION TO PROPANE Follow-on tasks • Stick the sticker provided with the conversion kit on the boiler and check the box to indicate the type General remark of gas to be now used with the boiler. • Reconnect the gas pipe connection. •... -
Page 40: Configuration And System Set-Up
0 - 10 V Modulation Signal The illustrations are for information only. For more details on the required accessories, refer to the latest ACV price list. For electrical detail, refer to wiring diagram in “Electrical Characteristics HeatMaster® 25-35-45 TC” on page 24. -
Page 41: Cascade Configuration, Controlled By Ebv Controller
NTC 4 0-10 Volt - Input 0-10 Volt - Ground For additional information and specific system configurations, please contact your ACV representative. HeatMaster 25 - 35 - 45 - 70 - 85 - 120 TC : A1003129 - 664Y6900 • C... -
Page 42: Starting Up
STARTING UP SAFETY INSTRUCTIONS FOR STARTING UP FILLING THE SYSTEM Put the DHW tank under pressure before pressurizing the heating (primary) circuit. General remark • In normal operation, the burner starts automatically as soon as the boiler Set-up conditions temperature drops below the preset temperature. •... -
Page 43: Checking And Adjusting The Burner
Setup Guide” on page 8 and to the Installer’s Handbook. maximum. If there is a significant deviation, please contact ACV's maintenance department. After 5 minutes of operation, bleed the heating circuit until all air is evacuated and restore a 1.5 bar pressure. -
Page 44: Safety Instructions For The Boiler Maintenance
MAINTENANCE PERIODIC BOILER MAINTENANCE TASKS SAFETY INSTRUCTIONS FOR THE BOILER MAINTENANCE Essential recommendations for the electrical safety • Turn off the boiler by pushing on the ON/OFF master switch. Frequency • Isolate the external power supply of the appliance before performing any Periodic 1 year 2 years... -
Page 45: Maintenance
MAINTENANCE REMOVAL, CHECK AND INSTALLATION OF THE BURNER ELECTRODE DRAINING THE BOILER Essential recommendations for the correct operation of the appliance Essential recommendations for safety Remove the electrode to control it in case of ignition problems. • • Before draining the DHW tank, drain the heating (primary) circuit or bring its pressure to 0 bar. -
Page 46: Removal And Installation Of The Burner
MAINTENANCE REMOVAL AND INSTALLATION OF THE BURNER Set-up conditions • Boiler shut down • External power supply isolated • Gas supply closed • Front and top panels removed (refer to “Removal and Installation of the Front and Top Panels” on page 38). -
Page 47: Torque Values
MAINTENANCE TORQUE VALUES Tightening torque (Nm) Description Min. Burner flange screws Electrode screws Venturi screws (except HM 120 TC) Gas valve screws (except HM 120 TC) HeatMaster® 120 TC Detail of the burner components Gas connection Gas valve Air inlet elbow Air inlet check valve Venturi Burner tube... -
Page 48: Cleaning The Exchanger
MAINTENANCE CLEANING THE EXCHANGER RESTARTING AFTER MAINTENANCE Set-up conditions Set-up conditions • Boiler shut down • All removed components reinstalled • External power supply isolated • • Gas supply closed All connections made • • Burner removed i.a.w. procedure “Removal and Installation of the Burner” on page 46. Power supply •... -
Page 49: Locking Codes
LOCKING CODES Codes Description of the fault Solution for the fault 1. Check gas supply to boiler. 2. Check Ignition cable connection in control box. E 01 Failed ignition: The burner failed to light after 5 ignition attempts. 3. Check electrode for defects, and distance between the pins. 4. - Page 50 LOCKING CODES Codes Description of the fault Solution for the fault E 25 Internal Control Fault: CRC check error. Turn unit off and on to resume normal operation. 1. Check supply temperature sensor and wiring harness for a short circuit. Supply Sensor Shorted: A short circuit has been detected in the boiler supply 2.
- Page 51 LOCKING CODES Codes Description of the fault Solution for the fault 1. Check Mix circuit temp. sensor and wiring harness for an open circuit. 2. If necessary replace the sensor, or the wire harness. E 79 Mix-circuit sensor Open 3. After fixing the problem reset the appliance and resume normal operation. E 80 Return >...
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Page 52: Service Log
SERVICE LOG SERVICE LOG Service date CO2 % Flue gas T° Efficiency Remarks Name Signature HeatMaster 25 - 35 - 45 - 70 - 85 - 120 TC : A1003129 - 664Y6900 • C... -
Page 53: Declaration Of Conformity
DECLARATION OF CONFORMITY HeatMaster 25 - 35 - 45 - 70 - 85 - 120 TC : A1003129 - 664Y6900 • C... -
Page 54: Product Fiche
No No off-‐peak h ours: ACV International Oude Vijverweg, 6 1653 Dworp (Belgium) 20/8/2015 A1002289 – R ev A HeatMaster 25 - 35 - 45 - 70 - 85 - 120 TC : A1003129 - 664Y6900 • C...