HeatMaster®
Installation, Operating and
Servicing Instructions
HeatMaster® 201
excellence in hot water
08/2006 - 66402500.C
INDEX
INTRODUCTION
INTRODUCTION
1
TARGET GROUP
Target group
Symbols
Certification
General information and safety instructions
1
1
1
2
This manual is intended for the use of:
- final users of the appliance;
- the engineer installing and starting up the appliance;
- the engineering and design department;
- the installer responsible for servicing or maintaining the appliance.
USER GUIDE
2
Using the boiler
Setting the parameters
2
3
DESCRIPTION
4
Operating principle
Packing
Construction features
4
4
4
TECHNICAL SPECIFICATION
6
Effective dimensions
General characteristics
Maximum operating conditions
Domestic hot water performances
HeatMaster® setting instructions
6
6
7
7
7
INSTALLATION
8
SYMBOLS
The following symbols are used in these instructions:
Boiler room
Chimney connections
Hot water connections
Heating connection
Electrical connections
8
8
9
10
10
COMMISSIONING
12
Filling the hot water and heating circuits
12
BURNER FEATURES
12
ACV BG 2000-M modulating premix gas burner
12
MAINTENANCE
14
Service intervals
Servicing the boiler
Servicing the safety devices
Servicing the burner
Draining the boiler
14
14
14
14
14
MCBA FOR SPECIALISTS: INSTALLER,
SERVICE ENGINEER
15
Pilot mode
Safety stop (Error mode)
Setting the parameters
Entering the code
Information on the installation
Communication mode (with code)
Error mode
15
16
17
20
20
21
21
SPARE PARTS
22
Jackets
Accessories
Setting and electrical accessories
Burner
22
22
22
22
SERVICE RECORD
23
Installation details
Service notes
23
23
Essential instruction for operating the system
correctly.
Essential instruction for personal safety or
environmental protection.
Danger of electrocution.
Risk of scalding.
CERTIFICATION
The appliances carry the “CE” mark, in accordance with the
standards in force in the various countries (European Directives
92/42/CEE “Efficiency” and 90/396/CEE “Gas Appliances”). They
also carry the labels, “HR+”.
1
INTRODUCTION
GENERAL INFORMATION AND
SAFETY INSTRUCTIONS
USING THE BOILER
IF YOU SMELL GAS:
- Immediately shut off the gas supply.
- Ventilate the boiler room.
- Do not use electrical appliances and do not switch anything on or
off.
- Immediately notify your gas company and/or your installer.
During operation, the burner starts automatically as soon as the
temperature of the boiler is below the set point and goes off when
this value is reached.
General information
Summer/Winter switch
Starting the burner
This documentation forms part of the items delivered with the
appliance and must be given to the user to keep in a safe place!
Control panel
Main switch
This appliance must be serviced and repaired by an approved
installer, in accordance with current standards in force.
Display – MCBA controller
ACV declines all liability for any damage caused as a result of
incorrect installation or as a result of the use of components or
connections that are not approved by ACV for this application.
Thermostat-pressure gauge
Temperatures
This boiler is designed for central heating systems
with a maximum outlet temperature of 90°C.
Therefore, the central heating pipelines and the
radiators must reach this temperature.
The waste-gas pipe lines
temperatures in excess of 100°C.
must
reach
The user must not attempt to gain access to the components
inside the control panel.
The hot water can reach temperatures in excess
of 60°C.
Heating system pressure
Installation
Before installing and commissioning the boiler, first
carefully read this manual.
Position the HeatMaster® according to the safety rules and
standards in force. You must comply with the ventilation
requirements for the room where appliances of this type are
installed. All air vents must remain unobstructed at all times.
It is prohibited to modify the interior of the appliance in any way,
without the manufacturer’s prior written agreement.
Service
In order to ensure the appliance operates safely and correctly, it is
important to have it serviced and reconditioned every year by an
installer or an approved service company.
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. The fill valves A and B are located at the
rear of the HeatMaster® (see photo A and B below). Open both valves
and allow thesystem 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.
Faults
Despite the strict quality standards imposed on its appliances by
ACV during production, inspection, and transport, faults may occur.
Please immediately inform your approved installer about such faults.
Remember to give the fault code as it appears on the screen. (See
also the list of faults on page 16)
Only genuine factory parts may be used as replacement parts.
Please go to page 22 for a list of spare parts and their ACV
reference numbers.
Note: ACV reserves the right to change the technical characteristics
and specification of its products without notices.
A
B
Safety Valves
If water discharges from any of the safety valves, switch the boiler
off and call a service engineer.
2
USER GUIDE
SETTING THE PARAMETERS
Setting the temperature of the hot water
Stand by mode
1X
1X
Store
Mode
2X
1X
Mode
Step
Stand
by
mode
1X
Setting the temperature of the hot water:
Store
(Temperature of the hot water)
- Press “Mode”: “PARA” comes up on the screen.
- Press “Step”: the first digit is 1 and the last two digits indicate the
current temperature setting for the hot water.
- To change this temperature, press the “+” or “-” keys until the
temperature indicated by the last two digits is the desired
temperature.
- Press “Store” to save the setting.
- Press “Mode” twice to return to Standby mode (normal operating
mode).
Enabling and disabling hot water mode
Stand by mode
1X
1X
Store
Mode
Enabling and disabling hot water mode:
(hot water)
- Press “Mode”: “PARA” comes up on the screen.
- Press “Step” twice: the first digit is 2 and the last two digits
indicate the current setting:
00 = disabled; 01 = enabled.
- To change this parameter, press the “+” or “-” keys until you reach
the desired value:
00 = disabled; 01 = enabled.
- Press “Store” to save the setting.
- Press “Mode” twice to return to Standby mode (normal operating
mode).
2X
2X
Stand
by
mode
Mode
Step
1X
Store
Enabling and disabling central heating mode
Stand by mode
Enabling and disabling central heating mode:
1X
1X
(heating)
- Press “Mode”: “PARA” comes up on the screen.
- Press “Step” three times: the first digit is 3 and the last two digits
indicate the current setting:
00 = disabled; 01 = enabled.
- To change this parameter, press the “+” or “-” keys until you reach
the desired value:
00 = disabled; 01 = enabled.
- Press “Store” to save the setting.
- Press “Mode” twice to return to Standby mode (normal operating
mode).
Setting the temperature of the central heating:
Store
Mode
2X
3X
Stand
by
mode
Mode
Step
1X
Store
Setting the temperature of the central heating
(the maximum temperature for the heating circuit)
- Press “Mode”: “PARA” comes up on the screen.
- Press “Step” four times: the first digit is 4 and the last two digits
indicate the current temperature setting for the central heating.
- To change this temperature, press the “+” or “-” keys until the
temperature indicated by the last two digits is the desired
temperature.
- Press “Store” to save the setting.
- Press “Mode” twice to return to Standby mode (normal operating
mode).
Stand by mode
1X
1X
Store
Mode
2X
4X
Mode
Step
Stand
by
mode
1X
Store
Fault:
The temperature setting of the appliance and the safety functions of its
parts are constantly monitored by a microprocessor controller (MCBA).
In the event of a fault, this MCBA disables the appliance and displays
an error code: the screen flashes and the first character is an “E”
followed by the fault code, (see the list of faults on page 16).
Fault
Reset the appliance
Reset the appliance:
- Press “Reset” on the screen.
- If the fault code appears again, contact your installer.
Status
T°
1
Reset
3
DESCRIPTION
OPERATING PRINCIPLE
CONSTRUCTION FEATURES
The HeatMaster® is a high performance, direct fired hot water
storage heater, which has indirect heat transfer due to its Tank-inTank construction.
Outer body
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.
TANK-IN-TANK heat exchanger
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.
Combustion gas circuit
The burner heats the primary water, which indirectly heats the
stainless steel tank containing the hot water. As in all Tank-in-Tank
systems, the tank 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 HeatMaster® 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® 201 includes the following parts as standard:
- On/off switch
- Summer/Winter switch
- MCBA controller, including
• an electronic controller
• a low-water-level safety device
• a burner modulator
- Primary circulating shunt pump
- Primary expansion vessels
- Primary safety valve
- Pressure and temperature gauge
- Drain valve
- Body completely insulated in rigid polyurethane foam
PACKING
The HeatMaster® is delivered in 4 separate packages.
• Package No. 1:
• Package No. 2:
• Package No. 3:
• Package No. 4:
4
Foam-insulated body, hydraulic accessories,
and control panel.
Chimney reducing pipe.
The jacket.
The burner and its cover, the door insulation
and the sealing cord.
The outer body containing the primary fluid is made of thick STW 22
steel.
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.
The combustion gas circuit is paint-protected and comprises:
• Flue pipes
The HeatMaster® 201 range has 15 steel flue ways with an
inside diameter of 64 mm. Each flue way has turbulators
made of special stainless steel designed to improve the heat
exchange and reduce the flue-gas outlet 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 jacket which has been scoured and
phosphated before being stove enamelled at 220°C.
Burner
Models in the 201 range are always delivered with an ACV
BG 2000-M 201 air-gas premix burner.
DESCRIPTION
“Tank-in-Tank” type storage
exchanger
Turbulators
Heating outlet
Flue ways
Stainless steel pocket
Primary circuit
Heating return
Combustion chamber
Boiler drain cock
NTC 3 sensor
Hot water outlet
Chimney reducer
Cold water inlet
Steam trap
NTC1 and NTC2 sensor
T&P valve (optional)
Insulation
Thermostat-pressure gauge bulb
Low-water-level pressure switch
Flange of the burner chamber plate
5
TECHNICAL SPECIFICATION
EFFECTIVE DIMENSIONS
The appliances delivered are factory-tested. Upon receipt, remove the packing and check that there is no damage to the appliances. Refer to the
dimensions and weights listed below for transport purposes.
The jacket is fitted by the installer on site (see the assembly instructions in the wooden protective case).
338
250
250
302
190
F
G
506
A
C
D
B
H
E
HeatMaster® 201
A mm
B mm
C mm
D mm
E mm
F mm
G mm
H mm
2085
300
1020
1320
1020
600
1383
590
GENERAL CHARACTERISTICS
Type
HM 201
Fuel
Natural gas/propane
Heating
Hot water
Maximum Input
kW
60 - 220
60 - 240
Maximum Output
kW
56.4 - 200.2
56.4 - 218.4
Maintenance loss at 60°C as rated value
%
0.3
Total capacity
L
641
Primary circuit capacity
L
241
Heating connection
Ø
2”
Hot water connection
Ø
2”
Chimney connection
Ø mm
250
Hot water tank heat exchange surface
2
m
5.30
Weight empty
Kg
550
mbar
240
Pressure drop primary circuit
6
TECHNICAL SPECIFICATION
MAXIMUM OPERATING CONDITIONS
HEATMASTER® SETTING INSTRUCTIONS
Maximum service pressure (tank full of water)
- Primary circuit: 3 bar
- Secondary circuit: 10 bar
Description
The HeatMaster® 201 range is equipped with an electronic
controller (MCBA) which controls the burner (start-up, safety, and
modulation) and allows the controller to be adapted to the selected
application.
Test pressure (tank full of water)
- Primary circuit: 4.5 bar
- Secondary circuit: 13 bar
The MCBA system includes a controller with 3 levels for setting the
parameters: manufacturer, installer, and user. It includes 3
temperature sensors located in the primary and secondary circuits.
Operating temperature
- Maximum temperature: 90°C
Water quality
• Chlorures: < 150 mg/l (304)
< 2000 mg/l (Duplex)
There are two operating modes:
1. Heating mode
The T° is set by the user in the range 60 to 90°C.
• 6 ≤ ph ≤ 8
DOMESTIC HOT WATER PERFORMANCES
HM 201
•
•
•
•
Differential “ON” starts the burner.
Differential “OFF” stops the burner.
PI controller (Proportional Integral) in “Heating” mode.
The controller compares the primary temperature with the
setting and the module.
The room thermostat detects the demand for heat.
Peak delivery at 40°C
L/10’
1745
Peak delivery at 45°C
L/10’
1489
Peak delivery at 60°C
L/10’
971
Peak delivery at 70°C
L/10’
763
Peak delivery at 80°C
L/10’
586
Peak delivery at 40°C
L/60’
6690
Peak delivery at 45°C
L/60’
5667
Peak delivery at 60°C
L/60’
3534
Peak delivery at 70°C
L/60’
2554
Peak delivery at 80°C
L/60’
1723
Continuous delivery at 40°C
L/h
6117
Continuous delivery at 45°C
L/h
5039
Parameters accessible by the user
Continuous delivery at 60°C
L/h
2914
Continuous delivery at 70°C
L/h
2128
Continuous delivery at 80°C
L/h
1468
1.
2.
3.
4.
N.B.:
The outputs above are given for a hot water temperature of 90°C and
a cold water temperature of 10°C.
2. Hot water mode (with priority to the hot water)
The T° is set by the user in the range 60 to 90°C.
The sensor located in the secondary tank detects the demand for
hot water.
As soon as the draw-off is detected, the controller goes to “demand
for hot water” mode:
•
•
•
•
•
•
•
Differential “ON” starts the burner.
Differential “OFF” stops the burner.
PI controller (Proportional Integral) in “Hot water” mode.
The controller compares the primary temperature with the
setting and the module.
The charging pump starts up.
The heating circulator pump is no longer supplied.
The burner starts and the controller controls the modulation
based on the primary pump.
“Hot water” temperature, which can be set to 20 - 90°C.
Hot water mode ON/OFF.
Heating mode: ON/OFF.
“Heating” temperature, which can be set to 60 - 90°C.
Parameters accessible for “service”
Main basic characteristics:
- Hot water priority active.
- Demand for heat detected by the room thermostat.
- Only one heating circuit.
An access code is required to access “Service” parameters.
Please see pages 17 to 19 for further details.
7
INSTALLATION
BOILER ROOM
Note:
Regulations vary from country to country therefore
the table above is intended only as a guide.
Important
• Keep vents free at all times.
• Do not store inflammable products in the boiler room.
• 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.
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.
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
side
behind
above
500
100
150
350
Connecting the boiler to an air vent type: C
• C53: parallel connection
total loss of pressure (air intake + flue-gas discharge) may not exceed
250 Pa. See the table below showing the pressure drops for the various
components.
mm
mm
mm
mm
A condensation drain outlet must be fitted close to the
boiler to prevent condensation products from the
chimney running into the boiler.
Ventilation
The boiler room must have both low- and high-level ventilation,
in accordance with the local standards and provisions force.
To avoid condensation water running out of the
terminal, all horizontal flue runs must fall back towards
the boiler.
The table below gives an example conforming to the Belgian standards.
Ventilation
201
Min. fresh air requirement
m /h
436
Bottom
dm
2
2.45
Top
dm2
7.30
3
Other countries should refer to their own standards.
Base
A.
B.
C.
D.
E.
F.
Top vent
Bottom vent
Draught regulator
Inspection window
Height of lined chimney
Chimney diameter
The base on which the boiler rests must be made of non-combustible
materials.
F
CHIMNEY CONNECTIONS
A
C53
IMPORTANT
Boilers must be installed by an approved heating
engineer, in accordance with the prevailing local
standards and regulations.
E
A
Typical boiler connection: B23
C
B
D
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.
Chimney / minimum flue diameter
201
E=5m
Ø F min.
mm
350
E = 10 m Ø F min.
mm
300
E = 15 m Ø F min.
mm
270
A
B23
C53
The duct size may not be smaller than the boiler outlet
duct.
Air
Ø 100 mm
Flue gas
Ø 250 mm
Pipe, L. 1000mm
18.0
1.0
90° bend
70.0
3.0
45° bend
28.0
-
-
5.0
50.0
3.0
Condensates trap
Terminal
When connecting the flue gas outlet to an existing
chimney, do not take into account the pressure drop
on the “flue gas side”.
8
INSTALLATION
HOT WATER CONNECTIONS
Example of parallel connection
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 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 series connection
Example of hot water connection
with thermostatic mixer
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
Preferable for high temperature applications with up to three units.
Stop cock
Non-return valve
Pressure reducing valve
Expansion relief valve
Hot water expansion vessel
Hot water secondary pump (it fitted)
Thermostatic mixing valve
Drawoff tap
Drain cock
Stop cock for cleaning
Temperature relief valve (UK-only)
2
1
2
3
6
8
7
4
10
11
5
Example of heating + storage connection
Recommended for applications requiring a high peak flow.
9
DANGER!
As a safety measure, we strongly advise
installing a thermostatic mixer to prevent the
risk of burns.
9
INSTALLATION
HEATING CONNECTION
ELECTRICAL CONNECTIONS
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.
Electrical supply
WARNING
The power supply to the heating pump for the MCBA is
limited to 250W. In the event of a higher wattage,
provide a relay between the pump and the MCBA.
The boiler operates on a single-phase supply of 230V/50Hz. You
should install a control box with a double-pole switch and a 6 A fuse
or a 6A circuit breaker externally to the boiler to allow the boiler to
be isolated from the power supply for servicing and repairs.
Conformity
Boiler installation must comply with the prevailing local standards and
legislation.
Expansion
The HeatMaster® 201 models are equipped with 4 8-litre expansion
vessels. These expansion vessels are sized for hot water operation
only. If a heating system is connected to the primary circuit, calculate
the expansion capacity necessary for the total volume of the heating
system. (Refer to the technical instructions from a relevant manufacturer of
expansion vessels).
Safety
The stainless steel tank must be earthed separately.
The power to the boiler must be switched off before
any work is carried out.
Example of a single circuit connection
1. 4-way valve
2. Heating pump
3. Non-return valve
4. Isolating valves
5. Safety valve set to 3 bar with pressure gauge
6. Expansion vessel
7. Drain cock
8. MCBA controller, module AM3-11
9. Surface-mounted sensor (optional)
HeatMaster® 201 wiring diagram key
01.
02.
03.
04.
05.
06.
07.
08.
09.
10.
11.
12.
13.
14.
15.
16.
8
5
1
4
9
6
7
3
2
4
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
Main switch
Module AM3-11
Module AM3-2
MCBA
24V transformer
Display
Room thermostat (optional)
Low-water-level safety device
NTC1 primary temperature sensor
NTC2 primary temperature sensor
NTC3 hot water temperature sensor
NTC4 outdoor sensor (optional)
Summer/Winter switch
NTC6 heating outlet sensor (optional)
Heating circulator pump (not supplied)
Heating circulator pump (not supplied) for use with 4-way poweroperated valve
Charging pump
Charging pump
Charging pump Booster
4-way power-operated valve
Alarm switch
Outside gas valve/burner operation switch
Hot water mode operating switch
Fan (BG 2000-M / 201)
Gas valve (BG 2000-M / 201)
Gas pressure switch (BG 2000-M / 201) (optional)
Charging circulator pump control relay
Note: The switches have zero voltage.
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.
WARNING
In the case of heating at low temperature, the use of
the kit (code: 10800099) is required.
10
Y/Gr
M5
Y/Gr
M4
Y/Gr
M3
Y/Gr
M2
Y/Gr
M1
M
M
M
M
M
M
N
Bl
R
Bl
R
Bl
R
Bl
R
Bl
R
24
5
4
3
2
1
3
2
1
26
25
P
Bl
2 x 0,75 Br
T8
T7
T6
B5
X5
S3
B4
4
T1
N
L1
T2
4 x 0,75
3 x 0,75
X4
28
27
26
25
24
23
22
21
20
19
18
5
23
22
21
Y/Gr
17
16
15
14
13
12
11
10
09
08
07
06
05
04
03
02
01
X2
1
2
3
1
2
BG 2000-M/201
20 M6
19
18
17
16
15
02
N
03
01
L
Or
V
G
Bk
W
R
R
Bl
W
Bl
W
Bl
W
Bl
G
Bl
V
Bl
Or
Bl
Bl
W
2
27
Or
G
Bl
Br
Bk
R
V
W
Bl
Bk
Bl
A2
14
6
4
A1
13
5
3
1
Bl
Bl
Bk
Bk
1
Br
W
Bl
Bk
Bl
Bk
Bl
W
V
R
W
R
R
R
W
W
Bk
Bk
G
G
V
V
Or
Or
Or
Bl
R
W
V
Bk
Or
Bl
Br
Bk
R
V
W
W
Or
Bl
Bl
Bk
X2.6
X2.12
X2.11
X2.1
X2.2
X2.3
X2.4
X1.6
X1.5
X1.4
X1.3
X1.2
X1.1
X3.1
X3.2
X2.1
X2.2
X1.1
X1.2
X3.1
X3.2
X2.1
X2.2
X1.1
X1.2
X10
5
X7
MCBA
4
2
X2.5
X5.2
X5.1
X4.2
X4.3
X5.4
X5.3
X3.4
X3.5
X3.3
X3.2
X3.1
X2.9
X2.10
X2.8
2 x 2 fils
X7
AM3 - 2
3
AM3 - 11
X7
X7
X1
G
13
14 x 0,25mm2
Bk
V
W
Bl
Br
Bk
Or
Bk
Bl
Or
Br
R
G
G
V
Bl
14 x 0,25mm2
X3
19
18
17
16
15
14
13
12
11
10
09
08
07
06
05
04
03
02
01
6
11
P
t
8
7
O Volt
BUS A
BUS B
14
12
10
B.
Br.
Bk.
Or.
G.
R.
W.
Y.
V.
9
Blue
Brown
Black
Orange
Grey
Red
White
Yellow
Violet
HeatMaster® 201 wiring
INSTALLATION
11
COMMISSIONING
BURNER FEATURES
FILLING THE HOT WATER AND HEATING CIRCUITS
IMPORTANT
Hot water tank must be pressurised before the heating
circuit is filled.
1. Close the primary circuit filling valves (A and B)
2. Open the stop valve (1) and the draw-off tap (8). Fill the tank
with the water from the tap; close the draw-off tap (8).
3. Fill the primary (heating) circuit by opening the valves (A and B)
and pressurising to 1 bar.
ACV BG 2000-M MODULATING PREMIX GAS
BURNER
Description and operating method:
The BG 2000-M modulating burner's output is constantly adjusted to
suit the fluctuating demand for heat, thus optimising operating
efficiency.
The gas tube is covered with a metal fibre (NIT), which, in addition to
its outstanding heat-exchange properties, increases its life.
The main parts are a venturi and a valve, a unit developed specially
by Honeywell for low NOx air/gas premix burners with automatic
ignition and flame detection by ionisation.
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:
• 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.
A
B
2
1
2
3
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.
•
The BG 2000-M burner on the HeatMaster® 201 is controlled by
an MCBA controller (Honeywell), which controls the safety of
operation of the burner and its modulation according to the
temperature.
6
8
7
4
•
10
11
5
The BG 2000-M burners are factory-set for
natural gas.
Air/gas mixture control system
Venturi
Fan
Air/gas
mixture
Air
Offset adjuster
screw
9
Gas
Gas flow adjuster
screw
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 = 10 m 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 values (see page 17).
9. Check the gas supply pressure (see page 13).
10. When the burner is on, check that the flue gas discharge pipes
are completely gas tight.
11. After operating for five minutes, turn off the boiler and drain the
heating circuit again, maintaining a pressure of 1 bar.
12. Turn the appliance back on and check the combustion (see
page 13).
12
BURNER FEATURES
201 gas burner characteristics
Type
Heating
Hot water
Input
Kw
60 - 220
60 - 240
Nominal output
Kw
56.4 - 200.2
56.4 - 218.4
Combustion efficiency - natural gas
%
96.6 - 91.5
96.6 - 91.5
Natural gas CO2
%
9
9
Pressure loss of the flue-gas circuit
mbar
2.4
2.9
°C
180
190
110.3
120.3
m3/h
6.35 - 23.28
6.35 - 25.40
m3/h
7.38 - 27.08
7.38 - 29.54
Net T° of combusted gases
Mass flow rate of combustion products
g/sec.
Gas G20 - 20 mbar - I 2E(R)B - I 2 Er - I 2H - I 2E - I 2ELL
Flow
Gas G25 - 20 mbar - I 2ELL / 25 mbar - I 2L
Flow
Gas G31 - 30/37/50 mbar - I 3P
Flow
m3/h
2.45 - 9.00
2.45 - 9.81
CO2
%
11.0 - 11.2
11.0 - 11.2
Gas category
BE
I 2Er
FR
AT
DK
ES
UK
IT
PT
IE
SE
X
X
X
X
X
X
X
X
X
X
X
X
NL
LU
DE
X
I 2E(R)B
x
I 2H
I 3P
X
X
I 2L
X
I 2ELL
X
I 2E
X
BG 2000-M/201
Burner adjustment
(Prohibited in Belgium).
Tube
Flame inspection window
Ignition electrode
With the burner operating at full
power, the CO2 must be in the
range 8.8 to 9.2 % (natural gas)
or 10.5 to 10.6 % (propane).
If necessary, adjust the CO2 by
turning the screw clockwise to
reduce it and counter-clockwise
to increase it. (see photo
opposite).
Gas valve
Ø 5/4” gas supply
flange
Venturi
Increase
Fan
Reduce
13
MAINTENANCE
SERVICE INTERVALS
ACV recommends that boilers 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
Draining the boiler’s primary circuit
1. Put the main switch on the control panel to OFF, cut the outside
power supply and close the gas-supply valve to the boiler.
2. Close the isolating valves (4) or manually set the 4-way valve (1)
to “0”.
3. Connect a flexible tube to the drain cock (7). Make sure it is
properly connected.
4. Open the drain cock and allow the hot water to flow into the
drain.
1. Turn OFF the on/off switch on the boiler control panel and isolate
external electrical supply.
2. Turn off the gas or oil supply to the boiler.
Vertical flue-gas outlet reducer
3. Take down and remove the flue lining to release the top of the
boiler.
4. Loosen the nuts and remove the chimney reducer.
5. Take out the turbulators from the flue ways to clean them.
6. Dismantle the chamber plate and remove the burner.
7. Brush the flue ways.
8. Clean the combustion chamber and the burner.
9. Replace the turbulators, the chimney reducer, and the flue lining;
check that the seal on the chimney reducer is in good condition.
Replace the seal if necessary.
Horizontal flue-gas outlet reducer
3. Loosen the nuts and remove the chimney reduction.
5. Take out the turbulators from the flue ways to clean them.
6. Dismantle the chamber plate and remove the burner.
7. Brush the flue ways.
8. Clean the combustion chamber and the burner.
9. Replace the turbulators, the chimney reducer, and the flue lining;
check that the seal between the chimney reducer and the
chimney is in good condition. Replace the seal if necessary.
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.
8
5
1
6
7
3
2
4
Drain the hot water circuit.
1. Put the main switch on the control panel to OFF, cut the outside
power supply and close the gas-supply valve to the boiler.
2. Release the pressure in the heating circuit until the pressure
gauge reads zero.
3. Close the cocks (1 and 8).
4. Open valve (9) and then (10).
5. Allow the hot water to flow into the drain.
2
SERVICING THE BURNER
- Check that the insulation and the seal on the chamber plate are in
good condition; replace them if necessary.
- Check and clean the burner and the electrodes. Replace the
electrodes if necessary (1 x per year in normal usage conditions)
- Check that the safety devices are in good working order.
- Check the combustion (CO2, CO, and gas pressure) and record the
values and any other comments on page 23 of the service record.
4
9
1
2
3
6
8
7
4
10
11
5
DRAINING THE BOILER
Water flowing out of the drain cock may be
extremely hot and could cause severe scalding.
Keep people away from discharges of hot
water.
9
The drain cock (9) must be at ground level for the
circuit to drain fully.
14
MCBA FOR SPECIALISTS:
INSTALLER, SERVICE ENGINEER
Once the cause of the blockage has been resolved, the burner starts
automatically within 150 seconds at most.
PILOT MODE
Pilot mode
After you power down the appliance the screen displays Pilot mode,
as shown in the figure above.
Status
Boiler function
Internal check — three-way valve
This is the standard MCBA mode. The MCBA automatically returns
to this mode after 20 minutes if no keys have been pressed on the
screen. Any parameters that were modified are then enabled.
The first character shows the current status of the boiler depending
on the condition of both the boiler and the burner. The last
2 characters indicate the start temperature.
Boiler burner in hot water ready function
Test function: Central heating high power
Test function: Central heating low power
Status
Boiler function
Test function: Boiler with fixed number of
revolutions
Pilot, no demand for heat
Fan first, fan after
Ignition
Operation of the boiler burner for the heating
Operation of the boiler burner for the domestic hot
water
Air pressure limit or obtaining the number of start
revolutions.
The burner goes out when the specified value is
reached. A demand for heat is present nonetheless.
Pump over-run time after the demand for domestic
hot water
Pump over-run time after the demand for central
heating
Burner blocked:
•
:T1 > 95°C
•
:T2 > 95°C
•
: T2 - T1 > 10.20 or 40°C after a time of xx
•
: dT1/dt > maximum gradient T1
•
: water pressure switch not off
•
: no fan signal
•
: erroneous fan signal
•
: T1 - T2 > max Delta
•
: NTC3 short-circuit
•
: NTC3 interrupt
•
: wait for the fan to start
If the burner is blocked for one of the reasons mentioned above, the
screen display alternates between a 9 followed by the temperature
(two last digits) and b with the error code.
15
MCBA FOR SPECIALISTS:
INSTALLER, SERVICE ENGINEER
SAFETY STOP (ERROR MODE)
To unlock the system:
• Press RESET on the screen.
• Contact your installer if the fault happens again.
If a fault occurs while the appliance is running, the system locks and
the screen starts to flash. The first character is an E and the next two
characters give the code for this fault, as illustratedin the table below.
Table of error codes and how to resolve them
Codes
To
Description of the fault
Resolution of the fault
Abnormal flame signal
- Check the wiring (short-circuit in the 24V wiring)
- Check the electrode/ replace the MCBA (water damage).
No flame signal after five attempts at firing the
boiler
- Check the ignition cable, the electrode and the
position of the electrode.
- Check that there is gas at the burner.
Persistent lock
- Press RESET
EPROM error
-If the problem persists after two RESET attempts,
replace the MCBA.
Low water pressure or 24V fuse gone.
- Add primary water
- Check the low pressure sensor, the wiring and the 24V fuse on the MCBA.
Internal error
- If the problem persists after two RESET attempts,
replace the MCBA.
T1 > 110°C
- Check the NTC wiring and replace if necessary.
T2 > 110°C
- Check the NTC wiring and replace if necessary.
T1 gradient too high
- Check that the pump is turning. If there is
no problem with the pump, drain the system.
No fan signal present
- If the fan is working:
• Check the fan control connection and the fan wiring
• if the problem persists after 2 RESET attempts, replace the fan
• if the problem persists, replace the MCBA.
- If the fan is not working:
• Check that the fan 230V connection. If the problem persists, replace the fan.
16
NTC 1 short-circuit
- Check the connection and the NTC1 wiring
If the problem persists, replace the NTC1.
NTC 2 short-circuit
- Check the connection and the NTC2 wiring
If the problem persists, replace the NTC2.
NTC 3 short-circuit
- Check the connection and the NTC3 wiring
If the problem persists, replace the NTC3.
NTC 1 connection open
- Check the connection and the NTC1 wiring
If the problem persists, replace the NTC1.
NTC 2 connection open
- Check the connection and the NTC2 wiring
If the problem persists, replace the NTC2.
NTC 3 connection open
- Check the connection and the NTC3 wiring
If the problem persists, replace the NTC3.
Internal error
- If the problem persists after two RESET attempts,
replace the MCBA.
Error while reading the parameters
Press RESET. If the error persists, replace the MCBA.
Problem with the power supply to the fan
Check the MCBA power supply voltage. If it is OK, replace the fan.
MCBA FOR SPECIALISTS:
INSTALLER, SERVICE ENGINEER
SETTING THE PARAMETERS
Parameter mode
To access Parameter mode when the system is in Pilot mode, press MODE once.
To scroll through the list of parameters, simply press “step”. To modify a parameter value, use the + or - keys.
Then press “Store” to save the value you just changed. The screen flashes once to confirm the data has been saved.
To activate the parameters you changed, press “Mode” once more (which brings you into Info mode). However, if you do not press a key, the
system returns to Pilot mode after 20 minutes and automatically enables the changes.
Key
Display
MODE
Key
Display
Description of parameters
Adjusting the hot water temperature
Factory setting
90
STEP
Production
of hot water
00
01
02
03
=
=
=
=
Stop
Start
Stop + pump continuously on
Start + pump continuously on
01
Turn on/Turn off
the heating
00
01
02
03
=
=
=
=
Stop
Start
Stop + pump continuously on
Start + pump continuously on
01
STEP
STEP
Maximum temperature in Central Heating mode
90
STEP
Parameters for the specialist: only accessible by using the Code
Key
Screen
Description of parameters
Factory setting
Minimum central heating temperature when using an outdoor sensor
60
Minimum outdoor temperature
(adjust the heating curve)
0
Maximum outdoor temperature
(adjust the heating curve)
20
STEP
STEP
STEP
Frost protection temperature
- 15
STEP
Correction based on the outdoor temperature
00
Blockage T 0 = Disabled
00
Booster 00 = Stop (minute)
00
STEP
STEP
STEP
17
MCBA FOR SPECIALISTS:
INSTALLER, SERVICE ENGINEER
Key
Display
Description of the parameters
Factory setting
Night-time heating temperature reduction (°C)
10
Fan speed in heating mode (rpm x 100)
52
Max. fan speed in heating mode (rpm x 100)
00
Max fan speed in hot water mode (rpm x 100)
57
Max. fan speed in hot water mode (rpm x 100)
00
Min. fan speed (rpm x 100)
15
Min. fan speed (rpm x 100)
00
Fan speed at ignition (rpm x 100)
37
Heating pump time delay 0 = 10 sec (minute)
00
Hot water pump time delay 10.2 = 10 sec (minute)
16
Burner interlock hysteresis (heating)
00
Burner trigger hysteresis (heating)
01
Burner interlock hysteresis (hot water)
01
Burner trigger hysteresis (hot water)
03
Hot water mode interlock hysteresis
04
Hot water mode trigger hysteresis
01
STEP
STEP
STEP
STEP
STEP
STEP
STEP
STEP
STEP
STEP
STEP
STEP
STEP
STEP
STEP
STEP
18
MCBA FOR SPECIALISTS:
INSTALLER, SERVICE ENGINEER
Key
Display
Description of the parameters
Factory setting
Heating lock time (sec x 10.2)
00
Hot water lock time (sec x 10.2)
00
Lock time to switch from hot water mode to heating mode (sec x
10.2)
00
Difference T1 - T2 for modulation
05
STEP
STEP
STEP
STEP
BUS address (-1 = disabled)
- 01
STEP
Increase the primary temperature value to generate hot water
(relative to the hot water temperature)
05
STEP
1st digit: heating circuit (AM3-11 – 4-way valve)
0 = disabled
5 = enabled
00
STEP
2nd digit: the demand for heat comes from:
0 = room thermostat
1st digit: Hot water circulator pump (= 1)
12
STEP
2nd digit: tank with NTC3 sensor (= 2)
Manual fan speed (- 01 = modulation)
- 01
STEP
1st digit: PWM pump operating speed
11
2nd digit: PWM pump speed during time-delay
STEP
Holding temperature
00
Maximum temperature for the heating circuit outlet
(AM3-11 – 4-way valve)
60
Minimum temperature for the heating circuit outlet
(AM3-11 – 4-way valve)
30
Hysteresis of the heating circuit outlet temperature
(AM3-11 – 4-way valve)
01
STEP
STEP
STEP
STEP
1st digit: Special pump (0 = disabled)
00
2nd digit: Minimum disable cycle (0 = disabled)
STEP
19
MCBA FOR SPECIALISTS:
INSTALLER, SERVICE ENGINEER
ENTERING THE CODE
INFORMATION ON THE INSTALLATION
Code mode
Info mode
You can access the following parameters by entering the service
code:
To switch from Pilot mode to Info mode, press “Mode” twice.
•
•
•
•
Parameters 5 - 42
Communication mode
Fan Speed mode
ERROR mode
Key
Display
MODE
To access Code mode, press
MODE and STEP simultaneously
(only from Pilot mode!).
MODE
Press “STEP” until the system displays the information you need.
The point located behind the first position flashes to indicate that
the boiler is in “INFO” mode.
MODE
STEP
Key
Press “STEP” once and the system displays “C”
in position 1, followed by arbitrary
characters in positions 3 and 4.
Display
Description of parameters
Start temperature T1 in °C
STEP
Return temperature T2 in °C
STEP
STEP
Hot water temperature T3 in °C
STEP
Press “+” or “-” to change the code.
Outdoor temperature T4 in °C
STEP
+
or
-
Not used
STEP
Start temperature calculated in °C
Press “STORE”, the screen flashes
briefly to indicate that the code has been accepted.
STEP
Rate of increase in the start
temperature in °C/s
STEP
STORE
Rate of increase in the return
temperature in °C/s
STEP
Press “MODE” until
the system displays the correct mode.
Rate of increase in the hot water
temperature in °C/s
STEP
Heating circuit outlet temperature
(AM3-11 – 4-way valve)
Only ACX authorised installers know the access code.
STEP
For further information, please contact our after-sales
department.
20
MCBA FOR SPECIALISTS:
INSTALLER, SERVICE ENGINEER
COMMUNICATION MODE (WITH CODE)
ERROR MODE (WITH CODE)
When in this mode, the system displays the communication between
the boiler and the control module, the optional interface kit or the
optional programmable room thermostat.
“ERROR” mode indicates the most recent error, as well as the
status of the boiler and its readings at the time this error occurred.
Key
Key
Display
Display
MODE
MODE
Key
Key
Display
Display
Description of parameters
Description of parameters
Code mode
(See the table on page 16 for a full list)
No communication
Communication between the boiler
module and the optional control
modules only (RMCI)
STEP
Status of the boiler at the time of the
error (See the table on page 16)
STEP
STEP
Start temperature T1 at the time of
the error
Communication between all the
devices connected
MODE
Return temperature T2 at the time of
the error
STEP
Hot water temperature T3 at the time
of the error
FAN MODE (WITH CODE)
STEP
Key
Display
Description of parameters
Fan speed
Outdoor temperature T4 at the time of
the error
STEP
MODE
The current fan speed is 5,500 rpm.
STEP
Temperature sensor resistance tables
Temp. °C
RΩ
Temp. °C
RΩ
-20
-15
-10
-5
0
5
10
15
20
25
30
35
98200
75900
58800
45900
36100
28600
22800
18300
14700
12000
9800
8050
40
45
50
55
60
65
70
75
80
85
90
95
100
6650
5520
4610
3860
3250
2750
2340
1940
1710
1470
1260
1100
950
21
SPARE PARTS
No.
Jackets
Codes HeatMaster® 201
A01
Right side
21471415
A02
Left side
21471415
A03
Right side rear corner
21478415
A04
Left side rear corner
21473415
A05
Rear panel
21474415
A06
Right side front corner
21472415
A07
Left front side
21479415
A08
Upper front panel
2147A415
A09
Lower front panel
2147B415
A10
Burner cover
21476415
A11
Rear top cover
21475415
A12
Front top cover
21475416
A13
Rear half-base
2147S415
A14
Unequipped control panel
21477416
A15
Body + accessories (package No. 1)
27300047
No.
Accessories
B01
Low-water-level pressure switch
557D3011
B02
Wilo circulator pump
557A4007
B03
3 bar / Ø 3/4” - 1” safety valve
557A1048
B04
Burner chamber insulating cover
51700041
B05
8-l expansion vessel
55301200
B06
Steam trap, Ø 1/2”
557A3001
B07
Drain cock, Ø 3/4”
557A1000
B08
Fill set, Ø 1/2”
55426018
B09
Type A, high-level turbulators
507F2009
B10
Type B, low-level turbulators
507F2010
No.
Setting and electrical accessories
C01
MCBA
537D8016
C02
Transformer
547D3021
C03
NTC Duplo (NTC1 - NTC2)
5476G002
C04
NTC Single (NTC3)
5476G003
C05
Module AM3-11
10800080
C06
Module AM3-2
10800060
C07
Full control panel
24614133
C08
Display
537D3020
C09
Display case
537D3023
C10
Pressure gauge-thermometer
54441008
C11
ON/OFF switch
54766016
C12
Summer/Winter switch
54766017
C13
Control panel self-adhesive
617G0105
No.
Burner
D01
Full burner
237D0118
D02
Fan
537D3034
D03
Venturi
537D4042
D04
110 x 3.5mm O-ring
557A0045
D05
Plate fan seal
557A0040
D06
Burner chamber plate seal
557A0020
D07
Ø 98mm burner tube + NIT
537DZ019
D08
Chamber plate sealing cord
51700025
D09
Ignition electrode
537DZ020
D10
Ignition cable
25760046
D11
Burner chamber plate insulating stone
51700040
D12
Burner chamber plate
2147P416
D13
Gas valve
537D4041
D14
Valve flange
537D8021
22
SERVICE RECORD
INSTALLATION DETAILS
Service date:
Flue gas T°:
Model:
% CO2 (min. load):
Efficiency:
Serial number:
% CO2 (max. load):
Gas pressure:
Heating system pressure setting:
❏
❏
Name and signature:
Gas
Propane
SERVICE NOTES
Service date:
Flue gas T°:
% CO2 (min. load):
Efficiency:
% CO2 (max. load):
Gas pressure:
❏
❏
Name and signature:
Comments:
Gas
Propane
Service date:
Flue gas T°:
% CO2 (min. load):
Efficiency:
% CO2 (max. load):
Gas pressure:
❏
❏
Name and signature:
Comments:
Gas
Propane
Service date:
Flue gas T°:
% CO2 (min. load):
Efficiency:
% CO2 (max. load):
Gas pressure:
❏
❏
Name and signature:
Comments:
Gas
Propane
Service date:
Flue gas T°:
% CO2 (min. load):
Efficiency:
% CO2 (max. load):
Gas pressure:
❏
❏
Name and signature:
Comments:
Gas
Propane
Service date:
Flue gas T°:
% CO2 (min. load):
Efficiency:
% CO2 (max. load):
Gas pressure:
❏
❏
Name and signature:
Comments:
Gas
Propane
23
SERVICE RECORD
Service date:
Flue gas T°:
% CO2 (min. load):
Efficiency:
% CO2 (max. load):
Gas pressure:
❏
❏
Name and signature:
Gas
Propane
Service date:
Flue gas T°:
% CO2 (min. load):
Efficiency:
% CO2 (max. load):
Gas pressure:
❏
❏
Name and signature:
Comments:
Gas
Propane
Service date:
Flue gas T°:
% CO2 (min. load):
Efficiency:
% CO2 (max. load):
Gas pressure:
❏
❏
Name and signature:
Comments:
Gas
Propane
Service date:
Flue gas T°:
% CO2 (min. load):
Efficiency:
% CO2 (max. load):
Gas pressure:
❏
❏
Name and signature:
Comments:
Gas
Propane
Service date:
Flue gas T°:
% CO2 (min. load):
Efficiency:
% CO2 (max. load):
Gas pressure:
❏
❏
Name and signature:
Comments:
Gas
Propane
Service date:
Flue gas T°:
% CO2 (min. load):
Efficiency:
% CO2 (max. load):
Gas pressure:
❏
❏
Name and signature:
24
Comments:
Gas
Propane
Comments:
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