ACV BNE 2 Condens Manual

EN
21.8 kW
BNE 2 Condens
664Y5900 • A
InstallatIon, operatIon and
maIntenance InstructIons

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Table of ConTenTs
664Y5900 • A
GENERAL RECOMMENDATIONS..............................................................4
USER'S GUIDE.............................................................................................5
Instructions for the end-user........................................................................................................................ 5
APPLIANCE DESCRIPTION........................................................................6
TECHNICAL CHARACTERISTICS ..............................................................8
Electrical Characteristics................................................................................................................................... 8
Dimensions................................................................................................................................................................10
Combustion Characteristics.........................................................................................................................12
Hydraulic Characteristics................................................................................................................................13
Chimney Connection Characteristics ..................................................................................................14
DHW Performance...............................................................................................................................................15
Maximum Operating Conditions.............................................................................................................15
INSTALLATION........................................................................................16
Package Contents.................................................................................................................................................16
Tools required for the installation...........................................................................................................16
How to move the boiler ..................................................................................................................................17
Safety Instructions for the Installation................................................................................................18
Recommendations for the Prevention of Corrosion and Scaling.................................20
Boiler Preparation.................................................................................................................................................22
Burner installation ...............................................................................................................................................24
Electrical Connections......................................................................................................................................26
Flue connection.....................................................................................................................................................27
Heating circuit connection...........................................................................................................................28
DHW Connection..................................................................................................................................................29
Oil Connection........................................................................................................................................................30

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ENTable of ConTenTs
664Y5900 • A
STARTING UP ...........................................................................................31
Tools required for starting up.....................................................................................................................31
Checks before starting up.............................................................................................................................31
Filling the System.................................................................................................................................................32
Starting up the Boiler........................................................................................................................................33
Combustion adjustment ................................................................................................................................33
MAINTENANCE .......................................................................................34
Safety Instructions for the Boiler Maintenance...........................................................................34
Periodic boiler maintenance tasks.........................................................................................................35
Cleaning the burner and the heating body....................................................................................36
Cleaning the condenser..................................................................................................................................36
Cleaning the condensate trap ...................................................................................................................37
Draining the Boiler ..............................................................................................................................................38
Restart after maintenance.............................................................................................................................39
In case of problem... ...........................................................................................................................................39
DECLARATION OF CONFORMITY  EC..................................................40
DECLARATION OF CONFORMITY  RD 17/7/2009................................41

NOTE
This manual contains important information with respect to the installation, the starting up and the
maintenance of the boiler.
This manual must be provided to the user, who will read it carefully and keep it in a safe place.
We accept no liability should any damage result from the failure to comply with theinstructions
contained in this technical manual.
Essential recommendations for safety
It is prohibited to carry out any modifications to the appliance without the
manufacturer’s prior and written agreement.
The product must be installed by a qualified engineer, in accordance with applicable
standards and regulations.
The installation must comply with the instructions contained in this manual and with
the standards and regulations applicable to installations.
Failure to comply with the instructions in this manual could result in personal injury or
a risk of environmental pollution.
The manufacturer declines all liability for any damage caused as a result of incorrect
installation or in the event of the use of appliances or accessories that are not specified
by the manufacturer.
Essential recommendations for the correct operation of the appliance
In order to ensure that the appliance operates correctly, it is essential to have it
serviced by a certified installer or maintenance contractor every year.
In case of anomaly, please call your service engineer.
Faulty parts may only be replaced by genuine factory parts.
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GENERAL RECOMMENDATIONS

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EN
664Y5900 • A
USER'S GUIDE
Description
1. ON/OFF master switch of the boiler - To turn the boiler on and o.
2. Summer-winter switch - To activate or deactivate the heating pump.
3. Energy source selector switch - To activate or deactivate the heating pump and the burner, and
turn on or o a 2.4 kW heating element to meet the need in domestic hot water
4. Heating element indicator - The built-in indicator lights when the heating element is activated.
5. Safety cutout warning indicator - The built-in indicator lights when the ue gas or primary circuit
water temperature is too high.
6. DHW Thermometer - Shows the temperature of the domestic hot water.
7. Domestic hot water temperature adjustment thermostat - In DHW mode, the domestic hot
water temperature can be set from 60 to 80°C.
8. Temperature and pressure gauge - Indicates the boiler temperature and the primary circuit
pressure.
9. Heating temperature adjustment thermostat - Allows to set the boiler between 60 and 90°C.
It is recommended to set the thermostat 10°C above the set point of the domestic hot water
adjustment thermostat.
INSTRUCTIONS FOR THE ENDUSER
Essential recommendations for safety
• Do not store any flammable or corrosive products, paint, solvents, salts, chloride products
and other detergent products near the appliance.
• This appliance is not intended for use by persons (including children) with reduced physical,
sensory or mental capabilities, or lack of experience and knowledge, unless supervised or
unless they have been given instruction concerning the use of the appliance by a person
responsible for their safety.
PERIODIC CHECKS
Essential recommendations for the correct operation of the appliance
• Check regularly that the system water pressure is at least 1 bar when cold.
• If it is required to top up the system to maintain the minimum recommended water
pressure, only add small amounts of water at a time. If a large amount of cold water is
added in a hot boiler, the boiler can be damaged definitively.
• If the boiler safety cutout system is frequently activated, contact your installer.
• If the system needs to be refilled repeatedly with water, please contact your installer.
• Regularly check that there is no water on the floor in front of the boiler. If there is, please
call your installer.
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APPLIANCE DESCRIPTION
The BNE 2 Condens condensation fuel boiler is a heat generator for central heating, with a a built-in
domestic hot water preparation tank. The DHW preparation tank can operate independently from
the boiler thanks to a built-in heating element (2,4 kW).
Detail of components
1. A chimney connection with measuring port.
2. Cold water inlet
3. Domestic hot water outlet
4. Manual air bleed valve
5. Control panel
6. Safety thermostat
7. Hard expanded polyurethane foam insulation
8. Stainless steel "Tank in Tank" hot water production tank
9. Condenser
10. 2.4 kW electric heating element
11. Combustion chamber
12. Heating circuit
13. Turbulators (6 pieces)
14. Burner chamber plate with insulation block
15. Blue ame oil burner
16. Removable panels
17. Charging pump connection
18. Class A-type charging pump
19. Minimum thermostat 45°
20. Drain valve
21. Electrical plug of the boiler
22. Flue gases safety thermostat
23. Exhaust ue duct
24. Condenser access door
25. Heating circuit outlet
26. Auxiliary heating circulation loop
27. Condensate trap
28. Condensate evacuation hose
23
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5
1
7
4

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ENAppliAnce Description
664Y5900 • A
9
10
11
8
13
12
15
14
19
18
17
16
16
20
21
24
22
23
25
26
28
27

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ELECTRICAL CHARACTERISTICS
TECHNICAL CHARACTERISTICS
Wiring diagram caption
1. ON/OFF master switch
2. Minimum thermostat 45°
3. Summer/winter switch
4. Safety thermostat
5. Oil burner
6. Safety cutout indicator
7. Heating element indicator
8. 2.4 kW electric heating element
9. Energy source selector switch
10. Room thermostat (option)
11. Heating pump of the system (optional)
12. Heating temp. adjustment thermostat
13. DHW temp. adjustment thermostat
14. Flue gas safety thermostat for ue pipe
15. Charging pump
16. Daily timer (optional)
17. Relay
Main electrical characteristics BNE 2 Condens
Rated voltage V~ 230
Rated frequency Hz 50
Rated current with oil burner A2.2
Rated current with electrical heating element A20
Electrical consumption with oil burner W276
Electrical consumption with electrical heating element W2496
IP Class IP30
The heating element is composed of two 2.4 kW resistances.
One of the resistances is connected through a cable and used as the main heating element, while
the second one is a back-up that is used in case the main one fails.
Never connect both resistances simultaneously or the internal cables of the boiler will be
damaged.

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ENTechnical characTerisTics
664Y5900 • A
t
21
DC
4
1
t
L1 PEN
10
t
1211
12
t
11
14
12 13 t
P
1
2
14
3
1
5
4
2
16
3
6
9
?
?
?
?
?
?
t
21
2
M15
M11
B1
A1
1
34
NPEB4
S3
PEN
L1 L1
PE
8
7
5
17

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Technical characTerisTics
664Y5900 • A
DIMENSIONS
Boiler Dimensions BNE 2 Condens
A= Width mm 590
B= Height mm 1650
C= Depth mm 990
Volume of the combustion chamber dm³ 42.3
Combustion chamber
Height mm 295
Width mm 330
Depth mm 435
Drained weight Kg 215
102 mm
1570 mm
B
427 mm
676 mm
A
51 mm
296 mm
80 mm
128 mm
C

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ENTechnical characTerisTics
664Y5900 • A
Boiler Clearance BNE 2 Condens
Recommended Minimum
A(mm) 800 650
B(mm) 1000 900
C(mm) 600 400
D(mm) 150 100
E(mm) 400 300
C
972
A
BD
E
Leave a clearance to
access the condenser

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Technical characTerisTics
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COMBUSTION CHARACTERISTICS
Main Characteristics BNE 2 Condens
Fuel type EL fuel
Max. input (PCI) kW 22.4
Output at 100% (80/60°C) kW 21.8
(50/30°C) kW 23.5
Eciency at 30% load (EN 677)%104
Eciency at 100% (80/60°C) %97.5
(50/30°C) %103.5
Combustion eciency at 100% %98.2
Flue gas temp. at water temp. (80/60°C) °C 67
(50/30°C) °C 48.5
NOx (Class 5) Max. output mg/kWh 87
CO Max. output mg/kWh 4
CO2Max. output %CO213.1
Standby loss ∆T = 45 K W144
∆T = 30 K W87
8
9
10
11
12
13
14
15
16
0 500 1000 1500 2000250 750 1250 1750
0
5
10
15
20
25
Altitude (m)
Pump pressure (bar)
Power (kW)
Power
Pump pressure
Maximum operating conditions of the burner in altitude
Area not recommended

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ENTechnical characTerisTics
664Y5900 • A
Hydraulic pressure drop curve
Main hydraulic characteristics BNE 2 Condens
Water content of the boiler L184
Primary circuit capacity L67
Heating inlet/outlet connection (F) "1
DHW inlet/outlet connection (M) "3/4”
Max. service pressure of DHW circuit bar 7
Max. service pressure of heating circuit bar 3
Primary circuit water pressure drop (∆T = 20 K) mbar 20
HYDRAULIC CHARACTERISTICS
0
20
40
60
80
100
0 0,5 1 1,5 2 2,5
Pressure drop (mbar)
Water flow rate (m3/h)

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Technical characTerisTics
664Y5900 • A
Flue pipe length curve
Chimney connection diagram
Chimney characteristics BNE 2 Condens
Connection type B23
∅of boiler connection to the chimney mm 80
min. ∅of ue pipe mm 80
L = maximum length of ue pipe ( ∅80 mm) m9
Max. temp of ue gases °C 80
Flue pipe pressure drop Pa 20
CHIMNEY CONNECTION CHARACTERISTICS
1 x 45° elbow ≈ 1 m straight pipe
1 x 90° elbow ≈ 1.5 m straight pipe
Length of ue gas pipe (m)
Ø of ue gas pipe (mm)
8
10
12
14
16
18
60 80 100 120
B23
L
Max. length
according to Ø of
ue gas pipe
Area not
recommended

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ENTechnical characTerisTics
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DHW PERFORMANCE
Domestic Hot Water Performance BNE 2 Condens
Operating conditions at 80°C
Peak ow at 40 °C [∆T = 30 K] L/10’ 395
Peak ow at 50 °C [∆T = 40 K] L/10’ 293
Peak ow at 40 °C [∆T = 30 K] L/60’ 935
Peak ow at 50 °C [∆T = 40 K] L/60’ 689
Constant ow at 40 °C [∆T = 30 K] L/h 616
Constant ow at 50 °C [∆T = 40 K] L/h 475
Reheat time from 10°C to 80°C minutes 17
MAXIMUM OPERATING CONDITIONS
Maximum Service Pressure [DHW tank full of water]
- Primary circuit:....................................................................3 bar
- DHW circuit: .........................................................................7 bar
Operating temperature
- Max. temperature of the primary circuit: ...................90°C
- Max. temperature of the DHW circuit :from 60°C to 80°C
Mains supply pressure
- Max 6 bar, without a pressure reducing valve being required
Water Quality
See "Recommendations for the Prevention of Corrosion and Scaling".
Oil quality
• Low sulfur oil (50 ppm)
• Standard oil (2000 ppm)
• Bio-oil 0 at 7% methyl esters of fatty acids

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InstallatIon
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PACKAGE CONTENTS
The appliances are delivered assembled, tested and packaged separately.
The manufacturer reserves the right to change the technical characteristics and
features of its products without prior notice.
The availability of certain models as well as their accessories may vary according to
markets.
TOOLS REQUIRED FOR THE INSTALLATION
INSTALLATION
Package 1 contents
• One BNE 2 Condens boiler.
• Installation, Operation and Maintenance
Instructions
• A stainless steel chimney connection with
measuring element.
Package 2 contents
• A BMR 33 blue ame oil burner.
• Installation, Operation and Maintenance
Instructions
   
 

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ENInstallatIon
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HOW TO MOVE THE BOILER
Using a hand truck
Use a means of transport adapted to the boiler weight.
Minimum width of the door and the hall necessary to pass the boiler
C
B
A
D
A = maximum boiler width
B = maximum boiler length
C = Door width
D = Hall width
Door height = std
Hall width : C = Ax B
D
Example of calculation to determine the minimum hall width, with adoor width: D = 800 mm
C = 540 x 1000 = Hall width ≥ 675 mm
800
Door width: D = Ax B
C
Example of calculation to determine the minimum door width, with ahall width: D = 900 mm
D = 540 x 1000 = Hall width ≥ 600 mm
900

SAFETY INSTRUCTIONS FOR THE INSTALLATION
General remarks
The connections (electrical, flue pipe, hydraulic) must be carried out in accordance
with current standards and regulations in force.
If the water drawing off point is far from the tank, installing an auxiliary DHW loop can
allow to get hot water more quickly at all times.
Essential recommendations for the correct operation of the appliance
The boiler must be installed in a dry and protected area.
Install the appliance to ensure easy access at all times.
To avoid any risk of corrosion, connect the stainless steel DHW production tank
directly to the earth.
Make sure to install a pressure reducing valve set at 4.5 bar if the mains supply
pressure is in excess of 6 bar.
The DHW circuit must be fitted with an approved safety group, comprised of a 7 bar
safety valve, a check valve and a shut-off valve.
If works need to be performed (in the boiler room or close to the air vents), make sure
to turn off the boiler to prevent dust from entering and accumulating in the boiler
heating system.
Essential recommendations for safety
Install the boiler on a base made of non-combustible materials.
Make sure that all air vents are unobstructed at all times.
A condensation outlet connected to the sewer must be fitted close to the boiler to
prevent the condensation products from the flue pipe from running into the boiler.
The horizontal flue pipes must be installed with a slight slope of 5 cm per meter, so
that the acid condensation water flows to a condensate recovery container and does
not damage the heating body.
Do not store any corrosive products, paint, solvents, salts, chloride products and other
detergent products near the appliance.
The flue pipe diameter must not be smaller than that of the boiler flue gas outlet
connection.
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InstallatIon
664Y5900 • A

Hot water can cause scalding!
In the event of small amounts of hot water repeatedly being drawn off, a stratification
effect can develop in the tank. The upper hot water layer may then reach very high
temperatures.
ACV recommends using apre-set thermostatic mixing valve in order to provide hot
water at a maximum of 60°C.
Water heated to wash clothes, dishes and for other uses can cause serious burns.
In order to avoid exposure to extremely hot water that can cause serious burns, never
leave children, old people, disabled or handicapped people in the bath orshower
alone.
Never allow young children to turn on the hot water or fill their own bath.
The temperature of the domestic hot water can be adjusted up to 90 °C in the boiler.
However, the temperature of the domestic hot water at the drawing off point must
comply with local regulations. (E.g. in Belgium, the maximum DHW water temperature
at a drawing off point must be 75°C for boilers < 70 kW).
The risk of developing bacteria exists, including “Legionella pneumophila”,
ifaminimum temperature of 60°C is not maintained in both the DHW tank andthe
hot water distribution network.
Essential recommendations for the electrical safety
Only an approved installer is authorized to carry out the electrical connections.
Install a 2-way switch and a fuse or circuit breaker of the recommended rating outside
the appliance, so as to be able to shut power down when servicing the appliance or
before performing any operation on it.
Isolate the external electrical supply of the appliance before performing any operation
on the electrical circuit.
This appliance is not intended for use by persons (including children) with reduced
physical, sensory or mental capabilities, or lack of experience and knowledge, unless
supervised or unless they have been given instruction concerning the use of the
appliance by a person responsible for their safety.
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ENInstallatIon
664Y5900 • A

RECOMMENDATIONS FOR THE PREVENTION OF CORROSION AND
SCALING
How oxygen and carbonates can affect the heating system
Oxygen and dissolved gasses in the water of the primary circuit contribute to the oxi-
dation and the corrosion of the system components that are made of ordinary steel
(radiators, ...). The resulting sludge is then deposited in the boiler exchanger.
The combination of carbonates and carbon dioxide in the water results in the formation of scale
on the hot surfaces of the installation, including those of the boiler exchanger.
These deposits in the heat exchanger reduce the water ow rate and thermally insulate the ex-
change surfaces, which is likely to damage them.
Sources of oxygen and carbonates in the heating circuit
The primary circuit is a closed circuit; the water it contains is therefore isolated from the mains
water. When maintaining the system or lling up the circuit, water renewal results in the addition
of oxygen and carbonates in the primary circuit. The larger the water volume in the system, the
larger the addition.
Hydraulic components without an oxygen barrier (PE pipes and connections) admit oxygen into
the system.
Prevention Principles
1. Clean the existing system before installing a new boiler
- Before the system is lled, it must be cleaned in accordance with standard EN14868.
Chemical cleaning agents can be used.
- If the circuit is in bad condition, or the cleaning operation was not efficient, or the volume of
water in the installation is substantial (e.g. cascade system), it is recommended to separate
the boiler from the heating circuit using a plate-to-plate exchanger or equivalent.
2. Limit the fill frequency
- Limit fill operations. In order to check the quantity of water that has been added into the
system, a water meter can be installed on the filling line of the primary circuit.
- Automatic filling systems are forbidden.
- If your installation requires frequent water refilling, make sure your system is free of water
leaks.
3. Limit the presence of oxygen and sludge in the water
- 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.
- The additives must be used in accordance with the instructions issued by the manufacturer
of the water treatment product.
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InstallatIon
664Y5900 • A