ACV N2 CONDENS Assembly instructions

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21.8 kW
N2 Condens
INSTALLATION, OPERATING AND
MAINTENANCE INSTRUCTIONS

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TABLE OF CONTENTS
GENERAL RECOMMENDATIONS .................................................................................. 4
USER GUIDE................................................................................................................................. 5
APPLIANCE DESCRIPTION................................................................................................. 6
TECHNICAL CHARACTERISTICS ................................................................................... 8
Electrical characteristics ..............................................................................................................8
Dimensional characteristics........................................................................................................9
Combustion characteristics......................................................................................................11
Hydraulic characteristics .......................................................................................................... 12
Characteristics of flue connection........................................................................................ 13
Operating limits.......................................................................................................................... 14
INSTALLATION .......................................................................................................................15
Contents included in delivery................................................................................................ 15
How to move the boiler........................................................................................................... 16
Tools required for installation ............................................................................................... 17
Installation instructions............................................................................................................. 17
Recommendations for preventing corrosion and scaling............................................. 19
Boiler preparation...................................................................................................................... 21
Fitting the burner .......................................................................................................................23
Electrical connection ................................................................................................................. 24
Flue connection...........................................................................................................................25
Hydraulic connections ..............................................................................................................26
Connection to a hot water tank.............................................................................................27
Fuel oil connection.....................................................................................................................28

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TABLE OF CONTENTS
COMMISSIONING..................................................................................................................29
Commissioning safety instructions.......................................................................................29
Tools required for commissioning........................................................................................29
Checks before bringing into service....................................................................................29
Preliminary filling of the heating system ............................................................................30
Starting the boiler ......................................................................................................................30
Full flush of the heating system .............................................................................................30
MAINTENANCE.......................................................................................................................31
Safety instructions for maintenance..................................................................................... 31
Regular check............................................................................................................................... 31
Cleaning the combustion assembly ..................................................................................... 32
Inspection of safety devices ................................................................................................... 33
Draining of the boiler................................................................................................................ 33
Commissioning after maintenance ....................................................................................... 33
DECLARATION OF CONFORMITY - CE ...................................................................34
ROYAL DECREE DECLARATION OF CONFORMITY 17/07/2009 - BE .....35

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GENERAL RECOMMENDATIONS
These instructions contain important information necessary for the installation,
commissioning and maintenance of the boiler.
These instructions must be given to the user who should keep them in a safe place after
carefully reading them.
Important safety recommendations
It is strictly prohibited to modify the inside of the appliance in any way, without
the manufacturer's prior written agreement.
The appliance must be installed by a qualified engineer, in accordance with the local
regulations in force.
The installation must comply with the instructions contained in this manual as well
as the local regulations governing installations.
Failure to comply with the instructions of this manual may lead to personal injury
or a risk of environmental pollution.
The manufacturer does not accept any liability for any damage caused as a result
of incorrect installation or in the event of using appliances or accessories that are not
specified by the manufacturer.
Important recommendations for the correct operation of the appliance
In order to ensure the appliance operates correctly, it is important to have it serviced
each year by an approved contractor/installer.
If there is a problem please contact your installer for advice.
Faulty parts must only be replaced with genuine parts.
We accept no liability in the event of damage caused by failure to comply with the
instructions appearing in this technical manual.

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USER'S GUIDE
1. Boiler on/off switch
2. Summer/winter switch (is used to turn the heating circulator on and off).
3. Safety warning indicator (lights up when the temperature of the flue gas or water of the
primary system is too high).
4. Thermo-pressure gauge (displays the boiler temperature and the pressure within the
primary system).
5. Manual reset safety thermostat (enables the boiler to be reset after overheating of the
primary water system).
6. Thermostat control (allows the boiler temperature to be set between 60°C for the minimum
position and 90°C for the maximum position).
Important recommendations for the correct operation of the appliance
If the boiler switches frequently to safety, contact your installer.
If your boiler is connected to a Domestic Hot Water (DHW) heating tank, make sure
that the temperature of the heating thermostat is higher than that of the DHW
thermostat in order to guarantee optimal operating conditions.

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The N2 Condens condensing fuel oil boiler is a heat generator that enables the water for the
central heating and DHW heater to be reheated (if the latter is connected to the boiler).
Key
1. Condenser
2. Flue outlet
3. Vent for measuring flue gas temperatures
4. Turbulators (6 parts)
5. Blue flame oil burner
6. Burner chamber plate with insulation brick
7. Boiler body
8. Thermal insulation
APPLIANCE DESCRIPTION

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APPLIANCE DESCRIPTION
9. Minimum thermostat
10. Heating flow
11. Heating return
12. Removable panels
13. Condensate trap
14. Condensate exhaust hose
15. Electrical connection socket of the boiler
16. Connection socket of flue gas safety thermostat (optional)
17. Drain valve

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T2T1
L1 PE
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Br B
Bk G
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Bk G
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BR R
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G V Gr B
Y/Gr
Y/Gr
Y/Gr
Bk
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TECHNICAL CHARACTERISTICS
ELECTRICAL CHARACTERISTICS
Main electrical characteristics N2 Condens
Nominal voltage V~ 230
Nominal frequency Hz 50
Nominal intensity A 6
Wiring diagram
Key
1. On/Off switch
2. Minimum thermostat 45°C
3. Summer/winter switch
4. Safety thermostat
5. Burner
6. Safety warning indicator
7. Room thermostat (optional)
8. Installation heating pump (not provided)
9. Control thermostat of the boiler
10. Flue gas safety thermostat for flue pipe
(optional)
B : Blue
Bk : Black
Br : Brown
G : Grey
Gr : Green
R : Red
V : Violet
Y : Yellow
Y/Gr : Yellow/Green

760 mm
B
355 mm
650 mm
A
50 mm
235 mm
80 mm
105 mm
C
86 mm
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TECHNICAL CHARACTERISTICS
DIMENSIONAL CHARACTERISTICS
Boiler dimensions N2 Condens
A= Width mm 470
B= Height mm 840
C= Depth mm 925
Volume of the combustion chamber dm342.3
Combustion chamber
Height mm 295
Width mm 330
Depth mm 435
Empty weight kg 155

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TECHNICAL CHARACTERISTICS
Overall dimensions of boiler N2 Condens
Recommended Minimum
A (mm) 800 650
B (mm) 1000 900
C (mm) 600 400
D (mm) 150 100
The two lateral rear panels allow access to the components inside the boiler from the left or right hand side.

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TECHNICAL CHARACTERISTICS
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0 500 1000 1500 2000250 750 1250 1750
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Altitude (m)
Pump pressure (bar)
Power (kW)
Power
Pump pressure
Burner operating limit at altitude
Operating range not recommended
COMBUSTION CHARACTERISTICS
Main characteristics N2 Condens
Fuel type EL fuel oil
Heat ow (input - NCV) kW 22.4
Output rate (80/60°C) kW 21.8
Output rate (50/30°C) kW 23.3
Eciency at 30%load (EN 677) % 104
Eciency at 100% load (80/60°C) % 97.5
Eciency at 100% load (50/30°C) % 103.5
Combustion eciency at 100% load (80/60°C) % 98.2
Combustion eciency at 100% load (50/30°C) % 99
Flue gas temperature (return 30°C) °C 48.5
Flue gas temperature (return 60°C) °C 66.7
NOx mg/kWh 87
CO mg/kWh 4
Drop when o W 87

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TECHNICAL CHARACTERISTICS
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60
80
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0 0,5 1 1,5 2 2,5
Water flow rate (m3/h)
Pressure drop (mbar)
HYDRAULIC CHARACTERISTICS
Main hydraulic characteristics N2 Condens
Boiler water capacity L 37
Heating ow connection (female) Ø 1"
Heating return connection (female) Ø 1"
Max operating pressure of the heating circuit Bar 3
Heating exchanger pressure drop (∆t = 20°C) mbar 18
Curve for drop in hydraulic pressure

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TECHNICAL CHARACTERISTICS
CHARACTERISTICS OF FLUE CONNECTION
Flue characteristics N2 Condens
Connection type B23
Ø of boiler connection to ue mm 80
Ø of minimum ue pipe mm 80
L = Maximum length of Ø 80 mm ue pipe m 10
Maximum ue gas T° °C 120
Flue gas temperature - Max. ouput power 80/60°C °C 67
Flue pressure drop Pa 20
Mass ow of ue gas g/s 9.5
Flue connection diagram
1 45° pipe bend ≈ 1 m straight pipe
1 90° pipe bend ≈ 1.5 m straight pipe
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60 80 100 120
Ø of flue pipe (mm)
Length of flue pipe (m)
Length limit
according to the Ø of
the flue gas pipe
Area not
recommended
Curve of flue pipe lengths

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OPERATING LIMITS
Maximum service pressure
- Primary circuit : .......................................................................................................... 3 bar
Operating temperature
- Maximum temperature of the primary circuit : .............................................. 90°C
Water quality
See Recommendations for the prevention of corrosion and scaling
Fuel oil quality
• Low sulphur fuel oil (50 ppm)
• Standard fuel oil (2000 ppm)
• Biofuel oil 0 to 7% of fatty acid methyl esters
TECHNICAL CHARACTERISTICS

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INSTALLATION
CONTENTS INCLUDED IN DELIVERY
The appliances are delivered tested and separately packaged.
Contents of package No. 1
• N2 Condens boiler.
• Multilingual installation, operating and
maintenance instructions.
• A stainless steel flue outlet with measuring
vent.
Contents of package No. 2
• A blue flame fuel oil burner BMR 33.
• Multilingual installation, operating and
maintenance instructions.
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.
General comments

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INSTALLATION
HOW TO MOVE THE BOILER
Move using a hand truck
Use a hand truck suitable for the weight of the boiler.
Minimum door and hall width required to pass the boiler through
Width of corridor:
Example of calculation in order to determine the minimum hall width with a door width
of D = 800 mm
C = 540 x 1000 = Hall width ≥ 675 mm
800
Width of door:
Example of calculation in order to determine the minimum door width with a hall width
of C = 900 mm
D = 540 x 1000 = Hall width ≥ 600 mm
900
C
B
A
D
A = maximum boiler width
B = maximum boiler length
C = door width
D = hall width
C = Ax B
D
D = Ax B
C

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INSTALLATION
TOOLS REQUIRED FOR INSTALLATION
INSTALLATION INSTRUCTIONS
General comments
The connections (electrical, flue and hydraulic) must be made in accordance with
current standards and regulations.
Important recommendations for the correct operation of the appliance
The boiler must be installed in a dry and weather-protected room.
Make sure to position the appliance so that it is always easily accessible.
In case of work in the boiler room, make sure to switch off the boiler in order
to prevent the accumulation of dust in the burner.
Provide a safety valve set to 3 bar, as well as a primary expansion vessel sized
according to the volume of water contained in the heating system.
Important safety recommendations
Place the boiler on a base made of incombustible material.
Make sure that the air vents remain unobstructed at all times.
Provide a drain outlet close to the boiler in order to discharge the flue condensates.

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INSTALLATION
Make a slight gradient of 3% to the horizontal flue gas pipes so that the acid
condensation water runs towards a condensate collector and does not damage the
heating unit.
Do not store any flammable or corrosive materials, or paint, solvents, salts, chlorine
products or any other detergent products in the vicinity of this appliance.
The diameter of the flue must not be smaller than that of the boiler's flue gas outlet.
Important recommendations for electrical safety
Only an approved installer is authorized to carry out electrical connections.
Provide a 2-way switch and a fuse or the recommended rated circuit breaker on the
outside of the boiler in order to allow the electrical supply to be switched off during
servicing and before any maintenance on the boiler.
Disconnect the electrical supply outside of the appliance before any maintenance on
the electrical circuit.
This appliance can be used by children aged from 8 years and above and persons with
reduced physical, sensory or mental capabilities or lack of experience and knowledge,
only if they have been given supervision or instruction concerning use of the appliance
in a safe way and understand the hazards involved.
Children shall not play with the appliance.
Cleaning and user maintenance shall not be made by children unless they are aged from
8 years and above and supervised.
This appliance is not intended for use by persons (including children) with reduced
physical, sensory or mental capabilities, unless used under the supervision of a person
responsible for their safety.
Children should be supervised to ensure that they do not play with the appliance.

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INSTALLATION
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
4. Limit the carbonate concentration in the water
- The fill water must be softened if its hardness is higher than 20° fH (11,2° dH).
- Check regularly the water hardness and enter the values in the service log.
- Water hardness table :
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
5. Control the water parameters
- In addition to the oxygen and the water hardness, other parameters of the water must be
checked.
- Treat the water if the measured values are outside the range.
Acidity 6,6 < pH < 8,5
Conductivity < 400 μS/cm (à 25°C)
Chlorides < 125 mg/l
Iron < 0,5 mg/l
Copper < 0,1 mg/l