ACV Delta G25 Troubleshooting guide

INSTALLATION, OPERATING
AND SERVICING INSTRUCTIONS
DELTA Classic
Combination boiler
with atmospheric burner
ACV reserves the right to modality the technical specifications and components of its products without prior notice. 664Y0100
05/11/2002

1.1 INTENDED USERS OF THESE INSTRUCTIONS
These instructions are intended for:
- the specifying engineer
- the installation engineer
- the user
- servicing technicians
1.2 SYMBOLS
The following symbols are used in these instructions:
Essential instruction for operating the system
correctly.
Essential instruction for personal safety and
environmental protection.
Danger of electrocution.
Risk of burns.
1.3 APPLICABLE STANDARDS
The products have received the “EC” certificate in accordance with the
standards prevailing in different countries (European Directives
90/42/EEC, “efficiency”, 90/396/EEC “gas appliances”). These products
have also received the Belgian “HR+” mark.
1 INTRODUCTION 2
1.1 Intended users of these instructions 2
1.2 Symbols 2
1.3 Applicable standards 2
1.4 Warnings 2
2 INSTALLATION 3
2.1 Boiler room 3
2.2 Connections 3
2.4 Electrical connection 5
3 START-UP 6
3.1 Filling the heating and hot water circuits 6
3.2 Atmospheric burner troubleshooting 6
4 SERVICING 6
4.1 Recommendation 6
4.2 Servicing the gas boiler 6
4.3 Servicing the safety devices 6
4.4 Servicing the burner 7
4.5 Emptying the boiler 7
4.6 Spare parts 7
5 DESCRIPTION 8
5.1 Overview 8
5.2 Description of operation 8
5.3 Design features 9
6 TECHNICAL SPECIFICATION 10
6.1 Effective dimensions 10
6.2 Maximum operating conditions 10
6.3 Domestic hot water performance 10
6.4 Boiler performances 10
6.5 Atmospheric burner 11
7 USER GUIDE 12
7.1 Using the boiler 12
7.2 Boiler room 13
1.4 WARNINGS
These instructions are an integral part of the equipment to which they
refer and must be supplied to the user.
The product must be installed and serviced by qualified engineers, in
compliance with the prevailing standards.
ACV accepts no liability for any damage resulting from incorrect
installation or from the use of components or fittings not specified by
ACV.
Failure to observe instructions regarding tests and test
procedures can result in personal injury or pollution
risks.
Note:
ACV reserves the right to modify the technical specifications and
components of its products without prior notice.
INDEX 1 INTRODUCTION
2

2.1 BOILER ROOM
2.1.1 ACCESS
The boiler room must be large enough to allow good access to the
boiler. The following minimum distances (mm) are required around the
boiler:
- front 500 - sides 100
- rear 150 - above 700
2.1.2 VENTILATION
The boiler room must be fitted with top and bottom vents according to
the table below.
2.1.3 BASE
The base on which the boiler rests must be made of non-combustible
materials.
2.2 CONNECTION
2.2.1 CHIMNEY CONNECTION
The boiler can be connected to a standard flue that complies with the
regulations in force or is connected to a chimney. It must be easy to
remove to give access to the flue pipes when servicing the boiler.
IMPORTANT
Boilers must be installed by a qualified engineer, in
accordance with the prevailing local standards and
regulations.
2.2.2 CENTRAL HEATING CONNECTION
2.2.2.1 Examples of basic circuit configurations
The drain valve and safety valve must be connected to the sewer
drain.
1. 3-way manual motorisable mixer valve
2. Safety valve pre-set to 3 bar with pressure gauge
3. Circulator
4. Non-return valve
5. System filling valve
6. Expansion tank
7. Room thermostat
8. ACV 13 controller (see controller kit page 5)
9. Central heating isolating valve
10. Drain valve
Fig. 2: Configuration with circulator controlled
by a room thermostat
2 INSTALLATION
6
2
3
47
5
99
10
1
6
2
3
48
5
99
10
Fig. 3: Configuration with motor driven mixer valve
Fig. 1: Boiler room ventilation and chimney connection
A
B
D
C
A. Top vent
B. Bottom vent
C. Chimney height
D. Chimney diameter
3
G20 G25 G30-P30
Ventilation
Min. fresh air requirement m3/h 96,6 119,3 140,4
Top vent (A) dm21,5 1,5 1,5
Bottom vent (B) dm21,6 2 2,3
Chimney
C = 5 m Ø min. F mm 153 157 170
C = 10 m Ø min. F mm 153 153 153
C = 15 m Ø min. F mm 153 153 153

2.2.2.2 ACV circulation kit
ACV offers an optional pre-assembled circulation kit comprising:
- a circulator.
- a 3-way manual motorisable valve.
- connecting pipes including a second optional circuit.
- two isolating valves.
- adapters for mounting safety valve and filling valve to right or
left of expansion tank.
2.2.2.3 Discharge
The drain cock and safety valve must be connected to the waste
water system in accordance with current regulations.
2.2.3 DOMESTIC HOT WATER CONNECTION
2.2.3.1 Pressure reducer
If the water mains pressure is greater than 6 bar, a pressure
reducer calibrated to 4.5
bar must be fitted.
2.2.3.2 Safety unit
The tank safety unit must be ACV approved and calibrated to 7
bar.
The valve discharge must be connected to the sewer drain.
2.2.3.3 Hot water expansion tank
Installing a hot water expansion tank avoids any risk of pressure
surges due to water-hammer.
2.2.3.4 Hot water circulation
If the tank is situated a long way from the point of use, then
installing a closed return circuit can provide a faster supply of
hot water always available.
2.2.3.5 Description
1. Safety unit
2. Pressure reducer
3. Thermostatic mixing valve
4. Hot water circulator
5. Non-return valve
6. Hot water expansion tank
7. Inlet valve
8. Draw-off valve
9. Emptying valve
IMPORTANT
As a safety measure against burns, we strongly advise
installing a thermostatic mixing valve (recommended
temperature: 60° C).
Optional fittings available
2 INSTALLATION
Fig. 5a: Configuration without thermostatic mixing valve
1
2
4
6
5
7
9
8
1
2
3
4
6
5
7
9
8
Fig. 5b: Configuration with thermostatic mixing valve
4
Fig. 4: ACV circulation kit assembly
Safety unit Ø 3/4”
Pressure reducer Ø 3/4”
Thermostatic mixer Ø 3/4”
Hot water expansion tank 5 litres

Wiring diagram of ACV controller kits (fig. 7)
2 INSTALLATION
2.3 ELECTRICAL CONNECTION
2.3.1 POWER SUPPLY
The boiler operates with a 230 V - 50 Hz single phase supply. An
on-off switch box with 6 A fuses must be fitted outside the boiler to
allow power to be shut off during servicing and before any repairs are
carried out on the boiler.
2.3.2 COMPLIANCE
Boiler installation must comply with the prevailing local standards and
legislation.
2.3.3 SAFETY
The stainless steel tank must be earthed separately.
2.3.4 BURNER ELECTRICAL CONNECTION
The burner is supplied with power by a 3-core cable.
1. Boiler thermostat (60/90° C)
2. On/off switch
3. Summer/winter selector
4. Thermometer
5. Controller (optional)
6. TTB
7. Cut-off thermostat (95° C max.)
8. Safety thermostat (103° C max.)
9. Plug (power and control)
10. Room thermostat
11. Heating pump connection
12. To gas valve
Fig. 8: Control panel
The power to the boiler must be switched off before any
work is carried out. Fig. 9: Boiler wiring
M. Brown
O. Orange
N. Black
B. Blue
R. Red
T. Green-yellow
12
C
L1
L1
NT1 T2
NT1 T2
S3
S3
N
L1
230V-50 Hz
6A
M
R
B
B
O
B
B
O
M
M
T
N
N
1O 11
9
2
8
7
3
6
1
12
241 3 5
20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
bl n/z br
SQK 349
QAAD50
(QAAD70) QAC32 QAD22
P1 B5 B9 B3 B2
P1Y1Y2NB5B9B3B2
B2. Water temperature detector
B9. Outside temperature detector
B5. Analogue/digital room thermostat
P1. Central heating pump
Y1/Y2/N. Mixer valve (SQK349)
bl. Blue N
n/z. Black Y2
br. Brown Y1
N
230V / 50 Hz
L1
ALIMENTATION
230V
5
Fig. 6a: kit 1
Fig. 6b: kit 2
2.2.4 CONTROLLER KITS
KIT 1: ACV 13.00 / Basic
Basic kit for regulating flow temperature according to
weather conditions.
It comprises: temperature regulator with analogue timer,
water temperature detector (-30/130° C), outside temperature
detector (-30/50° C), 230V - 3 spindle servomotor SQY 31
and intermediate socket.
KIT 1: ACV 13.00 / Standard
Basic kit for regulating flow temperature according to
weather conditions.
It comprises: temperature regulator with analogue timer,
water temperature detector (-30/130° C), outside temperature
detector (-30°/50'C), 230V - 3 spindle servomotor SQY
349 and intermediate socket.

3.1 FILLING THE HEATING AND HOT
WATER CIRCUITS
1. Fill the domestic hot water circuit and bring it up to pressure.
IMPORTANT
The hot water tank must be pressurised before the
heating circuit is filled.
2. Fill the heating circuit taking care not to exceed the 2 bar pressure
limit.
3. Vent the air from the top of the boiler.
4. After venting the air from the system, bring the pressure up to the
static head plus 0.5 bar: 1.5 bar = 10 m – 2 bar = 15 m.
5. Check the power connection, the boiler room ventilation, and ensu-
re that there are no leaks in the flue gas discharge pipes.
6. Set the thermostat (1) to between 60 and 90° C.
3 START-UP 4 SERVICING
Fig. 10: Control panel
7. Set the Summer/Winter selector (3) to the desired position.
8. Switch the on/off switch (2) to the ON position.
9. Check the gas supply pressure on starting up.
3.2 BURNER TROUBLESHOOTING
Refer to the servicing and troubleshooting instructions for the burner.
Before servicing or repairs, switch off the power at the
mains switch fitted in the boiler room by the electrician.
21 3
3
2
5
4
7
1
8
6
4.1 RECOMMENDATION
ACV advises that boilers should be serviced at least once a year.
The burner must be serviced and tested by a competent engineer.
4.2 SERVICING THE GAS BOILER
1 - Switch off the power at the mains switch outside the boiler and
close the gas tap.
2 - Set the on/off switch on the control panel to the OFF position.
3 - Release and remove the chimney flue (1) to free the top of the
boiler.
4 - Remove the jacket top (2) and lift off the flue reducer (3).
5 - Remove the baffles (4) from the flue pipes (5) for cleaning. Replace
them if in poor condition.
6 - Unscrew the burner chamber plate (6).
7 - Brush the flue pipes (5).
8 - Clean the burner chamber (7) and the burner (8).
9 - Check that the insulation on the burner chamber plate (6) is in
good condition.
1. Chimney flue
2. Jacket top
3. Chimney flue reducer
4. Baffles
5. Flue pipes
6. Burner chamber plate
7. Burner chamber
8. Burner
Fig. 11: Main components.
4.3 SERVICING THE SAFETY DEVICES
- Check that all thermostats and safety devices are working properly:
boiler thermostat, cut-off thermostat and manually reset safety
thermostat.
- Test the safety valves on the central heating and hot water circuits
6

4.4 SERVICING THE BURNER
- Check and clean the burner and ignition electrode.
- Check that the safety components are working properly.
4.5 EMPTYING THE BOILER
4.5.1 EMPTYING THE PRIMARY CIRCUIT (central heating):
1. Switch off the power to the boiler at the mains switch installed by
the electrician.
2. Close the isolating valves (1) of the boiler system.
3. Connect a hose to the drain valve (2).
Ensure that it is attached properly.
4. Open the drain valve and let the hot water drain out.
5. When the boiler is empty, return the isolating and safety valves to
their initial positions.
4.5.2 EMPTYING THE HOT WATER TANK:
1. Switch off the mains power to the boiler at the external switch
installed by the electrician.
2. Relieve the pressure in the primary circuit.
3. Close valves (A) and (B).
4. Open valves (C) and (D) (first C then D).
5. Let the water drain away.
6. After emptying, return the valves to their initial positions.
For the tank to be emptied, valve (C) must be situated at
ground level.
4.6 SPARE PARTS
Refer to the specific document available from ACV or your distributor.
4 SERVICING
Fig. 12a: Emptying the primary circuit
Fig. 12b: Emptying the hot water circuit
11
2
A
C
B
D
7