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HeatMaster
Installation, Operating and
Servicing Instructions
HM 60 N / 70 N / 100 N / 150 JUMBO
HM 60 N / 70 N / 100 N
With ACV BG 2000-S premix gas burner
HM 60 N / 70 N / 100 N
With ACV BM 101 oil burner
HM 150 JUMBO
With ACV BM 151 oil burner
excellence in hot water
66400501
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INDEX INTRODUCTION INTRODUCTION 1 INTENDED USERS OF THESE INSTRUCTIONS Intended users of these instructions 1 These instructions are intended for Symbols 1 - specifying engineers Applicable standards 1 - installing engineers Warnings 1 - end-users - servicing engineers DESCRIPTION 2 SYMBOLS Operating principle 2 Construction features 2 The following symbols are used in these instructions: Essential instruction for operating the system TECHNICAL SPECIFICATION 5 correctly. Maximum operating condit
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DESCRIPTION OPERATING PRINCIPLE CONSTRUCTION FEATURES The HeatMaster is a high performance, direct fired hot water storage Outer body heater, which has indirect heat transfer due to its Tank-in-Tank The outer body containing the primary fluid is made of thick STW 22 construction. steel. At the heart of the HeatMaster is a stainless steel cylinder through TANK-IN-TANK heat exchanger which the flue tubes pass. This is surrounded by a mild steel shell The ring-shaped inner tank with its large heati
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DESCRIPTION Features of HeatMaster 70 N / 100 N Flue reduction collar Top cover Central heating Automatic air vent flow pipe Domestic hot water outlet Domestic cold water inlet Flue pipes and Heating circuit filling valve turbulators with removable hose and non-return valve Tank-in-Tank heat exchanger Primary expansion vessel Insulation Primary shunt pump Burner Casing front panel Heating return Primary circuit Combustion chamber Burner chamber plate Safety features of the HeatMaster 60 N Contro
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7 8 9 0 . 1 1 1 . 2 1 . 3 1 . 4 1 . 5 1 . 6 1 7 . 1 8 . 1 DESCRIPTION Safety features of the HeatMaster 70 N and 100 N Control panel HeatMaster 70 N and HeatMaster 100 N Thermal reset high limit thermostat Combined temperature Manual reset high and pressure gauge limit thermostat Manual reset high Burner limit thermostat Summer / Winter switch lockout indicator Time clock Low water pressure switch I O Control thermostat Primary circuit low water pressure indicator Control ON / OFF switch thermos
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TECHNICAL SPECIFICATION MAXIMUM OPERATING CONDITIONS BURNER CHAMBER PLATE Maximum service pressure (tank full of water) - Primary circuit: 3 bar The burner chamber plate has 4 threads (M 10 x 20) for attaching - Secondary circuit: 10 bar the burner. It is protected from heat by a blanket insulation. Test pressure (tank full of water) - Primary circuit: 4.5 bar 5xØ6.5(M8) Ø130 Ø28 - Secondary circuit: 13 bar Operating temperature 60 - Maximum temperature: 90 °C 60 Water quality • Chlorures: < 150
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TECHNICAL SPECIFICATION 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 (page 5) and dimensions given below. A mm B mm C mm D mm E mm F mm G Ø mm H mm J mm K mm HM 60 N 1698 1583 538 625 540 390 150 1098 281 1665 HM 60 N BG 2000-S 60 1698 1583 538 801 540 390 150 1098 281 1665 HM 70 17
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TECHNICAL SPECIFICATION HeatMaster 70 N and HeatMaster 100 N G Without burner With ACV BG 2000-S premix gas burner F K A A B H C/2 J C C E D D HeatMaster 150 Jumbo F 562 H A K C D G J E 7
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INSTALLATION BOILER ROOM CHIMNEY CONNECTIONS Important •Keep vents free at all times. IMPORTANT • Do not store inflammable products in the boiler room. Boilers must be installed by an approved heating • Do not store corrosive products near the boiler, such as paints, engineer, in accordance with the prevailing local solvents, chlorine, salt, soap and other cleaning products. standards and regulations. • If you smell gas, do not switch on the light or light a flame. Turn off the mains gas tap at
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INSTALLATION Balanced flue boiler connection type: C • C13: concentric horizontal connection • C33: concentric vetical connection • C53: parallel chimney connection • C63: concentric vertical connection without terminal (only in Germany and Luxembourg). C33 120 C13 C53 Maximum length concentric : 6 metres Maximum length parallel : 12 metres Note: a 90 degree bend = 1 metre equivalent length A condensation drain outlet must be fitted close to the boiler to prevent condensation products from the c
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INSTALLATION HOT WATER CONNECTIONS Example of parallel connection Recommended for applications with a high continuous flow. Pressure reducing valve If the mains water pressure is greater than 6 bar, a pressure reducing valve must be fitted. Expansion relief valve The tank expansion relief valve must be ACV approved and calibrated to a maximum of 7 bar. The valve discharge must be connected to the drain. Hot water expansion vessel A hot water expansion vessel must be installed. I I I O O O Hot wa
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INSTALLATION HEATING CONNECTION OIL SUPPLY CONNECTIONS - ACV BM BURNERS (If another make of buner is fitted please refer to that manufacturers technical The HeatMaster has two connections at the rear that can be used to connect a central heating circuit. Connecting a heating system may manual) reduce the domestic hot water performance. Installation without return Expansion The HM 60 is fitted with an 8 litre expansion vessel. HM 70/100 models are fitted with two 10 litre expansion vessels, and t
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INSTALLATION ELECTRICAL CONNECTIONS WIRING DIAGRAM Power supply HeatMaster wiring diagram legend The boiler operates with a 230 V - 50 Hz single phase supply. 60 N, 70 N, 100 N (page 13) and 150 Jumbo (page 14) A double pole isolator with a 6 amp fuse or a 6 amp MCB must be fitted outside the boiler to allow power to be shut off during 1. 230 V power connection plug servicing and before any repairs are carried out on the boiler. 2. On/off switch 3. Temperature high limit cutoff indicator (except
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INSTALLATION Electrical connection HeatMaster 150 Jumbo B. Blue Pk. Pink Bk. Black R. Red Br. Brown V. Violet G. Grey W. White Gr. Green Y. Yellow Or. Orange Y/Gr. Yellow / Green W Bk 19 A2 A1 6 1 11 9 5 4 A1 A2 16 95 °C B W B C 1 10 - 100 °C W 2 1 17 Br C 1 3 5 5 7 4 103 °C 2 4 C W 1 2 21 2 6 R R B B C B Bk Y/Gr 18 Br Y/Gr Or BR 6,3 A B B 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 L1 N T1 T2 S3 1 W R Y/Gr 220/240V 15 ~ 50 Hz 11 14 L1 N T1 T2 S3 B4 ph n 230V signal connections Boiler run
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7 . 8 9 . 0 1 . 1 1 . 2 1 3 . 1 4 1 . 5 1 . 6 1 7 . 1 8 1 COMMISSIONING HeatMaster 70 N and 100 N FILLING THE HOT WATER AND HEATING CIRCUITS C IMPORTANT Hot water tank must be pressurised before the heating B circuit is filled. 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 pr
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BURNER FEATURES ACV BG 2000-S premix gas burners dimensions ACV BG 2000-S PREMIX GAS BURNERS Description Type A B C The burner tube is coated with metal fibre (NIT) which, in addition to its remarkable heat exchange capabilities, gives greater durability. BG 2000-S / 60 375 228 248 The main components are a venturi and one (model 60 and 70) or BG 2000-S / 70 375 248 342 two (model 100) gas valves, technology specially developed by BG 2000-S / 100 375 248 342 Honeywell for low Nox premix air/gas
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BURNER FEATURES Burner electrical connection BG 2000-S/60 and BG 2000-S/70 Electrical connections B. Blue Bk. Black Br. Brown L1 N T2 S3 B4 T1 G. Grey Gr. Green Y. Yellow Y/Gr. Yellow / Green 123 45 6 7 8 9101112 L1 N Burner electrical connection BG 2000-S/100 Electrical connections B. Blue Bk. Black Br. Brown L1 S3 B4 N T1 T2 G. Grey Gr. Green B Y. Yellow Y/Gr. Yellow / Green Br 123 45 6 7 8 9101112 L1 N 16 Y/Gr Y/Gr Br Br B B Br Br Br Br Y/Gr Y/Gr B B B B B B Gr Gr Br Br Y Y Bk Bk G G Br Br Bk
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BURNER FEATURES ACV premix gas burner BG 2000-S/60 and BG 2000-S/70 Ignition electrode Burner chamber plate insulation Burner tube Gas valve Fan Venturi Chamber plate Ionisation probe Potentiometer setting Relay Gas inlet Burner plug connector Fan power plug ACV premix gas burner BG 2000-S/100 Ignition electrode Burner chamber plate insulation Burner tube Gas valve Fan Venturi Chamber plate Potentiometer setting Ionisation probe Relay Gas inlet Burner plug connector Fan power plug 17
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BURNER FEATURES HeatMaster 60, 70 and 100 Gas burner features - BG 2000 HM 60 N HM 70 N HM 100 N HM 100 N HM 150 Jumbo + BG 2000-S/60 + BG 2000-S/70 + BG 2000-S/100 + gas pressure + gas pressure jet burner jet burner Input kW 69.9 69.9 85.0 96.8 154 Output kW 63.0 63.0 77.4 90.0 139.1 Combustion efficiency - natural gas % 91.2 91.5 92.9 92.9 91.5 Natural gas CO2 % 9.5 9.0 9.0 9.0 9.0 Gas G20 - 20 mbar - I 2E(S)B - I 2 Er - I 2H 3 Flow m /h 7.40 7.40 8.99 10.24 16.30 Gas G25 - 20/25 mbar - I 2L
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LK BURNER FEATURES Features ACV BM 101 AND BM 151 OIL BURNERS - Easy to install – fitted with safety closure and new burner suspension system. Description - The burner air pressure adjusts to the pressure in the burner The use of new technology enables our medium output burners to chamber. meet current performance and emissions quality requirements. - An automatic damper shuts off the air flow when the burner is These burners are fitted with high quality components including a turned off, preven
