Heatmaster 100 N User manual

EN • 1
ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH
664Y0500.A
Installation, operating and
servicing instructions
HeatMaster®60N / 70N / 100N
HeatMaster®60N / 70N / 100N
With ACV BG 2000-S premix gas burner
HeatMaster®60N / 70N / 100N
With ACV BM oil burner
HeatMaster®

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ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH
664Y0500.A
WARNINGS 3
Who should read these instructions 3
Symbols 3
Recommendations 3
Applicable standards 3
Warnings 3
DESCRIPTION 4
Operating principle 4
Construction features 4
USERS GUIDE 6
Using the boiler 6
Resetting the pressure jet oil or Gas burner 7
Ressetting the BG 2000-S premix gas burner 7
Burner troubleshooting 7
TECHNICAL CHARACTERISTICS 8
Maximum operating conditions 8
Burner chamber plate 8
General features 8
Domestic hot water features 8
ELECTRICAL CONNECTION 9
Wiring diagram 9
INSTALLATION 10
Dimensions 10
Boiler room 11
Connection to the chimney 11
Domestic hot water connection 12
Heating connections 13
Oil supply connections - ACV BM burners 13
Connection to the gas 13
COMMISSIONING 14
Filling the domestic hot water and heating circuits 14
BURNER FEATURES 15
ACV BG 2000-S premix gas burners 15
ACV BM 102 and BM 152 oil burners 18
MAINTENANCE 19
Servicing intervals 19
Servicing the boiler 19
Servicing the safety devices 19
Servicing the burner 19
Draining the boiler 19
SPARE PARTS See at the end of this manual
INDEX

ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH
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664Y0500.A
WHO SHOULD READ THESE INSTRUCTIONS
These instructions should be read by:
- the specifying engineer
- the installer
- the user
- the service engineer
SYMBOLS
The following symbols are used in this manual:
• The parts may only be replaced by genuine factory parts. You
will find a list of the spare parts and their ACV reference
number at the end of this document.
• The gas burners are preset in our factory for use with natural
gas [equivalent to G20].
• Specific regulation applicable in Belgium [for the gas burners]:
The CO2level, the air and gas flows and the gas / air ratio
are factory set . Any field adjustments of those settings is
not allowed in Belgium.
• It is important to switch the boiler off before carrying out
any work.
• There are no user accessible parts inside the boiler casing.
APPLICABLE STANDARDS
The appliances carry the CE mark in accordance with the
standards in force in the various countries (European Directives
92/42/EC “Efficiency”, 90/396/EC “Gas appliances”).
They also carry the “HR+” label (Gas boilers) and “OPTIMAZ” label
(Oil boilers).
WARNINGS
IF YOU SMELL GAS:
- Immediately isolate the gas supply.
- Open windows and doors to ventilate the area.
- Do not use any electrical appliances and do not operate any
switches.
- Immediately notify your gas supplier and/or your installer.
This documentation is part of the information delivered with the
appliance and must be given to the user and stored in a safe
place!
An approved installer must carry out the assembly, commissioning,
maintenance and repair of the system, in accordance with current
standards in force.
ACV shall not accept any responsibility for damage caused by
non-compliant location of the system or by use of the parts or
connections not approved by ACV for this application.
The manufacturer reserves the right to change the
technical characteristics and specification of its
products without notice.
The availability of some versions and their accessories
is market dependant.
WARNINGS
RECOMMENDATIONS
• Please, carefully read this manual before installing and
commissioning the boiler.
• It is prohibited to carry out any modifications to the inside of
the appliance without the manufacturer’s prior and written
agreement.
• The product must be installed and serviced by trained
engineers, in compliance with current standards.
• Any failure to follow instructions relating to tests and test
procedures may result in personal injury or risks of pollution.
• To guarantee safe and correct operation of the appliance, it
is important to have it serviced and maintained every year by
an approved installer or maintenance company.
• In case of anomaly, please call your service engineer.
• Despite the strict quality standards imposed by ACV during
the manufacture, inspection and transport of its appliances,
you might notice some errors. Please report immediately any
fault to your approved installer.
Risk of scalding
Essential instruction for
the safety of persons
and the environment.
Danger of electrocution.
Essential instruction for
the correct operation of
the installation.

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ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH
664Y0500.A
OPERATING PRINCIPLE
The HeatMaster®is a high performance, direct fired hot water
storage heater, which has indirect heat transfer due to its Tank-
in-Tank construction.
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.
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.
The burner, either gas or oil, fires onto the primary water which
indirectly heats the stainless steel cylinder containing the DHW.
As with all Tank-in-Tanks, this 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®60 N, 70 N and 100 N has the following items
as standard :
- ON/OFF switch
- Summer/Winter switch
- Timeclock
- Primary circulating shunt pump
- Primary expansion vessels
- Primary safety valve
- Pressure and temperature gauge
- Drain valve
- Body completely insulated in rigid polyurethane foam
CONSTRUCTION FEATURES
Outer body
The outer body containing the primary fluid is made of thick STW
22 steel.
Tank-in-Tank heat exchanger
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.
Combustion gases within the boiler
The combustion gas circuit is paint-protected and comprises:
• Flueways
Depending on output, HeatMaster®models contain several
steel flueways with an internal diameter of 64 mm. Each
flueway is fitted with a baffle of special steel designed to improve
heat exchange and reduce flue gas temperatures.
• 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
All HeatMaster®models can be fitted with pressure jet gas
burners or oil burners. The HeatMaster®60, 70 and 100 can also
be fitted with the low-NOx pre-mix BG 2000 gas burner.
DESCRIPTION

ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH
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DESCRIPTION
Safety features of the HeatMaster®60 N Safety features of the HeatMaster®70 N and 100 N
1. Automatic air vent
2. Domestic cold water inlet
3. Brass pocket
4. Polyurethane foam insulation
5. Heating circuit filling valve with removable hose and
non-return valve
6. Casing front panel
7. P r i m a r y e x p a n s i o n v e s s e l
8. Control panel
9. Boiler shunt pump
10. Burner cover
11. Burner chamber plate insulation
12. To p casin g
13. Flue reduction collar
14. He a ting flow
15. Domestic hot water outlet
16. Stainlees steel Tank-in-Tank hot water store
17. Flue pipes and turbulators
18. Primary heating circuit
19. H e at ing r e t u r n
20. Combustion chamber
21. Burner
A. Thermal reset high limit thermostat
B. Manual reset high limit thermostat
C. Low water pressure switch
D. Primary safety valve
E. Control thermostat
1
2
3
4
8
12
19
13
14
17
18
6
5
7
9
10
11
20
21
16
15
A
C
D
E
B A
C
D
E
B

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ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH
664Y0500.A
USERS GUIDE
USING THE BOILER
Your system should be serviced at least once a year
by a qualified engineer.
If the boiler is subject to heavy use, it may require
servicing more than once a year - consult your service
engineer for advice.
Starting the burner:
In normal operation, the burner starts automatically
whenever the boiler temperature falls below the set
temperature.
Understanding the control panel
There are no user parts inside the control panel.
• ON/OFF switch
This turns the HeatMaster®on or off.
• Control thermostat - 60 to 90 °C
When using the HeatMaster®as a hot water generator only,
the temperature can be set between 60 °C and 90 °C.
If the HeatMaster®is used for both hot water and central
heating, the control thermostat would normally be set at 80 °C
to achieve optimum operating conditions.
• Summer/Winter switch
This turns the heating pump (if fitted) on or off.
• Manual reset high limit thermostat
If the boiler temperature exceeds 103 °C this safety device
will activate and the high temperature indicator will light up. To
reset - first allow the boiler to cool to below 60 °C, unscrew the
cap and press the reset button using a pencil or similar pointed
device, replace the cap. If the fault persists, turn the boiler off
and call an engineer.
• Time clock
This allows the HeatMaster®to be timed on and off and
operates on a 24 hour sequence. Around the outside of the
clock there are a number of white tabs, these allow 15 minute
switching periods. To set the time clock simply push outwards
the number of tabs required for ON period.
Remember: TAB IN = HeatMaster®OFF
TAB OUT = HeatMaster®ON
• Temperature and pressure gauge
This gauge indicates both the temperature of the HeatMaster®
and the pressure within the primary circuit.
The temperature should not exceed 90 °C - if it does, switch the
boiler off and check the thermostat setting. If the fault persists,
call an engineer.
The pressure should not fall below 1 bar, if it does the please
see the ‘Heating System Pressure’ paragraph later in this
section.
• Low primary water pressure indicator
If this indicator lights up, the primary circuit of the HeatMaster®
requires topping up with water. Please see the ‘Heating System
Pressure’ paragraph later in this section.
1. Burner lockout indicator
2. Primary circuit low water pressure indicator
3. High limit cutoff indicator
4. Combined temperature and pressure gauge
5. Control thermostat
6. Time clock
7. M a n u a l r e s e t h i g h l i m i t t h e r m o s t a t
8. ON / OFF switch
9. Summer / Winter switch
I
O
Control panel HeatMaster®60 N
I
O
1
4
53
2
76
8 9
Control panel HeatMaster®70 N and 100 N
1
4
53
2
76
8 9

ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH
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Heating system pressure
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. Then remove the
casing top front panel by pulling it forward. The filling
valves “A” and “B” can now be seen. Open both valves and
allow the system to fill. When the combined temperature
and pressure gauge shows the required pressure, close
bothvalves. Replace the casing top front panel. Restore
the power supply and switch the boiler on.
Safety Valves
If water discharges from any of the safety valves, switch
the boiler off and call a service engineer.
RESETTING THE PRESSURE JET OIL OR
GAS BURNER
• HeatMaster®60 N / 70 N and 100 N
the lockout indicator is situated on the burner and on the
control panel.
The red warning light indicates an operating fault.Wait five
minutes before resetting the burner.To reset : press the button
located on the burner.
If the burner does not relight, call the service engineer after
ensuring that the fault is not due to a power cut or low oil in
the tank.
USERS GUIDE
HeatMaster®70 N and 100 N
A
B
HeatMaster®60 N
A
B
RESETTING THE BG 2000-S PREMIX
GAS BURNER
• HeatMaster®60 N with BG 2000-S/60
HeatMaster®70 N with BG 2000-S/70
HeatMaster®100 N with BG 2000-S/100
the lockout indicator is situated on the burner and on the
control panel.
1. Remove the burner cover.
2. Press the red button to restart the burner.
3. If the burner lights, replace the cover.
4. If the fault persists, call a service engineer.
BURNER TROUBLESHOOTING
For all burners - please refer to the relevant servicing and
troubleshooting instructions in your burner’s technical
manual.

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ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH
664Y0500.A
TECHNICAL CHARACTERISTICS
MAXIMUM OPERATING CONDITIONS
Maximum service pressure (tank full of water)
- Primary circuit: 3 bar
- Secondary circuit: 10 bar
Test pressure (tank full of water)
- Primary circuit: 4.5 bar
- Secondary circuit: 13 bar
Operating temperature
- Maximum temperature: 90 °C
Water quality
• Chlorures: < 150 mg/l (304)
< 2000 mg/l (Duplex)
• 6 ≤ph ≤8
BURNER CHAMBER PLATE
The burner chamber plate has 4 threads M8 for attaching the
burner. It is protected from heat by a blanket insulation.
Ø130 Ø28
4x(M8)
60
60
60 60
DOMESTIC HOT WATER FEATURES
Operating conditions at 80°C HeatMaster®60 N HeatMaster®70 N HeatMaster®100 N
Peak flow at 40°C [ΔT = 30°C] L/10’ 474 646 905
Peak flow at 45°C [ΔT = 35°C] L/10’ 378 543 777
Peak flow at 60°C [ΔT = 50°C] L/10’ 245 346 514
Peak flow at 70°C [ΔT = 60°C] L/10’ 193 268 343
Peak flow at 80°C [ΔT = 70°C] L/10’ 135 207 258
Peak flow at 40°C [ΔT = 30°C] L/60’ 1942 2133 3172
Peak flow at 45°C [ΔT = 35°C] L/60’ 1656 1794 2680
Peak flow at 60°C [ΔT = 50°C] L/60’ 1106 1219 1813
Peak flow at 70°C [ΔT = 60°C] L/60’ 681 971 1226
Peak flow at 80°C [ΔT = 70°C] L/60’ 499 636 893
Constant flow at 40°C [ΔT = 30°C] L/h 1835 1835 2776
Constant flow at 45°C [ΔT = 35°C] L/h 1573 1573 2379
Constant flow at 60°C [ΔT = 50°C] L/h 1101 1067 1665
Constant flow at 70°C [ΔT = 60°C] L/h 791 918 1104
Constant flow at 80°C [ΔT = 70°C] L/h 455 580 804
Pre-heat time minutes 91613
GENERAL FEATURES
HeatMaster®60 N HeatMaster®70 N HeatMaster®100 N
Maximum Input kW 69,9 69,9 107,0
Maximum Output kW 62,9 62,9 96,3
Maintenance loss at 60°C as rated value %0,57 0,60 0,65
Total capacity L162 239 330
Primary circuit capacity L82 108 130
Heating connection [F] Ø1”1/2 1”1/2 1”1/2
Domestic hot water connection [M] Ø3/4” 1” 1”
Domestic hot water tank heat exchanger surface m22,46 3,14 3,95
Pressure drop primary circuit mbar 54 46 83
Pressure drop in the combustion chamber mbar 0,6 0,6 1,4

ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH
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ELECTRICAL CONNECTION
WIRING DIAGRAM : HeatMaster®60 / 70 / 100
1. 230 V power connection plug
2. ON/OFF switch
3. Temperature high limit cutoff indidicator
4. Manuel reset high limit thermostat
5. Primary circuit low water pressure indicator
6. Low water pressure switch
7. Time clock
8. Summer / Winter switch
9. Hot water priority link
10. Burner lockout indicator
11. Room thermostat (optional)
12. Central heating pump
13. HeatMaster®loading pump
14. Burner plug connector
15. Water flow switch connection (optional)
16. Termal reset high limit thermostat 95°C
17. Control thermostat
B. Blue
Bk. Black
Br. Brown
G. Grey
Gr. Green
Or. Orange
Pk. Pink
R. Red
V. Violet
W. White
Y. Yellow
Y/Gr. Yellow / Green
1234567891011121314151617181920
11
9
L1 N T1 T2 S3 B4
L1 N T1 T2 S3 B4
L1 N
L1 N
O
I
1
2
3
4
5
6
7
8
10
12 13
14
15
16
17
21
C
12
P
12
C
12
C
54
3
103 C
95 C
0 - 90 C
21
C
Br
Y/Gr
B
Y
G
Gr
Y/Gr
Br
B
Y
G
Y/Gr
Y/Gr
Y/Gr
Gr
Or
B R
Pk
W
Bk
W
Pk
Or
B B B
GG
G
G
G
Y/Gr
Or
B
Or
Or
B
B
Or
B
Br
Bk
Pk
Bk
W
W
B
B
B
B
G
B
Or Br
Br
B
Br
B
Y/Gr
B
The wiring shown is designed for
blown gas or oil burners.
It is important to move the link
from points (12 - 15) to (15 - 16)
when using the BG 2000-S burner.

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ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH
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INSTALLATION
HeatMaster®
60 N
HeatMaster®
60 N
+ BG 2000-S/60
HeatMaster®
70 N
HeatMaster®
70 N
+ BG 2000-S/70
HeatMaster®
100 N
HeatMaster®
100 N
+ BG 2000-S/100
A mm 1698 1698 1743 1743 2093 2093
B mm 1583 1583 1630 1630 2030 2030
C mm 540 540 678 678 678 678
D mm 625 801 797 937 797 937
E mm 540 540 680 680 680 680
F mm 390390390390390390
G mm 150 150 150 150 150 150
H mm 1098 1098 1289 1289 1693 1693
J mm 281 281 285 285 285 285
K mm 1665 1665 1720 1720 2120 2120
Weight empty (kg] 220 232 270 282 320 333
DIMENSIONS
The units are delivered fully assembled, tested and packed on a timber
base with shockproof edges and protected by heat-shrunk plastic film.
On reception and after unpacking, check the equipment for damage.
For transport purposes, refer to the weight and dimensions given below.
G
F
E
J
HBAK
D
C
A
D
C
C/2
D
G
F
E
J
HB K
A
C
D
A
C
C/2
Without burner With ACV BG 2000-S
premix gas burner
HeatMaster®60 N
HeatMaster®70 N / 100 N
Without burner With ACV BG 2000-S
premix gas burner

ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH
EN • 11
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INSTALLATION
BOILER ROOM
- Make sure that all air vents are unobstructed at all times.
- Do not store any flammable products in the boiler room.
- Do not store any corrosive products, paint, solvents, salts,
chlorine products and other detergent products near the
appliance.
- If you smell gas, do not switch ON or OFF any lights, turn off
the gas tap at the meter, ventilate the rooms and contact
your installer.
- The base on which the boiler rests must be made of
non-combustible materials
ACCESSIBILITY
The appliance must be positioned in such a way to be
accessible any time. In addition, the following minimum distances
are required around the appliance.
- Front 500 mm - Side 100 mm
- Behind 150 mm - Above 700 mm
CONNECTION TO THE CHIMNEY
- The chimney connections must comply with the applicable
standards (in Belgium: NBN D51-003), it must be installed by
an approved engineer, in accordance with the prevailing local
standards and regulations.
- Flue size should not be less then the outlet size of the boiler.
Chimney connection type B23P
The Boiler is connected to the chimney by 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.
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 and the
boiler. In order to avoid this risk, it is strongly recommended
that the chimney be lined and a condensate trap is fitted.
Ventialtion HM
60 N
HM
70 N
HM
100 N
Min. fresh air requirement m3/h 126 126 194
Bottom dm22,11 2,11 3,20
Top dm22,0 2,0 2,0
Chimney minimum flue Ø
E = 5 m Ø F min. mm 189 189 234
F = 10 m Ø F min. mm 159 159 178
E = 15 m Ø F min. mm 150 150 150
Note :
Regulations vary from the country therefore the
table above is intended only as a guide.
A. Top vent
B. Bottom vent
C. Draught regulator
D. Inspection window
E. Height of lined chimney
F. Chimney diameter
A
B
F
D
C
E
C53
C13
C33
2 m min.
150 min.
120
Balanced flue boiler connection type
C13 - C33 - C53 - C63
• C13 : Concentric horizontal connection
• C33 : Concentric vertical connection
• C53 : Parallel chimney connection
• C63 : Concentric vertical connection without terminal
(Only in Germany and Luxemburg).
The maximum flue resistance is 100 Pascal - the table below can be
used to calculate this value.
HeatMaster®
60N / 70N
HeatMaster®
100 N
Air
80 mm
Flue gas
150mm
Air
100 mm
Flue gas
150mm
1 m straight pipe 6162
90° pipe bende 15 2 15 5
45° pipe bende 6162
Condensate recovery _2_4
Outlet pipe 20 10 20 20
This table is based on the equipment offered by ACV and cannot be applied
generally.
The maximum length of concentric flue is 6 meters.
A condensation drain outlet must be fitted close to
the boiler to prevent condensation products from the
chimney running into the boiler.
To avoid condensation water running out of the
terminal, all horizontal flue runs must fall back
towards the boiler.

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ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH
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INSTALLATION
DOMESTIC HOT WATER CONNECTION
Before pressurizing the central heating circuit (primary)
you should first pressurize the domestic hot water
tank (secondary).
The HeatMaster®boiler can be connected directly on the
domestic hot water circuit.
Flush out the system before connecting the domestic hot water
part.
The installation must be fitted with an approved safety unit with
a 7-bar safety valve, a non-return valve and a shut-off valve.
During the heating process, the domestic hot water dilates and
the pressure increases. As soon as the pressure exceeds the
safety valve setting, the valve opens and discharges a small
quantity of water. Using a hot water expansion vessel (2 liters at
least) will prevent this phenomenon and reduce water hammer
effect.
The hot water output temperature may reach
temperatures in excess of 60°C, which can cause
burns. We therefore recommend that you install
a thermostatic mixer immediately after the
appliance outlet.
If stop valves are used in the domestic hot water
system, they can cause pressure waves when closed.
Use devices designed to reduce water hammer to
avoid this phenomenon.
1. Cold water supply tap
2. Non-return valve
3. Pressure reducing valve
4. Safety group
5. Hot water expansion vessel
6. Hot water secondary pump (it fitted)
7. Thermostatic mixing valve
8. Drawoff tap
9. Drain cock
10. Stop cock for cleaning
11. Temperature relief valve (UK-only)
123
4
5
26
7
8
9
10
11
I
O
Example of heating + storage connection
Recommended for applications requiring a high peak flow.
I
O
Example of parallel connection
Recommended for applications with a high continuous flow.
I
O
I
O
I
O
Example of series connection
Preferable for high temperature applications with up to three
units.
I
O
I
O
I
O

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664Y0500.A
INSTALLATION
CONNECTION TO THE GAS
- The HeatMaster®is fitted with a Ø 3/4” (BG 2000-S/60,
BG 2000-S/70) and Ø 1” (BG 2000-S/100) female
fitting connector, on which you can connect the gas tap.
- The gas connection must comply with the applicable
regulations (e.g. NBN D51-003 in Belgium) in the
country of installation.
- Where there is a risk of dirt stemming from the
network, place a gas filter upstream from the
connection.
- Fill the gas line the gas pipe and check in minute detail
that all the boiler pipes, both inside and outside, are
sealed.
- Check the gas pressure in the system. Consult the
technical characteristics.
- Check the gas pressure and consumption when
commissioning the appliance.
OIL SUPPLY CONNECTIONS - ACV BM BURNERS
(if another make of burner is fitted please refer to that manufacturers technical manual)
1
423
6
5
4
9
I
O
7
8
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. Controller
9. Contact sensor
HEATING CONNECTION
Before pressurizing the central heating circuit (primary)
you should first pressurize the domestic hot water
tank (secondary).
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.
Expansion
The HeatMaster®60 is fitted with an 8 litre expansion vessel.
HeatMaster®70/100 models are fitted with two 10 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).
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.
H
max 4m
L1
L1
L1
H
H
max 4m
Installation without return
L (m) (L = H + 1)
H (m) Ø int. 8 mm Ø int. 8 mm
0,5 10 20
12040
1,5 40 80
260100
Installation with return
L (m) (L = H + 1)
H (m) Ø int. 8 mm Ø int. 8 mm
035100
0,5 30 100
125100
1,5 2 0 90
21570
2,5 8 30
3,5 6 20

EN • 14
ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH
664Y0500.A
COMMISSIONING
1. Close the primary circuit filling valves (A)
2. Open the stop valve (B) and the drawoff tap (C).
When water flows out of the tap, the hot water tank is full
and the drawoff tap (C) should be closed.
3. Fill the primary (heating) circuit by opening the valves (A)
and pressurising to 1 bar.
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 = 10m and 2 bar = 15 m.
6. Check that the electrical connection and boiler room
ventilation conform to the relevant standards.
B
C
I
O
A
B
C
A
I
O
HeatMaster®60 N HeatMaster®70 N and 100 N
7. Set the thermostat between 60 and 90 °C.
8. Switch the on/off switch to the ON position.
9. For gas burner, check the gas supply pressure on starting
up.
10. For the oil burner, check the oil supply (and return).
Proceed with the necessary venting, measurements and
settings.
11. Set the heating control to heat demand. When the burner
operates, check the flue gas discharge pipes for leaks.
12. After 5 minutes of operation, vent the primary circuit again
maintaining the water pressure at 1 bar.
13. Then restart the unit and check the combustion.
FILLING THE DOMESTIC HOT WATER AND HEATING CIRCUITS
Before pressurizing the central heating circuit you should first pressurize the domestic hot water tank.
Both the domestic hot water tank and the central heating circuit must be filled before using the boiler.

ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH
EN • 15
664Y0500.A
BURNER FEATURES
ACV BG 2000-S PREMIX GAS BURNERS
Description
The burner tube is coated with metal fibre (NIT) which, in
addition to its remarkable heat exchange capabilities, gives
greater durability.
The principle componants of the burner are:
- a fan with adjustable speed
- an automatic ignition and flame detection system
- a gas valve and venturi specially developed for air/gas pre-mix
burners with low NOx
The pressure at the gas valve outlet is equal to the air pressure at
the neck of the venturi tube, reduced as the offset is adjusted. The
fan sucks in the combustion air through the venturi tube which the
gas inlet leads into. As it goes through, the air creates a vacuum
to the right of the neck of the venturi tube and sucks in the gas at
the venturi tube outlet. A perfect air/gas mix then goes through
the fan and then goes on towards 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 diminishes, the flame goes out
and the gas valve closes: the burner is in safety shutdown
mode.
• 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-S burner fitted to the HeatMaster®60, 70
and 100 is controlled by a Honeywell module which controls
burner operation and safety.
Air-gas mixture control system
AB
C
TYPE A B C
BG 2000-S / 60 375 228 272
BG 2000-S / 70 375 248 342
BG 2000-S / 100 375 248 342
A. Air inlet
B. Gas inlet
C. Venturi
D. Fan
E. Air - Gas mixture
F. Offset regulation screw
G. Gas flow regulation screw
A
C
E
D
B
G
F
BG 2000-S burners are preset at factory
for natural gas
Conversion to propane
Not applicable for Belgium.
Conversion kit included with burner
comprising :
- Restrictor(s)
- Nameplate(s)
- Sticker with settings
- Fitting instructions

EN • 16
ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH
664Y0500.A
BURNER FEATURES
HeatMaster®
60 N
+ BG 2000-S / 60
HeatMaster®
70 N
+ BG 2000-S / 70
HeatMaster®
100 N
+ BG 2000-S / 100
Input kW 69,9 69,9 107,0
Output kW 62,9 62,9 96,3
Combustion efficiency - natural gas %91,2 91,5 92,1
Natural gas CO2%9,5 9,0 9,5
Pressure drop combustion chamber mbar 0,6 0,6 1,4
Flue gas temperature °C 186 172 165
Mass flow rate of combustion products g/sec. 32,1 32,1 49,2
G20 gas flow rate - 20 mbar m3/h 7,40 7,40 11,32
G25 gas flow rate - 25 mbar m3/h 8,60 8,60 13,17
G31 gas flow rate - 30/37/50 mbar m3/h 2,86 2,86 4,50
Gas categories HeatMaster®N + BG 2000-S
I2E(S)B
I2E(R)B * II2H3B/P II2H3P II2E3B/P II2Er3P II2L3B/P II2L3P I3P
G20 20 mbar 20 mbar 20 mbar 20 mbar 20 mbar
G25 25 mbar 25 mbar 25 mbar 25 mbar
G30 30 - 50 mbar 30 - 50 mbar 30 - 50 mbar
G31 30 - 50 mbar 37 - 50 mbar 30 - 50 mbar 37 - 50 mbar 30 - 50 mbar 37 - 50 mbar 37 mbar
BE Belgium
CH Switzerland
CZ Czech republic
DE Germany
DK Denmark
EE Estonia
ES Spain
FR France
GB Great Britain
GR Greece
IE Ireland
IT Italy
LU Luxembourg
LT Lithuania
NL Netherlands
PL Poland
PT Portugal
SI Slovenia
SK Slovakia
SE Sweden
(*) HeatMaster® 100 N + BG 2000-S/100

ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH
EN • 17
664Y0500.A
BURNER FEATURES
L1 N 123456789101112
S3 B4
NT2
T1
L1
Y/Gr Y/Gr
B
Br Br Br
Gr
Y
G
Bk
B B
Y/Gr
Gr
Y
G
Br
B
Br Br Br Br
Bk
B B
L1 N 123456789101112
S3 B4
NT2
T1
L1
Y/Gr
Br Br Br Br
Y
G
Bk
B B
Gr
Y/Gr Y/Gr
Br Br
Gr
Y
G
Bk
B B
ACV Premix gas burner BG 2000-S/60 and BG 2000-S/70
1. I gn i t io n e l e c t r od e
2. Burner tube
3. Ionisation probe
4. Burner chamber plate insulation
5. Gas valve
6. Venturi
7. C h a m b e r p l a t e
8. Relay
9. Gas inlet
10. Fan power plug
11. Fan
12. Potentiometer setting
13. Burner plug connector
B. Blue
Bk. Black
Br. Brown
G. Grey
Gr. Green
Y. Yellow
Y/Gr. Yellow / Green
ACV Premix gas burner BG 2000-S/100
1. I gn i t io n e l e c t r od e
2. Burner tube
3. Ionisation probe
4. Burner chamber plate insulation
5. Gas valve
6. Venturi
7. C h a m b e r p l a t e
8. Relay
9. Gas inlet
10. Fan power plug
11. Fan
12. Potentiometer setting
13. Burner plug connector
B. Blue
Bk. Black
Br. Brown
G. Grey
Gr. Green
Y. Yellow
Y/Gr. Yellow / Green
1
4
2
3
5
6
1
4
2
3
5
6
711
8
10
12
13
9
711
8
10
12
13
9

EN • 18
ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH
664Y0500.A
BURNER FEATURES
ACV BM 102 AND BM 152 OIL BURNERS
Description
The use of new technology enables our medium output
burners to meet current performance and emissions quality
requirements.
These burners are fitted with high quality components including
a two-stage oil pump that permits soft start.
Features
- Easy to install – fitted with safety closure and new burner
suspension system.
- The burner air pressure adjusts to the pressure in the
burner chamber.
- An automatic damper shuts off the air flow when the burner
is turned off, preventing the boiler from cooling.
- Quiet and extremely reliable.
- Adjustable to the depth of the boiler burner chamber
thanks to the adjustable bracket at the mouth of the burner
chamber.
- Three air adjustment points to ensure the best air/oil
mixture.
• upstream air presetting
• primary setting
• combustion head setting
Oil burner specification and performances
HeatMaster®60 N HeatMaster®70 N HeatMaster®100 N
Burner type BM 102 BM 102 BM 152
Input kW 69,9 69,9 107,0
Nozzle flow US Gal/h 1,50 1,50 2,00
Nozzle angle 60° 60° 60°
Oil flow kg/h 5,9 9,9 8,9
Pump pressure bar 10,5 10,5 13,5
Flue gas temperature °C 175 170 170
CO2%12,5 12,5 12,5
Mass rate combustion products g/sec. 29,6 29,6 44,8
BM oil burners dimensions
A mm B mm C mm D mm E mm F mm G Ø L Ø LK Ø Kg
BM 102 350 350 285 325 50 M 8 100 / 82 110 150 16
BM 152 350 350 285 325 50 M 8 100 / 123 110 150 16
M 8
L
LK
A
B
DE
C
G

ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH
EN • 19
664Y0500.A
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.
SERVICE THE BOILER
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.
3. Remove the flue to gain access to the top of the boiler.
4. Remove the casing top panel and lift off the flue reduction
collar by undoing the fastening bolts.
5. Remove the turbulators from the flue pipes for cleaning.
6. Unscrew the burner chamber plate and remove the
burner.
7. Brush the flue pipes .
8. Clean the burner chamber and the burner.
9. Re-assemble turbulators, flue reduction collar and flue,
checking that the gasket on the flue reduction collar is in
good condition. Replace gasket 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.
SERVICING THE BURNER
Oil burner
- Check and if necessary clean the main filter on the oil line.
- Check the alignment of the nozzle: check, clean or change
the nozzle and its filter, check that the electrodes and flame
holder are clean and correctly adjusted.
- Reassemble and check that the safety components are
working properly.
- Set the combustion parameters.
- Check the combustion (CO2, CO and burner pressure)
Gas burner
- Check that the insulation and gasket on the burner chamber
plate are in good condition - replace if necessary.
- Check and clean the burner and electrodes. Replace
electrodes if necessary (under normal use once a year).
- Check that the safety components are working properly.
- Check the combustion (CO2, CO and gas pressure)
123
4
5
26
7
8
9
10
11
I
O
1
423
6
5
4
9
I
O
7
8
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.
Draining the heating circuit
1. Turn OFF the on/off switch on the boiler control panel,
isolate external electrical supply, and turn off the gas or oil
supply to the boiler.
2. Close the isolating valves (4).
3. Connect a hose to the drain cock (7).
4. Open the drain cock to drain the primary circuit.
Draining the domestic hot water circuit
1. Turn OFF the on/off switch on the boiler control panel,
isolate external electrical supply, and turn off the gas or oil
supply to the boiler.
2. Release the pressure in the heating circuit until the pressure
gauge indicates zero bar.
3. Close stop cock (1) and turn off tap (8).
4. Open valve (9) then valve (10) (first 9 then 10).
5. Let the water empty into the drain.
For the tank to be emptied, valve (9) must be situated
at ground level.

EN • 20
ENGLISHFRANCAISNEDERLANDSESPAÑOLITALIANODEUTSCH
664Y0500.A