ACV E-tech P 57 Owner's manual

E-Tech P
57 - 115 - 144 - 201 - 259
A1007843_664Y7900 • A
Installation,
Operation &
Maintenance
Instructions for the User and the Installer
EN

2
G I.......................................3
Meaning of Symbols............................................................ 4
What to Check on a Regular Basis.................................. 4
Boiler Marking....................................................................... 4
U’ G........................................................5
Using the Control Panel ..................................................... 5
Product Description............................................................. 6
Power variation (kW) relative to voltage........................ 6
T S................................7
Hydraulic Characteristics................................................... 7
Electrical Characteristics ................................................... 7
Recommendations for the prevention of corrosion
and scaling in Heating Systems....................................... 8
I ........................................................9
Tools required for the installation.................................... 9
Package Contents.............................................................. 10
Handling instructions........................................................ 10
Removing the boiler from the packaging.................... 10
Removal and Installation of the Access Panels......... 10
Recommendations for the hydraulic installation.........11
Heating Connection ............................................................11
Heating Circuit + DHW (2 Circulating pumps).............12
Safety instructions for the electrical installation........13
Electrical Connections.......................................................13
Power Limitation .................................................................14
Sizing of supply wires ........................................................14
Control Circuit Terminal.....................................................14
C .................................................15
Safety Instructions for starting up..................................15
Checks and setup before start up..................................15
Filling the system ................................................................15
Starting the boiler ...............................................................16
M..................................................... 17
Recommendations for the boiler maintenance ..........17
Boiler Shut-down for Maintenance ................................17
Draining the Boiler..............................................................17
Boiler maintenance.............................................................18
Checking the Safety Devices ..........................................18
Resetting the High Limit Safety Thermostat ...............18
Replacing the Heating Elements ....................................19
EN
Table of Contents

3
This manual contains important information with respect to
the installation, the starting up and the maintenance of the
appliance.
This manual must be provided to the user, who will read it
carefully and keep it in a safe place.
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 local
standards and regulations.
• The installation must comply with the instructions
contained in this manual and with the standards
and regulations applicable to heating systems.
• 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.
We accept no liability should any damage result from the failure to comply with theinstructions contained in this technical manual.
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.
General remarks
•
The availability of certain models as well as their
accessories may vary according to markets.
• The manufacturer reserves the right to change the
technical characteristics and features of its products
without prior notice. Please check for an updated
version of this manual in the documentation page
on the website www.acv.com.
• 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.
B      
,     
  .
M      
     
     ,
    
.
D     
 , , ,
,    
    .
T     
   ( )
  , 
  ,   
  , 
    
   
       
   .
C     
.
GENERAL SAFETY INSTRUCTIONS FOR ELECTRIC APPLIANCES
EN
G I

4
MEANING OF SYMBOLS
Symbols on the packaging
Fragile
Keep dry
Keep standing, up
Danger of tipping over
Hand truck or pallet truck required
for transport
Symbols on the appliance
Domestic Hot Water circuit
Primary circuit
Electricity
Symbols in the manual
Essential recommendation for safety
(of persons and equipment)
Essential recommendation for elec-
trical safety (electrical hazard)
Essential recommendation for the
correct operation of the appliance or
the system
General remark
Safety valve connected to the sew-
age system
Connection to the sewage system
WHAT TO CHECK ON A REGULAR BASIS
Essential recommendations for the correct
operation of the appliance
• Check regularly that the system water
pressure is at least 1 bar when cold. If the
pressure drops below 0.5 bar, the built-
in pressure sensor blocks the appliance
until the pressure exceeds 0.8 bar.
• If it is required to top up the system to
maintain the minimum recommended
water pressure, always turn the appliance
off and only add small amounts of water
at a time. If a large amount of cold water
is added in a hot boiler, the appliance can
be damaged definitively.
• If the system needs to be refilled
repeatedly with water, or if there is water
on the floor under the boiler, contact your
service engineer.
BOILER MARKING
Location: Back panel
The part number (Code) and serial number
(S/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.
EN
General Information

5
USING THE CONTROL PANEL
1. Control thermostat - Allows to define the tem-
perature setpoint for the primary circuit. Each
number around the dial corresponds to a spe-
cific temperature:
1 = 25°C
2 = 40°C
3 = 55°C
4 = 70°C
5 = 85°C
2. ON/OFF switch - to start and stop the appli-
ance.
3. Summer/Winter switch - Allows the operation
of the boiler for the exclusive production of
Domestic Hot Water, if an external tank is in-
stalled.
4. Manual reset high limit thermostat - If the
boiler temperature exceeds 103°C, the safe-
ty device is activated and the indicator light
is turned on. Refer to "Resetting the High Limit
Safety Thermostat" on page 18 for the reset
procedure.
5. Overheating Indicator light - The lamp turns
on when the safety thermostat is activated be-
cause the primary circuit temperature is too
high (103°C).
6. Low pressure indicator light - The lamp tuns
on when the water pressure is too low in the
primary circuit .
7. Combined temperature and pressure gauge
- Allows the direct reading of both tempera-
ture and pressure of the boiler primary circuit.
8. Power Indicators - These lamps indicate the
level of power that is produced by the boiler,
according to the stages that are activated.
9. Location for optional internal controller - Re-
fer to the manual provided with the accessory.
132
4 5 96 7 8
EN
U’ G

6
PRODUCT DESCRIPTION
This floor-standing electric boiler is available in
5 models:
E-Tech P 57 57.6 kW
E-Tech P 115 115.2 kW
E-Tech P 144 144.0 kW
E-Tech P 201 201.6 kW
E-Tech P 259 259.2 kW
• The power circuit is supplied with three-
phase 400 Volt, without neutral.
• The control circuit is supplied with
single-phase 230 Volt.
Casing
The boiler is protected by a steel casing that first
undergoes a degreasing and phosphation process
before being lacquered and burnt at 220°C.
Heating body
The heating body is constructed from mild steel with
welded joints. It is hydraulically tested at 5.2 bar
(maximum operating pressure = 4 bar).
Heating elements
Removable heating elements, constructed from
stainless steel Incoloy 800 and mounted from the
front of the heating body.
Connection
The boiler is suitable for connection to most sealed
heating and hot water systems, with a maximum
working pressure of 4 bar and a maximum tempera-
ture of 90°C.
Control
The boiler is equipped with an electronic sequenc-
ing controller that constantly adapts the required
power required through a four-stage modulation.
The boiler can also be controlled by an external con-
tact (i.e. room thermostat). The maximum power can
be limited to 25%, 50% or 75% of the nominal power
by adding/removing electrical bridges.
Electric Protection
The control circuit is protected by an internal 3 Amp
MCB. The power circuit is protected at its input by 3
power fuses.
In addition, each contactor - supplying a pair of elec-
tric stars (28,8kW) - is protected by an automatic
thermal and magnetic safety relay.
Frost protection
The boiler is NOT fitted with frost protection. If the
boiler is being installed in a position where freezing
could take place, then a suitable external frost ther-
mostat should be fitted.
Models 3 x 380 V 3 x 400 V 3 x 415 V 3 x 440 V
E-Tech P / 57 51.4 57.6 62.0 70
E-Tech P / 115 103.8 115.2 124.0 139
E-Tech P / 144 130.0 144.0 155.0 174
E-Tech P / 201 181.4 201.6 217.0 244
E-Tech P / 259 233.7 259.2 279.0 314
POWER VARIATION (KW) RELATIVE TO
VOLTAGE
EN
User’s Guide

7
NOMINAL CURRENT PER PHASE
Models Stage 1
(A)
Stage 2
(A)
Stage 3
(A)
Stage 4
(A)
Total current per
phase
(A)
E-Tech P 57 20.9 20.9 20.9 20.9 83.6
E-Tech P 115 41.7 41.7 41.7 41.7 166.8
E-Tech P 144 41.7 41.7 62.6 62.6 208.7
E-Tech P 201 62.6 62.6 83.5 83.5 292.2
E-Tech P 259 104.4 83.5 104.4 83.5 375.8
POWER
Models Power (kW)
Stage 1 Power (kW) Stage 2 Power (kW) Stage 3 Power (kW) Stage 4 Total power (kW)
E-Tech P 57 14.4 14.4 14.4 14.4 57.6
E-Tech P115 28.8 28.8 28.8 28.8 115.2
E-Tech P 144 28.8 28.8 43.2 43.2 144.0
E-Tech P 201 43.2 43.2 57.6 57.6 201.6
E-Tech P 259 72.0 57.6 72.0 57.6 259.2
E-TECH P
57 115 144 201 259
Power kW 57.6 115.2 144 201.6 259.2
Nominal supply
voltage
Power circuit V 3 x 400 3 x 400 3 x 400 3 x 400 3 x 400
Control circuit V 1 x 230 V
50/60 Hz
1 x 230 V
50/60 Hz
1 x 230 V
50/60 Hz
1 x 230 V
50/60 Hz
1 x 230 V
50/60 Hz
Number of heating elements 2 4 5 7 9
Ohmic value
of single resistance (2.4 kW) Ohm 22 22 22 22 22
Type of heating element 4 x 3 x 2.4 kW 4 x 3 x 2.4 kW 4 x 3 x 2.4 kW 4 x 3 x 2.4 kW 4 x 3 x 2.4 kW
Also refer to "Recommendations for the prevention of corrosion and scaling in Heating Systems" on page 8
Also refer to " " on page 4 of ML manual for the complete wiring diagrams.
ETECH P
57 115 144 201 259
Capacity (primary) L 60 60 60 102 102
Min. operating pressure bar 0.8
Max operating pressure bar 4
Hydraulic pressure drop (ΔT = 10°C) mbar 20 79 123 20 33
Max temperature °C 90°C
HYDRAULIC CHARACTERISTICS
ELECTRICAL CHARACTERISTICS
EN
T S

8
RECOMMENDATIONS FOR THE PREVENTION OF CORROSION AND SCALING IN
HEATING SYSTEMS
RECOMMENDATIONS FOR THE PREVENTION OF CORROSION AND SCALING IN HEATING
SYSTEMS
How oxygen and carbonates can aect the
heating system
Oxygen and dissolved gasses in the water of the prima-
ry circuit contribute to the oxidation and the corrosion of
the system components that are made of ordinary steel
(radiators, ...). The resulting sludge is then deposited in
the appliance 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 appli-
ance exchanger.
These deposits in the heat exchanger reduce the wa-
ter flow rate and thermally insulate the exchange sur-
faces, which is likely to damage them.
Sources of oxygen and carbonates in the heat-
ing circuit
The primary circuit is a closed circuit; the water it con-
tains is therefore isolated from the mains water. When
maintaining the system or filling up the circuit, water re-
newal 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
appliance
Before the system is filled, it must be cleaned in accord-
ance with standard EN14336. 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 appliance from the heating circuit using
a plate-to-plate exchanger or equivalent. In that case, it
is recommended to install a hydrocyclone or magnetic
filter on the installation side.
2. Limit the fill frequency
Limit fill operations. In order to check the quantity of wa-
ter 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 not recommended unless
the fill frequency is monitored and the scale and corro-
sion inhibitor remain at the correct levels.
If your installation requires frequent water refilling, make
sure your system is free of water leaks.
Inhibitors may be used in accordance with standard
EN 14868.
3. Limit the presence of oxygen and sludge in the
water
A deaerator (on the appliance flow line) combined
with a dirt separator (upstream of the appliance) must
be installed according to the manufacturer's instruc-
tions.
ACV recommends using additives that keep the ox-
ygen 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.
4. Limit the carbonate concentration in the water
The fill water must be softened if its hardness is high-
er than 20° fH (11,2° dH).
Check regularly the water hardness and enter the val-
ues in the service log.
Water hardness table :
5. Control the water parameters
In addition to the oxygen and the water hardness, oth-
er parameters of the water must be checked.
Treat the water if the measured values are outside the
range.
Water hardness °fH °dH mmolCa(HCO3)2 / l
Very soft 0 - 7 0 - 3.9 0 - 0.7
Soft 7 - 15 3.9 - 8.4 0.7 - 1.5
Fairly hard 15 - 25 8.4 - 14 1.5 - 2.5
Hard 25 - 42 14 - 23.5 2.5 - 4.2
Very hard > 42 > 23.5 > 4.2
Acidity 6,6 < pH < 8,5
Conductivity < 400 S/cm (at 25°C)
Chlorides < 125 mg/l
Iron < 0,5 mg/l
Copper < 0,1 mg/l
EN
Technical Specifications

9
TOOLS REQUIRED FOR THE INSTALLATION
SAFETY INSTRUCTIONS FOR THE INSTALLATION
General remarks
• The connections (electrical, hydraulic) must be
carried out in accordance with current applicable
standards and regulations.
Essential recommendations for the correct
operation of the appliance
• The boiler must be installed in a dry and protected
area, with an ambient temperature comprised
bewtween 0°C and 45°C.
• Install the appliance to ensure easy access at all
times.
• Make sure to install a pressure reducing valve set
at 4.5 bar if the mains supply pressure is in excess
of 6 bar.
Essential recommendations for safety
• Install the boiler on a base made of non-
combustible materials.
• Do not use or store any flammable, explosive or
corrosive products, such as paint, solvents, salts,
chloride products and other detergent products
near the appliance
• This appliance is not constructed for installation
in zone 3.
Essential recommendations for the electrical
safety
•
Only an approved installer is authorized to carry
out the electrical connections.
• The appliance must be connected to the earth.
•
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.
EN
I

10
PACKAGE CONTENTS
The E-Tech P 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.
• One E-Tech P boiler
• Installation, Operation and Maintenance Instruc-
tions
HANDLING INSTRUCTIONS
• The weight of this boiler is more than
100Kg, which could present a risk of
injury. Ask for help to lift it or handle it,
and use an appropriate transport/lifting
means.
• Bring the appliance as close as possible to
the installation location before removing
the packaging.
REMOVING THE BOILER FROM THE
PACKAGING
Before removing the packaging, ensure
that the installation area is clear and that
there are no obstacles, that would make the
installation difficult or unsafe.
1. Remove the packaging as well as the protection
pieces and discard in accordance with applicable
local regulations.
2. With help from another person and an appropri-
ate means of transport, bring the boiler to its lo-
cation of installation.
REMOVAL AND INSTALLATION OF THE
ACCESS PANELS
Set-up conditions
• Boiler shut down using the ON/OFF switch
• External power supply isolated (through the exter-
nal electrical box)
• Boiler cooled down (if it was in operation)
Before any operation on the system, make
sure that the boiler has cooled down and that
the electrical supply is isolated.
Procedure
Right panel:
1. Release eight screws. Retain for reinstallation.
2. Remove the panel
Top panel:
1. Release two screws. Retain for reinstallation
2. Remove the panel.
Front panel:
1. Release two screws located under the control
panel. Retain for reinstallation.
2. Remove the panel.
Follow-on tasks
Perform the operation in the reverse sequence to
reinstall the panels.
x 2
x 2
x 8
EN
Installation

11
RECOMMENDATIONS FOR THE
HYDRAULIC INSTALLATION
• Thoroughly rinse the system before
connecting the boiler
• Water treatment is recommended to
prevent corrosion and the formation of
scale in the boiler and piping.
• If the boiler is to be installed in an
existing system, ACV recommends using
a cleaning agent in the systems.
• After connecting the hydraulic circuit,
check the absence of leaks.
• The boiler is designed to operate on a
sealed system (ie. no open vent or feed
and expansion tank).
• An adequate expansion vessel, sized
accordingly must be installed in the
system
HEATING CONNECTION
Make sure to install isolating valves on the
system heating circuit, so as to be able to
drain the boiler, without draining the whole
system.
Typical system - high temperature
1. Isolation valve
2. Circulating pump
3. Filling valve
4. Check valve
5. Expansion vessel
6. Safety valve (built-in - 4 bar)
7. Draining valve
8. Automatic air vent (built-in)
Essential recommendation for the correct operation of the system
• The drain valve (7) and safety valve (5) must be connected to the sewage system.
• The boiler is equipped with a safety valve set at 4 bar.
Cold water
Hot water
1
12
4
5
63
7
8
EN
Installation

12
HEATING CIRCUIT + DHW (2 CIRCULATING PUMPS)
Essential recommendation for the correct operation of the system.
• The controller is factory programmed with DHW priority. To cancel the DHW priority, remove the
black wire from I7 and connect to I8 in the electronic controller.
• Size the flow rate in hydraulic circuit to ensure a max. 10°C T.
19 20
19 20
17 18
17 18
15 16
15 16
13 14
13 14
11 12
11 12
9 10
9 10
I max = 5A
19 20
19 20
17 18
17 18
15 16
15 16
13 14
13 14
11 12
11 12
9 10
9 10
Q1 Q3 Q5 Q6Q4 Q7 Q8Q2 Q1 Q3 Q5 Q6Q4 Q7 Q8Q2
L N I1 I2 I3 I4 I5 I6 I7 I8 I9 IA IB IC
L N I1 I2 I3 I4 I5 I6 I7 I8 I9 IA IB IC
B Bk Pk R W G W Bk G Pk V
B Bk Pk R W G W Bk G Pk V
Q2 Q3 Q4 Q5 Q6 Q7 Q8Q1 Q2 Q3 Q4 Q5 Q6 Q7 Q8Q1
I7 = DHW priority I8 = DHW priority
CH only CH and DHW
Cold water
Hot water
EN
Installation

13
SAFETY INSTRUCTIONS FOR THE
ELECTRICAL INSTALLATION
• Electrical connections must be carried
out by a qualified technician, in
accordance with regulations applicable
to electrical systems.
• Make sure that the boiler is connected
to the earth.
• As far as the power input to the boiler is
concerned, the installation must comply
with standard EN 60364-1 that define the
applicable levels of insulation, and with
all provisions applicable to installation
conditions.
• For protection against electrical hazard,
it is always recommended to install a
differential cut-out device (Ground Fault
Isolator) on the power supply circuit,
upstream of the boiler.
• The control circuit is protected by a 3A
magnetic circuit breaker.
• The default electrical safeties integrated
in the boiler protect the internal parts of
the boiler.
• Any additional electrical safety device
must be installed outside the boiler.
• For protection against overheating, it is
advisable to place an external positive
safety power cut-out, controlled by the
boiler safety thermostat.
ELECTRICAL CONNECTIONS
1. Remove the right and top panel of the boiler,
see "Removal and Installation of the Access Pan-
els" on page 10.
2. Connect the single phase 230 V power supply
on the control circuit connector, as well as all the
accessories (room thermostat, etc...)
3. Pass the power cables through the glands locat-
ed at the bottom of the rear panel.
Models Std glands optional
glands (*)
E-Tech P 57 1 x PG 36 4 x PG 21
E-Tech P 115 1 x PG 48 4 x PG 21
E-Tech P 144 1 x PG 48 4 x PG 21
E-Tech P 201 4 x PG 29 1 x PG 48
E-Tech P 259 4 x PG 29 1 x PG 48
4. Connect the boiler to the earth using a ring terminal.
5. Open the power connection box.
6. Remove the bottom protection.
7. Connect the power
wires to the mains us-
ing ring terminals.
* Optionally, the installer has the
possibility to remove the standard
cable glands and install the optional
cable glands (not supplied) on site.
** A transformation kit is supplied
with the boiler in order to connect
the power wires using compression
terminals (see detailed instructions
sheet in the kit). Optional connection**
34
1
2
5
6
EN
Installation

14
For higher temperatures, the supply wire diameter
should be adapted according the derating factor.
Ambient T° (°C) Current derating (%)
25 100
30 92
35 85
40 75
45 65
50 53
55 38
Power 25% 50% 75% 100%
SW1 0 1 0 1
SW2 0 0 1 1
25% = Only 1 stage
50% = Only stages 1 & 2
75% = Only stages 1 to 3
100% = All stages
POWER LIMITATION
The maximum power of the boiler can be limited
from 25 to 100% by acting on the SW1, SW2 electrical
bridges as mentioned in the table below:
Essential recommendation for the correct
operation of the system.
• Any change to the power limitation will alter
the current once the boiler has switched to
stand-by (busy signal is OFF). The external
management system can then open the ON/
OFF link.
• The external controller should NOT allow
the boiler to run continuously more than
24 hours. It is therefore necessary to
consider a minimum downtime of 1 hour.
CONTROL CIRCUIT TERMINAL
Power (L)
Power (PE)
Power (N)
230 V OUT (L)
230 V OUT (PE)
230 V OUT (N)
Safety relay (L)
Safety relay (N)
Central heating demand (OUT)
Central heating demand (IN)
DHW demand (IN)
DHW demand (OUT)
Central heating pump 230 V
Central heating pump (N)
Central heating pump (PE)
DHW pump 230 V
DHW pump (PE)
DHW pump (N)
Water pressure alarm 230 V
Water pressure alarm (N)
Safety thermostat alarm 230 V
Safety thermostat alarm (N)
Heating ON signal (busy) 230 V
Heating ON signal (busy) (N)
ON / OFF switch
ON / OFF switch
Heating power SW1
Heating power SW1
Heating power SW2
Heating power SW2
21 3 5 15 174 7 9 10 11 12 13 16 19 21 23 25 26 27 28 29 306 8 14 18 20 22 24
Diameter (mm Current (Amp)
1,5 16
2,5 25
4,6 36
10 47
16 65
25 87
35 115
50 143
70 178
95 220
120 265
150 310
185 355
240 480
SIZING OF SUPPLY WIRES
The supply wires are sized depending of the type and
current of the MCB. The MCB last is sized depending
of the nominal current of the boiler. The admissible cur-
rent of the supply wires depends of the ambient tem-
perature, the section, the length and the insulation of
the wires, the wires ducts, the mounting and the envi-
ronment.
The following values are given for information for an
ambient temperature of 25°C and a maximum length of
5 meters. In all the circumstances, the installation must
be in accordance with the current wiring regulations.
EN
Installation

15
CHECKS AND SETUP BEFORE START UP
Set-up conditions
• Boiler shut down using the ON/OFF switch
• External power supply isolated (through the exter-
nal electrical box).
Procedure
1. Remove the top, front and right side panels.
See"Removal and Installation of the Access Pan-
els" on page 10.
2. Place the internal circuit breaker to OFF (See "12.
Circuit breaker 3A 400 V" on page 17, ML sec-
tion).
3. Check that all electrical connections are tight,
and more particularly the attachment nuts of the
heating elements (nominal torque: 10 Nm).
4. Check that all internal relays and contactors are
secure on the DIN rails.
5. Place control thermostat on the required tem-
perature.
FILLING THE SYSTEM
If the system is fitted with an external
hot water tank, first put the DHW circuit
under pressure before pressurizing the
heating (primary) circuit. Refer to the hot
water preparation tank manual for more
information.
Set-up conditions
• External power supply isolated
• DHW circuit (if any) under pressure
Filling procedure
1. Open the isolating valves (1).
2. Make sure that the drain valve (3) is tightly closed.
3. Open the filling valve (2).
4. Make sure the air vent is open, as required.
5. Once the system is bled from air, bring the pres-
sure to the static pressure at 1.5 bar
6. Close the filling valve (2)
Follow-on tasks
• Check there is no leak.
Essential recommendations for safety
• The components inside the boiler may only
be accessed by an approved installer.
• Set the water temperature in accordance with
usage and local plumbing codes.
• Make sure that the heating circuit filling valve
is closed once the starting up process is
complete.
• Make sure that all connections are made and
tight.
SAFETY INSTRUCTIONS FOR STARTING UP
Cold water
Hot water
1
1
2
3
4
EN
C

16
STARTING THE BOILER
Set-up conditions
• Hydraulic and electric connections made
• External power supply isolated
• Boiler on/o switch to “O”
• Hydraulic circuit filled and under pressure
Procedure
Before starting the boiler, make sure that the
air is bled from the heating circuit using the
automatic air vent located at the top of the
boiler. Note that the black dust cap on the
air vent should be left loose to allow the auto
vent to function.
1. Set the internal MCB to ON (See "12. Circuit break-
er 3A 400 V" on page 17, ML Section).
2. Reinstall the removed access panels, refer to
"Removal and Installation of the Access Panels" on
page 10.
3. Provide power supply to boiler through the ex-
ternal electrical box.
4. Place boiler On/O switch to “On”.
5. Check that the following sequence takes place :
• The indicator shows that the first stage is ac-
tivated.
• The combined thermometer and pressure
gauge indicates the rise in temperature.
• As long as the preset temperature is not
reached, one additional stage is activated
every 2 minutes, until all stages are activat-
ed.
• Once the temperature set on the control
thermostat is reached, one stage is deac-
tivated at a time every 30 seconds, until all
stages are deactivated.
6. After a few minutes of operation of the circulat-
ing pump in the system, place the On/O switch
of the boiler (1) to O.
7. Bleed the air from the system and adjust the
pressure to the static pressure (height: 1 bar =
10 m - 1,5 bar = 15 m) + 0,5 bar. (min. pressure:
0,8 bar). Check the pressure on the combined
thermometer and pressure gauge.
8. The boiler is now ready to operate.
9. Place the boiler On/O switch (1) to “On”.
Follow-on Task(s)
After several days of operation, re-check
all electrical and hydraulic connections for
tightness, as well as the system operating
pressure. Correct and adjust as necessary.
EN
Commissioning

17
RECOMMENDATIONS FOR THE BOILER
MAINTENANCE
Essential recommendations for the electrical
safety
• Before opening the boiler for maintenance,
turn off the boiler by pushing on the ON/
OFF master switch.
• Isolate the external power supply of
the appliance before performing any
operation, unless it is required to take
measurements or perform system setup.
Essential recommendations for safety
• Water flowing out of the drain valve may
be extremely hot and could cause severe
scalding.
• Do not use solvents to clean any of the
components. The components could be
damaged, resulting in unreliable or unsafe
operation.
Essential recommendations for the correct
operation of the appliance
• It is recommended to have the boiler
serviced at least once a year or every
1,500 hours by a qualified technician,
preferably at the start of the heating
season. More frequent servicing may be
required depending on boiler use. Please
consult your installer for advice.
• The boiler maintenance will be carried out
by a qualified engineer, and the defective
parts may only be replaced by genuine
factory parts.
• Make sure to replace any gaskets or
seals on the removed components before
reinstalling them.
• Control the tightness of the hydraulic
circuit connections.
BOILER SHUT-DOWN FOR
MAINTENANCE
1. Switch the boiler o using the ON/OFF master
switch
2. Isolate the external power supply.
DRAINING THE BOILER
Set-up conditions
• Boiler shut down through the ON/OFF switch
• External power supply isolated (through the exter-
nal electrical box)
• Boiler cooled down (if it was in operation)
• Top cover removed to access the air vent. Refer
to "Removal and Installation of the Access Panels" on
page 10.
Procedure
1. Close the heating circuit isolating valves (1)
2. Open the draining valve (2) and allow the water
to flow to the drain
3. Actuate the automatic air vent (3).
Follow-on Task(s)
Reinstall the access panels, refer to "Removal and
Installation of the Access Panels" on page 10.
Cold water
Hot water
1
12
3
EN
M

18
BOILER MAINTENANCE
Set-up conditions
• Boiler shut down using the ON/OFF switch
• External power supply isolated (through the exter-
nal electrical box)
• Boiler cooled down (if it was in operation)
Procedure
1. Remove access panels. Refer to "Removal and In-
stallation of the Access Panels" on page 10.
2. Perform a visual inspection of the boiler looking
out for signs of water leakage from joints, expan-
sion vessel, and the area around the elements
on top of the boiler.
3. Perform a visual inspection of all wiring and ca-
bles in the boiler casing, checking for signs of
overheating or burning.
4. Check all push-on electrical connectors for tight-
ness and good connection to the relative com-
ponents.
5. Using an appropriate screwdriver, check all
electrical terminals on DIN rails and on all com-
ponents for tightness.
6. Check all individual circuit breakers are in the
normal position. If some fuses have tripped,
check the wiring and the resistance before re-
activating them.
7. Check the condition of the heating elements.
Follow-on task(s)
1. Replace the heating elements if necessary. See
"Replacing the Heating Elements" on page 19
2. Restart the boiler, refer to "Starting the boiler" on
page 16.
CHECKING THE SAFETY DEVICES
1. Check the correct operation of the thermostats
and safety devices.
2. Check the heating circuit safety valves, and
those in the DHW circuit, as required.
3. Check the correct operation of the automatic air
vent.
RESETTING THE HIGH LIMIT SAFETY
THERMOSTAT
Set-up conditions
• Boiler shut down through the ON/OFF switch
• External power supply isolated (through the ex-
ternal electrical box)
• Boiler cooled down (if it was in operation) to <60°C
Procedure
1. Unscrew and remove the cover from the safety
thermostat.
2. Press the safety thermostat to reset it.
3. Reinstall the cover on the safety thermostat.
Follow-on task(s)
1. Activate electrical power through the external
electrical box
2. Turn the boiler on using the ON/OFF switch.
3. Check that the overheating indicator is turned
o.
Before carrying out any work on the system ensure that the boiler is cool and all electrical
supplies are isolated.
EN
Maintenance

19
REPLACING THE HEATING ELEMENTS
Set-up Conditions
• Boiler shut down using the ON/OFF switch
• External power supply isolated (through the exter-
nal electrical box)
• Boiler cooled down (if it was in operation)
Before carrying out any work on the system
ensure that the boiler is cool and all electrical
supplies are isolated.
Procedure
1. Remove the front and side access panels (see
"Removal and Installation of the Access Panels" on
page 10).
2. Release eight nuts from the heating element
support plate. Retain for reinstallation.
3. Remove the plate and the heating elements, as
well as the seal (2).
4. Replace the heating elements (1).
5. Replace the seal.
6. Reinstall the plate and the heating elements in
the boiler, with the seal (2).
7. Tighten the eight screws in the order shown at
the bottom of the page.
8. Replace the main fuses (if necessary).
Follow-on Tasks
1. Check all the electrical connections
2. Close all open access panels. See "Removal and
Installation of the Access Panels" on page 10.
3. Restart the boiler. See "Starting the boiler" on
page 16.
Ohmic value : 22 
1
2
1
2
5 7
3 4
8 6
Make sure to tighten the nuts in the sequence
shown
Torque = 10 Nm
EN
Maintenance
1
2

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Oude Vijverweg, 6
B-1653 Dworp
Belgium
[e-mail]
www.acv.com