ACV 25 TC Evo HeatMaster Gas Boiler Instruction Manual

HeatMaster
25 – 35 – 45 – 70 – 85 – 120 TC Evo

Installation, Operation & Maintenance
Instructions for the User and the Installer

General Information

We accept no liability should any damage result from the failure to comply with the instructions contained in this technical manual.
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 instructions 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.

Essential instructions 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.

GENERAL SAFETY INSTRUCTIONS FOR GAS APPLIANCES
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.

Do not store anY flammable or corrosive products, paint, solvents, salts, chloride products and other detergent products near the appliance.
This appliance can be used bY children aged from 8 Years old and above and persons With reduced phYsical, sensorY or mental capabilities or lacK of eXperience and KnoWledge, if theY have been given supervision or instruction concerning the use of the appliance in a safe WaY and understand the haZards involved.
Cleaning and user maintenance shall not be performed bY children Without supervision.
Children shall not plaY With the appliance.
A bYproduct of anY gas fired appliance is carbon monoXide. ACV recommends the installation of a minimum of tWo (2) hard-Wired carbon monoXide detectors With an alarm and batterY bacK-up; one in the mechanical room Where the boiler is located and another installed in the living area outside the bedroom(s) for all installations.

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
| Symbols on the appliance
---|---
| Domestic Hot Water (DHW) circuit
| Primary circuit
| Electricity
| Symbols in the manual
---|---
| Essential instruction for safety (of persons and equipment)
| Essential instruction for electrical safety (electrical hazard)
| Essential instruction for the correct operation of the appliance or the system
| General remark
| Safety valve connected to the sewage system
| Connection to the sewage system

WHAT TO CHECK ON A REGULAR BASIS

ACV recommends to check the system at least every 6 months as follows:

• Check that the system water pressure is at least 1 bar when cold. If the pressure drops below 0.7 bar, the built-in pressure sensor blocks the appliance until the pressure exceeds 1.2 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 boiler can be damaged  definitively.
• If the system needs to be refilled repeatedly with water, please contact your installer.
• Check that there is no water on the floor under the boiler. If there is, please call your installer.
• If a condensate neutralisation system is installed, check it and have it cleaned regularly.
• Check regularly that there is no error message (lockout) on the screen. Refer also to the Troubleshooting table in “In case of Problem…” on page 7 or call your installer
  as required.

General remarks

• The end user is only allowed to carry out the basic set-up operations mentioned in “Controller Set-up Guide” on page 8, after he has received all relevant instructions from the installer. Any other set-up must be carried out by an approved installer.
• If the end user misuses the installer code to access installer-specific parameters and makes changes that cause a system failure, any warranty claim will be void.
• To get additional information on how to use the ACVMax interface, refer to the Installer’s Handbook available at www.acv.com.

END OF THE PRODUCT LIFE
At the end of the service life of the product, do not dispose of the product as solid urban waste. Hand it over to a differentiated waste collection centre.
Please contact your installer or your ACV representative for the removal and disposal of your appliance.

User’s Guide

USING THE CONTROL PANEL

1. ACVMax Touch control panel – It is comprised of an LCD display and soft keys reacting to the touch

2. ACVMax LCD Display – It is the setup interface of the boiler and indicates the parameter values, the error codes and the set-up status of the parameters.
   It displays a series of screens, each showing information and/or icons. The main icons are detailed on the following page.

3. Installer function – By touching simultaneously the up and down arrow keys for 3 seconds, the installer can open the access code window of the ACVMax controller and set up the system once the code has been filled in.

4. Arrow soft touch keys and OK/Reset touch key – To browse through the screens and menus of the ACVMax controller, set up the appliance, increase and decrease the displayed values and validate the selections. The OK/Reset key is also used to RESET the  appliance after a blocking (following the instructions on the screen).

5. Sleeping mode soft key – To put the unit in a sleeping mode.
   When touching the soft key, the unit is in a sleeping mode but is not isolated from power supply. Therefore, live current is still present in the unit. For your safety, disconnect electrical power supply to the unit before maintenance or making any electrical connections to avoid possible electric shock hazard. Failure to do so can cause serious injury, or death.
   • When putting in sleeping mode using the soft key, the appliance will not react to any heat demand. However, the basic appliance protection functions (such as frost protection, etc.) remain active.
   • In addition, the arrow soft keys are no longer illuminated, and the soft key lighting is dimmed.

6. ON/OFF master switch – To turn the appliance ON and OFF. When in OFF position, no power is supplied to the appliance.

The ACVMax navigation is performed through soft keys that react to the touch and emit a short beep when tapped.

Exert a light and short touch (tap) on the soft keys to activate their function. Holding the touch too long will not generate any reaction from the ACVMax Touch, unless it is a combination of soft keys meant to be touched simultaneously for a determined duration,  as instructed in this manual. The arrow keys can also be held longer to increase or decrease values faster.

Navigation through the menus and selection of items/ modification of values is performed through four arrow soft keys , , , . The center soft key is used for validation (and for Reset in some cases).
The installer is provided with full access to all available features after simultaneously touching the and soft keys for 3 seconds and entering a code.

HOME SCREEN
The Home Screen presents status information in a very user-friendly way so that the current state of the boiler can be quickly accessed.

• Screen backlight – it will illuminate when any soft key is touched, and remain illuminated for five minutes.
• Screen brightness – it can be adjusted at the Home screen by touching and holding simulta-neously the and soft keys for 2 seconds.
  Touch the and soft key to increase or decrease the contrast. Touch to end the process.

Main Icons of the ACVMAX Touch display

| CH – indicates information related to Central/space Heating.
---|---
| DHW – indicates information related to Domestic Hot Water.
| Home – to go back to the home screen.
| Back – to go back to the previous screen.
| Warm Weather Shutdown – displays on the home screen when the outdoor temperature reaches the Warm Weather Shutdown temperature.
| Reset – to reset the system to the factory settings.
| Settings – to access controller settings (languages, units, etc.).
| Easy Setup – to quickly adjust the most common settings.
| CH/DHW operation – to enable/disable the central/ space heating or Domestic Hot Water functions
| Information – to get information on the boiler.

STAND-BY SCREEN
This screen is displayed at start-up. It indicates that the Heat Master is ready to respond when a demand is received.

LOCKOUT SCREEN
If a problem occurs, the Lockout screen replaces the Home screen. The backlight also remains on as long as the problem is not solved. Pressing any arrow button will return to the Home screen.
Using the code located in the right bottom corner of the screen, troubleshoot the problem, either with the table located in paragraph “In case of Problem…” on page 7, or with the Lockout code table in the Installer’s Handbook (for the installer only). 

STATUS MESSAGES

• Stand-by – Indicates that the HeatMaster is ready to respond when a demand is received.

• CH Demand – A central heating call has been received.

• DHW Demand – A domestic hot water call has been received.

• CH / DHW Demand – Central heating and domestic hot water calls are being received simultaneously.
  Both calls are being satisfied simultaneously because domestic hot water priority has been disabled.

• DHW Priority – Central heating and domestic hot water calls are being received simultaneously. Domestic  hot water call is being satisfied first because it has  priority over central heating calls.

• Priority Timeout – Central heating and domestic hot water calls are being received simultaneously. The domestic hot water priority time limit has been exceeded. Priority will now switch back and forth between central heating and domestic hot water calls  until one call is  satisfied.

• External Demand – An external modulation call has been received.

•  Manual Operation – The burner or circulators have manually been enabled in the Installer Menu.

• CH Burner Delay – The burner will not fire until the call blocking time has elapsed.

• DHW Burner Delay – The burner will not fire until the call blocking time has elapsed.

• CH Setpoint Reached – The burner is not fired because the supply/system water temperature exceeds the setpoint.
  The central heating circulator continues to operate and the burner will fire again once the supply/system water temperature drops below the setpoint.

• DHW Setpoint Reached – The burner is not fired because the supply/system water temperature exceeds the setpoint. The domestic circulator continues to operate and the burner will fire again once the supply/ system water temperature drops below the setpoint.

• CH Post Pump – The central heating circulator is running to remove heat from the HeatMaster at the completion of a call.

• DHW Post Pump – The domestic hot water circulator is running to remove heat from the HeatMaster at the completion of a call.

• Freeze Protection – The burner is fired because the freeze protection feature has been activated. Freeze protection will end once the supply/system water temperature is raised to 15°C.

• Boiler Protection – The burner firing rate is being reduced because of an excessive difference between the boiler supply and return temperatures. The firing rate will begin increasing once the temperature difference is less than 25°C.

• Lockout Description – The lockout which currently has the HeatMaster shut down is displayed.

IN CASE OF PROBLEM…
Check the list of faults and corresponding codes below to get the solution(s). If no solution is provided here, please contact your installer who will determine the correct solution by referring to”Troubleshooting” on page 47.

connected to the net-work.
E 01| Failed ignition| The burner failed to light after 5 ignition attempts| Check gas supply to the boiler.
E 13| Reset limit reached| Resets are limited to 5 every 15 minutes| Turn unit OFF and ON to resume normal op eration.
E34| Low voltage| Line voltage has fallen below an accept- able operating level| The boiler will automatically reset once line voltage returns to normal.
E 37| Low Water| Water pressure has fallen below an ac- ceptable operating level (07 bar)| Refill the system to reach a normal range pressure. The boiler will automatically reset once water pressure returns to normal.
E 94| Internal Display Fault| Display memory error| and on to resume normal appliance o Turn off
operation.

CONTROLLER SET-UP GUIDE
Starting from the Home screen :

• To navigate on the screen, use the UP, DOWN, LEFT and RIGHT soft keys ,
• Use the OK key to validate a selection.
• To increase/decrease values, use the UP and DOWN keys, or LEFT and RIGHT, according to the situation

HEATING EZ SETUP

Heating EZ Setup allows the installer to quickly customize the central heating settings for the application.
Select CH Demand (No outdoor sensor connected)

Select CH Demand prompts the installer to select how a CH Demand is generated.
Thermostat & Setpoint – A central heating call from a thermostat or zone panel will enable the HeatMaster and the setpoint will be fixed for central heating calls. After Thermostat & Setpoint is selected, the CH1 Setpoint screen appears. (see below).

Constant & Setpoint – The HeatMaster will maintain setpoint without an external CH call from a thermostat or zone panel.
The setpoint will be fixed for CH calls. After Constant & Setpoint is selected, the CH1 Setpoint screen appears.
CH1 Setpoint prompts to enter the fixed setpoint for a CH1
heating call when a Setpoint option is chosen in Select CH Demand.
Touch the or soft keys to adjust the temperature setpoint then touch to store the setting. The CH2 Setpoint screen then appears.
CH2 Setpoint prompts to enter the fixed setpoint for a CH2  heating call when a Setpoint option is chosen in Select CH Demand.
Touch the or soft keys to adjust the temperature setpoint then touch to store the setting and complete the  Heating EZ Setup.
CH1 Default: 82°C
CH2 Default: 60°C

0 – 10V Modulation Signal – This option allows the HeatMaster firing rate to be controlled by an external control system.
Refer to the Installer’s Handbook, Volume 1, for more information.

Select CH Demand (Outdoor sensor connected)

Select CH Demand prompts the installer to select how a CH Demand is generated.
There are  severalSelect CH Demand options, among which  the installer must make a selection.
Thermostat & Outd. Curve – This option is only displayed when the outdoor temperature sensor is connected. A central heating call from a thermostat or zone panel will enable the boiler and the setpoint will vary with the outdoor temperature for central heating  calls.
After Thermostat & Outd. Curve is selected, the Select CH1 Reset Curve screen appears (see below).
Constant & Outdoor Curve – This option is only displayed when the outdoor temperature sensor is connected. The HeatMaster will maintain the setpoint without an external call from a thermostat or zone panel. The setpoint will vary with the outdoor  emperature for central heating calls.
Select CH1 Outd. Curve prompts to select an outdoor curve for a CH1 heating call when an Outdoor Reset option is chosen in Select CH Demand. Outdoor curve presets are available to cover most applications. The outdoor curve can also be adjusted to any desired settings in the Installer Menu (refer to Installer’s Handbook).
Touch the or soft keys to select the outdoor reset curve appropriate for the type of heating system, then touch to store the setting. The Select CH2 Reset Curve screen then appears.
Default: Systems with a temperature between 27°C and 82 °C.
Select CH2 Outd. Curve – prompts to select an outdoor curve for a CH2 heating call when an Outdoor Reset option is chosen in Select CH Demand. Outdoor curve presets are available to cover most applications. The outdoor curve can also be adjusted to any desired settings in the Installer Menu (refer to Installer’s Handbook)..
Touch the or soft keys to select the outdoor reset curve appropriate for the type of heating system, then touch to store the setting. The Warm Weather Shutdown screen then appears.
Default: Systems with a temperature between 27°C and 60 °C
Warm Weather Shutdown allows to enter an optional outdoor temperature at which to disable the central heating function. The HeatMaster will continue to respond to a domestic hot water call or a 0- 10V Modulation Signal when the outdoor temperature exceeds the Warm Weather Shutdown Temperature setting.
Touch the or soft keys to adjust the Warm Weather Shutdown Temperature then touch the soft key to store the setting and complete Heating EZ Setup.
The Warm Weather Shutdown icon ( ) is displayed on the home screen when the outdoor temperature reaches the Warm Weather Shutdown temperature.
Default: OFF.

DHW EZ SETUP

Select DHW Demand prompts the installer to select how a DHW
Demand is generated. There are two Select DHW Demand options, among which the installer must make a selection.
When Thermostat is selected in Select DHW Demand, a domestic hot water call from an aquastat or dry contact switch will enable the HeatMaster with a fixed setpoint for a domestic hot water call..
When Sensor is selected in Select DHW Demand, it operates with theIndirect Water Heater Sensor. The HeatMaster monitors the DHW storagetemperature and generates a DHW call whenever the temperature dropsbelow the DHW storage setpoint by 3°C.
Default : Sensor
DHW Boiler Setpoint prompts to enter the fixed boiler setpoint temperature during a hot water call when the Thermostat option is selected.
Touch the or  soft keys to adjust the required temperature setpoint then touch to store the setting.
Default: 75°C.

DHW Setpoint prompts to enter the DHW storage setpoint temperature.
Touch the or  soft keys to adjust the required temperature setpoint then touch store the setting.
Default: 60°C.
The DHW storage setpoint will automatically be set 15°C higher than the DHW Setpoint setting.

DHW Priority Timeout prompts to enter an optional time limit that a domestic hot water call has priority over central heating call.
Touch the or  soft keys to adjust the required timeout value, if required, then touch to store the setting and complete the DHW setting.
Default: Off

EASY SETUP RESET

EZ Setup Reset allows to reset all EZ setup settings back to the original factory defaults.
Follow the on-screen instructions to reset all EZ setup settings.

DISPLAY EASY SETUP

Display EZ Setup allows to select the interface language (Nine different languages: English, French, Dutch, Spanish, Italian, German, Czech, Polish and Russian).
Touch the or  soft keys to select the required language then touch to store the setting.
Display EZ Setup allows to select the interface temperature unit.
Touch the or  soft keys to select the required unit then touch to store the setting.

CH/DHW OPERATION

CH/DHW Operation provides a simple way to enable/disable either the CH or the DHW function of the HeatMaster.
Touch the or  soft keys to select the object (CH or DHW icon), then touch to toggle between the enabled/disabled status. The status of the circuit is displayed at the top of the screen.
Using the arrow keys, select the HOME or RETURN icon at the bottom of the screen to go back either to the home page or to the previous screen respectively.
Default: DHW enabled

BOILER INFORMATION

Boiler Information screen provides real time operating information of the HeatMaster. Each line contains an information item followed by its current value. Six lines are displayed on the screen at one time.
Touch the or  soft keys to scroll through the items. For more information, refer to the Installer’s Handbook of the HeatMaster boilers.

Lockout History records the last eight lockouts. Six lines are displayed on the Lockout History screen at one time. Each line contains a lockout description followed by how long ago  the lockout occurred.
Touch the or  soft keys to scroll through the items then touch to select any of them and get more details through the Lockout Details screen. For more information, refer to the Installer’s Handbook of the HeatMaster boilers.

APPLIANCE DESCRIPTION – HEATMASTER® 25 – 35 – 45 – 70 – 85 – 120 TC

The HeatMaster® TC series is a range of condensing combination boilers. The boilers combine ACV’s “Tank-in-Tank” concept with a double primary circuit to reach the high  performance of a TOTAL CONDENSATION, double-circuit boiler. Also refer to ML Book for component views.
All the HeatMaster® TC models are equipped with a high efficiency charging pump and with an ACV air/gas premix burner with low NOx emissions. During operation, the burner starts automatically as soon as the boiler temperature gets lower than the preset temperature and stops as soon as the preset temperature is reached.
The HeatMaster® TC series features a built-in frost protection mechanism: as soon as the flow temperature [NTC1 probe] drops below 7°C, the central heating pumps are activated. As soon as the flow temperature is at 5°C, the burner starts up until the flow temperature rises above 15°C. The pumps continue to run for around 10 minutes. The function can be enabled or disabled through the installer menu. When the frost protection is disabled, only the pumps operate.
An anti-freeze function is also available if an outdoor temperature sensor is connected, the pumps are activated when the outside temperature drops below the threshold defined through the Freeze protection function in the installer menu. In order  to enable the HeatMaster boiler to protect the whole system against freezing, all the valves of the radiators and the convectors should be completely open.

Configuration in a system
The HeatMaster® TC boilers can be set up in different types of systems, either high or low temperature, or both, with or without external Domestic Hot Water tank. The  eatMaster®  TC boilers can also be set up in a cascade system, using an external controller. Refer to “Configuration and system set-up” on page 35 for more information. It is up to the installer to  determine the best solution and reach the results the user is expecting.
One basic configuration is shown in this manual (see “Configuration and system set-up” on page 35), with the required accessories, required electrical connections and ACVMax setup using the EZ setup function.
Additional configurations requiring a more advanced setup are shown in the Installer’s Handbook of the appliance. The setup of those systems must be made exclusively by the installer using the installer code.
For any other configuration that is not mentioned in either manuals, please contact your ACV representative.

Technical Specifications

COMBUSTION CHARACTERISTICS

Main Characteristics| G20/G25| G31| G20/G25| G31| G20/G25| G31
---|---|---|---|---|---|---
Input (PCI)| max| kW| 25.0| 25.0| 35.0| 35.0| 45.0| 45.0
min| kW| 5.0| 5.0| 7.0| 7.0| 9.0| 9.0
Output at 100%| (80/60°C)| kW| 24.3| 24.3| 34.1| 34.1| 44.1| 44.1
(50/30°C)| kW| 26.0| 26.0| 36.4| 36.4| 46.8| 46.8
Efficiency at 100%| (80/60°C)| %| 97.3| 97.3| 97.9| 97.9| 98.0| 98.0
(50/30°C)| %| 103.9| 103.9| 103.9| 103.9| 103.9| 103.9
Efficiency at 30% load (EN677)| | %| 108.9| 108.9| 109.5| 109.5| 109.0| 109.0
Combustion efficiency| at 100%| %| 98.2| 98.2| 98.2| 98.2| 97.9| 97.9
NOx (Class 6)
i.a.w. EN15502-1+A1:2016| Max. output| mg/kWh| 64| —| 55| —| 53| —
Min. output| mg/kWh| 12| —| 12| —| 21| —
Weighted| mg/kWh| 24.6| —| 29.5| —| 33.2| —
CO| Max. output| ppm| 27| —| 48| —| 63| —
Min. output| ppm| 6| —| 4| —| 4| —
CO2| Max. output| %CO2| 8.8| 10.1| 9.2/8.9| 10.7| 9.0| 10.7
Min. output| %CO2| 8.3| 9.3| 8.8/8.4| 10.2| 8.4| 10.1
Max gas flow rate G20/G25| 20 mbar| m³/h| 2.66| —| 3.64| —| 4.67| —
25 mbar| m³/h| 2.96| —| 4.23| —| 4.67| —
Max. gas flow rate G31| 30/37/50 mbar| m3/h| —| 0.98| —| 1.4| —| 1.77
Kg/h| —| 1.9| —| 2.7| —| 3.5
Temp of flue gases| Normal| °C| 57.7| 57.7| 58.2| 58.2| 64.1| 64.1
Max.| °C| 120| 120| 120| 120| 120| 120
Min.| °C| 32.9| 32.9| 29.2| 29.2| 30.1| 30.1
Average temp. of combustion products| DHW mode| °C| 52.6| 52.6| 52.6| 52.6| 52.6| 52.6
Mass flow rate* of flue gases| Normal| g/s| 11.6| 11.6| 15.5| 15.5| 21.1| 20.1
Min. output| g/s| 2.45| 2.54| 3.26| 3.28| 4.36| 4.25
Standby loss| ∆T = 45 K| W| 187| 187| 187| 187| 187| 187
∆T = 30 K| W| 113| 113| 113| 113| 113| 113

• Mass flow rate values were calculated for G20 and G31 with an air factor of 1.3.

Main Characteristics| G20/G25| G31| G20/G25| G31| G20/G25| G31
---|---|---|---|---|---|---
Input (PCI)| max| kW| 69.9| 69.9| 85.0| 85.0| 115.0| 115.0
min| kW| 21.5| 21.5| 21.0| 21.0| 23.2| 23.2
Output at 100%| (80/60°C)| kW| 68.0| 68.0| 82.9| 82.9| 111.7| 111.7
(50/30°C)| kW| 74.0| 74.0| 89.9| 89.9| 121.7| 121.7
Efficiency at 100%| (80/60°C)| %| 97.3| 97.3| 97.0| 97.0| 97.0| 97.0
(50/30°C)| %| 105.8| 105.8| 105.8| 105.8| 105.8| 105.8
Efficiency at 30% load (EN677)| %| 109.0| 109.0| 108.0| 108.0| 108.0| 108.0
Combustion efficiency| at 100%| %| 98.1| 98.1| 98.0| 98.0| 97.5| 97.5
NOx (Class 6)
i.a.w. EN15502-1+A1:2016| Max. output| mg/kWh| 65| —| 48| —| 60.7| —
Min. output| mg/kWh| 23| —| 26| —| 24.1| —
Weighted| mg/kWh| 33.1| —| 29.3| —| 39.8| —
CO| Max. output| ppm| 34| —| 51| —| 50| —
Min. output| ppm| 7| —| 6| —| 0| —
CO2| Max. output| %CO2| 9.0| 10.6| 8.8/9.2| 10.8| 9.2| 10.6
Min. output| %CO2| 8.4| 10.0| 8.3/8.4| 10.0| 8.6| 10.0
Max gas flow rate G20/G25| 20 mbar| m³/h| 7.2| —| 8.6| —| 12.0| —
25 mbar| m³/h| 8.3| —| 10.0| —| 14.0| —
Max. gas flow rate G31| 30/37/50 mbar| m3/h| —| 2.77| —| 3.37| —| 4.68
Kg/h| —| 5.4| —| 6.6| —| 8.9
Temp of flue gases| Normal| °C| 60| 60| 62| 62| 64.6| 64.6
Max.| °C| 120| 120| 120| 120| 120| 120
Min.| °C| 29.0| 29.0| 28.7| 28.7| 28.7| 28.7
Average temp. of combustion products| DHW mode| °C| 51.0| 51.0| 51.0| 51.0| 51.0| 51.0
Mass flow rate* of flue gases| Normal| g/s| 31.6| 31.6| 30.8| 37.8| 50.8| 49.8
Min. output| g/s| 10.19| 9.98| 10.19| 9.98| 12.14| 11.5
Standby loss| ∆T = 45 K| W| 342| 342| 342| 342| 342| 342
∆T = 30 K| W| 206| 206| 206| 206| 206| 206

• Mass flow rate values were calculated for G20 and G31 with an air factor of 1.3.

ELECTRICAL CHARACTERISTICS
Also refer to ML Book for Wiring Diagrams.

Main Characteristics| | | HM 25 TC| HM 35 TC| HM 45 TC| HM 70 TC| HM 85 TC| HM 120 TC
---|---|---|---|---|---|---|---|---
Rated voltage| | V~| 230| 230| 230| 230| 230| 230
Rated frequency| | Hz| 50| 50| 50| 50| 50| 50
Electrical consumption| Max.| W| 95| 111| 126| 210| 266| 327
Min.| W| 19| 30| 40| 50| 46| 70
Electrical consumption at 30% load| | W| 24| 34| 45| 55| 51| 74
Electrical consumption in standby| | W| 3| 3| 3| 3| 3| 4
Rated current (Fuse)| | A| 16| 16| 16| 16| 16| 16
Class| | | IP 20| IP 20| IP 20| IP 20| IP 20| IP 20

ErP DATA (ECODESIGN)

111.6
Useful efficiency| | | | | |
at 30% of rated heat output| η1| %| 98.2| 98.6| 98.2| 98.2| 97.3| 97.3
at rated output and high-temp re- gime| η4| %| 87.6| 88.2| 88.2| 87.6| 87.4| 87.4
Auxiliary electricity consumption| | | | | |
At full load| elmax| W| 95| 110| 126| 210| 266| 327
At part load| elmin| W| 19| 30| 40| 50| 46| 70
In standby mode| PSB| W| 3| 3| 3| 3| 3| 3
Standby heat loss| Pstby| W| 92| 95| 113| 167| 167| 167
Product Fiche Data (i.a.w. Commission Delegated Regulation 811/2013)| | | | | |
Medium temperature application| Condensation
Declared load profile for water heating| XXL| XXL| XXL| XXL| XXL| XXL
Seasonal space heating energy efficiency class| A| A| A| A| A| A
Water heating efficiency class| A| A| A| A| A| A
Rated heat output| | kW| 24| 34| 45| 68| 83| 112
Annual energy consumption for space heating| kWh| 12170| 17154| 22496| 38253| 45233| 56518
Annual energy consumption for water heating| kWh| 6028| 6028| 6028| 6288| 6288| 6288
Seasonal space heating efficiency| | %| 93| 93| 93| 92| 92|
Water heating efficiency| | %| 87| 87| 87| 85| 85| 85
Sound power level indoors LWA| | dB| 60| 60| 59| 60| 61| 62
Able to work only during off- peak hours| Y/N| N| N| N| N| N| N

CHIMNEY CHARACTERISTICS

Air/flue pipe Ø| concentric| mm| 80/125| 80/125| 80/125| 100/150| 100/150| 100/150
---|---|---|---|---|---|---|---|---
parallel| mm| 80/80| 80/80| 80/80| 100/100| 100/100| 100/100
Max. allowed flue pipe pressure drop| Pa| 95| 130| 130| 110| 160| 170
Max recommended length of concentric flue pipe (corresponding length in meters of

straight pipes) * Ø 80/125, terminal included

| ****

60

| ****

39

| 22| —| —| —
Max recommended length of concentric flue pipe (corresponding length in meters of straight pipes) * Ø 100/150, terminal included| 130| 90| 53**| 20| 19| 18
Max recommended length of dual flow (corresponding length in meters of straight pipes) | Rigid Ø 80| Flex. Ø 80| Rigid Ø 80| Flex. Ø 80| Rigid Ø 80| Flex. Ø 80| Rigid Ø 100| Flex. Ø 100| Rigid Ø 100| Flex. Ø 100| Rigid Ø 100| Flex. Ø 100| Rigid Ø 100| Flex. Ø 100
56| 26| 37| 17| 19| 9| 76| 34| 17| 8| 17| 8| 9| 4

• See page 20 to calculate the flue pipe length.
  ** A C53 connection of the HeatMaster TC boilers requires an optional accessory.
  *** Not recommended – For more information, please contact your ACV representative.

It is mandatory to ventilate the boiler room. The high or low air vent opening dimensions depend on the boiler power and the boiler room size. Refer to the local regulations in force.

Make sure that the air inlet openings remain unobstructed at all times and that air and flue pipe connections are tight and secure.

FLUE PIPE CONNECTION TYPES

It is mandatory to use ACV flue systems to connect the appliance.

B23p Connection to a combustion product exhaust system designed to operate with positive pressure.

B23 Connection to an exhaust duct that discharges the combustion products outside the room where it is installed, with the combustion air being drawn directly from the boiler room.

C13(x) Connection using pipes fitted with a horizontal terminal that simultaneously takes in combustion air for the burner and discharges combustion products outside through openings that are either concentric or close enough together to be subjected to similar wind  conditions, i.e. openings shall fit inside a square of 50 cm for boilers up to 70 kW and inside a square of 100 cm for boilers above 70 kW.

C33(x) Connection using pipes fitted with a vertical terminal that simultaneously takes in fresh air for the burner and discharges combustion products outside through openings that are either concentric or close enough together to be subjected to similar wind conditions  , i.e. openings shall fit inside a square of 50 cm for boilers up to 70 kW and inside a square of 100 cm for boilers above 70 kW.

C43(x) Connection using two pipes to a collective duct system serving more than one appliance; this system of collective ducts features two pipes connected to a terminal unit that simultaneously takes in fresh air for the burner and discharges the combustion  products outside through openings that are either concentric or close enough together to be subjected to similar wind conditions. C43(x) boilers are suitable for a connection to a natural draught chimney only.

C53(x) Connection to separate ducts for supplying combustion air and discharging combustion products; these ducts may end in zones with different pressure levels, but are not allowed to be installed on opposite walls of the building.

C63(x) Type C boiler meant to be connected to a system for supplying combustion air and discharging combustion products, that is approved and sold separately (Prohibited in some countries (e.g. Belgium) – refer to local regulations and standards in force).
Terminals for the supply of combustion air and for the evacuation of combustion products are not allowed to be installed on opposite walls of the building. See also the following additional specifications:

• Maximum allowable draught is 200 Pa.
• Maximum allowable pressure difference between  combustion air inlet and flue gas outlet (including wind pressures) is as follows: 95 Pa (HM 25 TC), 130 Pa (HM 35- 45 TC), 110 Pa (HM 70 TC), 160 Pa (HM 85 TC) and 170 Pa (HM 120 TC).
• Condensate flow is allowed into the appliance.
• Maximum allowable recirculation rate of 10% under wind conditions.

C83(x) Connection using a single or double duct sys- tem. The system is made of a normal exhaust flue duct that discharges the combustion products. The appliance is also connected through a second duct fitted with a terminal, that supplies the burner with  resh outdoor air. Please contact your ACV representative for the meters of flue pipes that can be used to connect the appliance(s).

93(x) Connection using an individual system whose combustion product exhaust duct is installed in an exhaust duct that is integral with the building.
The appliance, the exhaust duct and the terminal units are certified as an inseparable assembly. Minimum usable diameter for the vertical duct supplying the combustion air is 100 mm

The C93 configuration enables airtight operation in a pre-existing chimney. The combustion air crosses the space between the tubing and the pre-existing chimney.
Make sure to clean the pre-existing chimney thoroughly prior to installation, especially if there is soot or tar residue. Make sure that there is a clearance area for the combustion air at least equivalent to the area that would have been provided by separate  concentric ducts or air intake ducts.

CALCULATION OF THE FLUE PIPE LENGTH

When connecting the flue pipes, make sure not to exceed the maximum flue pipe length, recommended for the product, or the system pressure might decrease.

The flue pipe length can be calculated using the method shown below. Please refer to the tables below indicating the values in meters, applied to each of the connection components. Then compare the calculation result to the recommended maximum flue pipe  ength indicated in the table on previous page.

The equivalent length for pipes equipped with a measuring unit is equal to a 1 meter straight pipe.

| Flue pipe length (L)
(corresponding length in meters of straight pipe)
---|---
HM 25 – 35 – 45 TC| HM 25 – 35 – 45 – 70 – 85 – 120 TC
Concentric flue pipe Ø 80/125 mm (Terminal incl.)| Parallel flue pipe Ø 80 mm (Terminal incl.)| Concentric flue pipe Ø 100/150 mm (Terminal incl.)| Parallel flue pipe Ø 100 mm (Terminal incl.)
1 m straight pipe| 1 m| 1 m| 1 m| 1 m
90° elbow| 2 m| 2.3 m| 2.2 m| 3.7 m
45° elbow| 1 m| 1 m| 1.3 m| 2.3 m

Example of verification of the flue pipe length (L)  in a concentric flue pipe system for HeatMaster 35 TC (80/125):
The figure above shows an assembly is comprised of: 1 pipe with a measurement unit + 3 x 90° elbows + 6 meters of straight pipes + 2 x 45° elbows

a) Using the above table, calculate the length in meters of the whole flue pipe assembly:
1 + (3 x 2) + (6 x 1) + (2 x 1) = 15 m
b) Compare the resulting value with the maximum length (39 m).
This flue pipe length is within the recommended range.

Concentric connection

Parallel connection

CASCADE : CALCULATION OF THE MAXIMUM LENGTH OF FLUE PIPES

|
---|---
HeatMaster 25 – 35 TC cascade in a C43 chimney connection configuration| HeatMaster TC cascade in a B23 chimney connection  configuration

Make sure to install an external non-return valve on the flue connection and/or an approved flue  cascade kit, as required. Please contact your ACV representative for the correct accessory.

Equivalent Length
45° [M]| 1.7m| 3.8m
90° [M]| 4.0m| 5.8m

• This table is for systems built with boilers of identical power. For any other configuration, please contact your ACV  representative.
  **Dn 150/200 : Hor. = 150 mm, Vert.=200 mm

APPROVED CHIMNEY COMPONENTS

• ACV/Groupe Atlantic references are provided in a separate crossreference table attached to this manual. Also refer to the latest ACV/Groupe Atlantic Price list for more information and the correct references.

• ACV/Groupe Atlantic references are provided in a separate crossreference table attached to this manual. Also refer to the latest ACV/Groupe Atlantic Price list for more information and the correct references.

HYDRAULIC CHARACTERISTICS

Main Characteristics| 25| 35| 45| 70| 85| 120
---|---|---|---|---|---|---
Capacity (primary)| L| 100| 100| 100| 125| 125| 125
Capacity (DHW)| L| 96| 96| 96| 190| 190| 190
Water pressure drop (primary circuit) (Δt = 20 K)| mbar| 3| 6| 10| 9| 14| 27

HYDRAULIC PRESSURE DROP CURVE OF THE BOILERS

DHW PERFORMANCE
Domestic hot water performance* (cold drink water at 10°C)

*Domestic hot water performance (cold drink water at 10°C)**

Operating conditions at 80°C| | HM 25 TC| HM 35 TC| HM 45 TC| HM 70 TC| HM 85 TC| HM 120 TC
| 40 °C [∆T = 30 K]| L/h| 788| 1,104| 1,390| 2,087| 2,534| 3,402
Constant flow at| 45 °C [∆T = 35 K]| L/h| 676| 946| 1,192| 1,789| 2,172| 2,928
| 60 °C [∆T = 50 K]| L/h| 473| 662| 820| 1,252| 1,520| 1,754
| 40 °C [∆T = 30 K]| L/10’| 361| 408| 471| 716| 783| 900
Peak flow at| 45 °C [∆T = 35 K]| L/10’| 301| 339| 373| 592| 646| 676
| 60 °C [∆T = 50 K]| L/10’| 183| 197| 320| 348| 371| 440
| 40 °C [∆T = 30 K]| L/60’| 1,018| 1,328| 1,610| 2,455| 2,895| 3,620
Peak flow 1st hour at| 45 °C [∆T = 35 K]| L/60’| 865| 1,127| 1,366| 2,083| 2,456| 3,098
| 60 °C [∆T = 50 K]| L/60’| 577| 749| 894| 1,391| 1,638| 1,847
Reheat time from 10°C to 80°C| min.| 35| 26| 23| 27| 24| 23
DHW efficiency at  T = 30 K| | %| 105.4| 105.4| 103.1| 103.9| 103.9| 102.2

MAXIMUM OPERATING CONDITIONS
**Maximum Service Pressure (tank full of water) *
– Primary circuit : ……………………………………………………………………………………….. 3 bar
– DHW circuit : ………………………………………………………………………………………… 8.6 bar
Maximum Operating Temperatures**
– Maximum temperature (primary) : …………………………………………………………..87°C
– Maximum temperature (DHW) : ………………………………………………………………75°C

Water Quality
See “Recommendations for the Prevention of Corrosion and Scaling in Heating Systems” on the following page.

• The hydraulics of the boiler have been tested according to EN-15502, and the boiler is classified as a pressure class 3 appliance.

RECOMMENDATIONS FOR THE PREVENTION OF CORROSION AND SCALING IN HEATING SYSTEMS

How oxygen and carbonates can affect the heating system
Oxygen and dissolved gasses in the water of the primary 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 appliance exchanger.
These deposits in the heat exchanger reduce the water flow rate and thermally insulate the exchange 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 istherefore isolated from the mains water. When maintainingthe system or filling up the circuit, water renewal results inthe addition of oxygen and carbonates in the primary circuit. The larger the water  volume in the system, the largerthe addition.
Hydraulic components without an oxygen barrier (PE pipesand 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 accordance 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 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 not recommended unless the fill frequency is monitored and the scale and corrosion 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

4. 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 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.

5. 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 :
   

6. 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.
   

Installation

SAFETY INSTRUCTIONS FOR THE INSTALLATION

Essential instructions for safety

1. The connections (electrical, flue pipe, hydraulic) must be carried out in accordance with local standards and regulations in force.
2. Install the appliance on level base or vertically plumb support made of non-combustible materials and of sufficient strength to support its weight.
3. Use extreme care not to drop the appliance or cause bodily injury while lifting or mounting the appliance onto the wall bracket or base. Once mounted, verify that the appliance is securely attached to the bracket and wall or safely set on its base.
4. Do not use or store any flammable or corrosive products, such as paint, solvents, salts, chloride products and other detergent products near the appliance.
5. Make sure that the condensate outlet is never obstructed and that a condensate neutralisation system is installed if required.
6. Make sure that all air vents are unobstructed at all times.

Essential instructions for the electrical safety

• Only an approved installer is authorized to carry out the electrical connections.
• Make sure that the appliance is 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.

Essential instructions for the correct operation of the appliance

• The appliance must be installed in a dry and protected area, with an ambient temperature comprised between 0 and 45°C.
• Install the appliance to ensure easy access at all times.
• If the appliance contains a stainless steel DHW production tank, connect it directly to the earth to prevent corrosion.
• If works need to be performed (in the boiler room or close to the air vents), make sure to turn off the appliance to prevent dust from entering and accumulating in the appliance heating system.

TOOLS REQUIRED FOR THE INSTALLATION

PACKAGE CONTENTS

At product reception and after removal of packaging, check the package contents and that the appliance is free of damages.

• Boiler
• Installation, Operation and Maintenance Instructions
• Orifice for the natural gas to propane conversion + stickers + procedure (Except in Belgium)
• Ball condensate trap to be installed.
• A primary safety valve Ø 1/2″ (F) to be installed

HANDLING INSTRUCTIONS

• The boiler weighs more than 180 kg, which could present a risk of injury. Ask for help to handle it and use an appropriate lifting means.

• If using a pallet truck to transport the boiler, remove the bottom front panel (see ML book for instructions).

• Bring the appliance as close as possible to the installation location before removing the packaging.

• If necessary and to make transport easier, the boiler casing can be removed for transportation to the final installation location.
  Refer to ML book for the correct procedure.

• Before removing the packaging, ensure that the installation area is clear and that there are no obstacles making the handling and installation difficult or unsafe.

REMOVING THE PACKAGING

1. Remove the plastic wrapping.
2. Remove the protection pieces and discard in accordance with applicable local regulations.

BOILER PREPARATION
Perform gas conversion to propane as required. Refer to  the procedure provided with the kit (Except in Belgium).

• Close the circulation tube end tap (1) (access from the bottom of the boiler)
  The circulation tube is equipped with an end tap that is open when the boiler is delivered (to prevent test water from being stuck in the circuit and freezing during transport). Make sure that you close the tap before filling the system with water.

• Install the ball condensate trap, then the bottom front panel (to be clipped in)
  Fit the condensate trap, complete with the ball, making sure to install the items in the correct sequence and connect the hose to the drain using a connection that can be inspected. Fill the trap with clean water.
  Make sure to prevent the condensates from freezing.

• Install the safety valve kit : primary circuit safety valve at the back of the boiler
  

CHIMNEY CONNECTION
General Recommendations and Safety Instructions

Essential instructions for safety

• Do not install the boiler into a common flue piping with any other gas or oil appliances. This will cause flue gas spillage or appliance malfunction.
• Verify installed combustion air and flue piping are sealed gas tight and meet all provided instructions and applicable codes and standards.
• Failure to properly support the flue system can cause the flue system to fail, resulting in substantial property damage, serious injury, or death.
• A byproduct of any gas/oil fired appliance is carbon monoxide. Failure to install carbon monoxide detectors with alarms can result in serious injury, or death. Refer to applicable local regulations.

1. Each elbow and straight element will be secured at the sleeve.
2. In case the straight element before or after the first elbow is shorter than 25 cm, secure the straight element after the elbow using a bracket.
3. In case a straight (horizontal or sloped) element is longer than 1 m, support the element in its center using a clamp, making sure to allow free movement of the pipe.
4. Secure with a clamp every 2 meters in vertical piping/1 meter in horizontal/sloped piping, making sure to distribute the clamps evenly on the length of piping.

Essential instructions for the correct operation of the appliance

• A condensation outlet connected to the sewer must be fitted close to the boiler to prevent the condensation products from the flue pipe from running into the boiler.
• Install a condensate neutralisation system if required by national and/or local regulations and have it cleaned regularly.
• Only use flue system components from the same manufacturer to connect this appliance and ensure that the pipe and connection diameters all match.
• Make sure to secure the flue piping to a solid structure.
• Exclusively use provided brackets to support the flue system.
• Install the horizontal flue pipes with a slight slope of 5 cm per meter (3°), so that the acid condensation water flows to a condensate recovery container and does not damage the heating body.
• If the appliance is provided with a condensate drain assembly, make sure to install the complete assembly on the boiler. If the assembly is incomplete, replace the entire assembly.
• Make sure that the condensate drain assembly is filled with water before starting up the boiler and check regularly the water level. Fill with water as necessary.
• It is mandatory to ventilate the boiler room. The high or low air vent opening dimensions depend on the boiler power and the boiler room size. Refer to the local regulations in force.
• If the combustion air inlet is located in an area likely to cause or contain contamination, or if products which could contaminate the air cannot be removed, the combustion air must be repiped and terminated at another location.
• Pool, laundry, common household, and hobby products often contain fluorine or chlorine compounds, which can form strong acids and corrode the internal components and flue system.
• In the case of parallel flue systems, make sure to maintain sufficient distance (at least 40 mm) between the boiler flue piping and combustible materials, and between the flue pipe and air inlet pipe if the latter is made of plastic material.
• Do not use screws to fasten together any flue pipe elements or any PP air inlet elements.
• Do not bond piping elements together using glue (e.g. silicone) or foam (e.g. PUR).

General remark

• For safety reasons and to make assembly easier, it is recommended to prefer the use of concentric flue pipes when possible.
• It is recommended to isolate the flue piping in damp rooms to prevent condensation water from forming on the piping and drip.
• When cutting the pipes to dimension, make sure to cut squarely and deburr the edges to prevent seals from being incorrect or damaged.
• To make piping assembly easier, exclusively use a mixture of water and soap (1%) on the extremity of the pipe to be fit in.
• When fitting metal flue pipes, make sure to always fit the pipe into the sleeve to the end stop.
• When fitting plastic flue pipes, make sure to allow material expansion by leaving about 10 mm between the pipe end and the sleeve end stop.
• Make sure to install the piping without any strain.
• Make sure to install an inspection opening in the flue system.
• When connecting the flue pipes, make sure not to exceed the maximum length recommended for the product, otherwise the system power might decrease.
• ACV-approved components will be used for the chimney connection. Failure to do so will make any warranty claim void.
• For C63 connection type (not allowed in Belgium), make sure to use the correct piping material according to the resistance to temperature, pressure, chemical composition of flue, condensation and soot. A code (as explained in EN 1443), marked on the  pipe, allows to determine if the material complies with the flue system requirements.

Perform Chimney installation according to the data available in section “Chimney Characteristics” on page 18

GAS CONNECTION

RECOMMENDATIONS FOR GAS CONNECTION

Essential recommendations for safety

• The gas connection must comply with all applicable local standards and regulations, and the circuit will be equipped with a gas pressure regulator as required.
• Do not check for gas leaks with an open flame. Use a gas detection device or bubble test.
• The gas burners are factory preset for use with natural gas [equivalent to G20]. Do not adjust or attempt to measure gas valve outlet pressure. The gas valve is factory-set for the correct outlet pressure and requires no field adjustment.
• The natural gas to propane conversion or the reverse is not authorized in certain countries such as Belgium. Refer to the table of gas categories in the technical characteristics of this manual.
• In Belgium, a conversion kit is available as a separate accessory and the conversion process must be carried out by Groupe Atlantic Belgium. Please contact Groupe Atlantic Belgium for gas conversion.
• The gas orifice installed on the boiler must never be modified or replaced with a different size orifice, except in the case of a gas conversion process, which shall be performed according to the provided procedure and requirements.
• The CO2, gas flow rate, air flow rate and air/gas supply parameters are factory-preset and may not be modified in Belgium, except for type I 2E(R) boilers.
• Do not change the OFFSET (A) setting of the gas valve: it is factory-preset and sealed.

Essential recommendations for the correct operation of the appliance

• Refer to the technical characteristics of this manual or to the burner documentation to know the connection diameters.
• Bleed the gas duct and check thoroughly if all the boiler tubes, both internal and external, are tight.
• Check that the gas type and pressure from the distribution network are compatible with the appliance settings. Refer to the product type plate.
• Check the boiler electrical connection, the boiler room air vent system, the tightness of flue gas outlet pipes and of the burner chamber plate.
• Control the gas pressure and consumption at appliance start up.
• Check the boiler CO2 adjustment (refer to the adjustment procedure and the technical data).

SAFETY INSTRUCTIONS – HYDRAULIC CIRCUITS

Essential instructions for safety

• If the appliance is not equipped with one, the heating circuit of the system must be fitted with an approved safety pressure relief valve, according to the pressure mentioned on the type plate.

• Please refer to the applicable local regulations for the installation of the required safety accessories in the hydraulic circuits. Please contact your ACV representative for more information.

• Use a two-wrench method when tightening field piping onto the appliance piping connections. Use one wrench to prevent the appliance connections from turning and the second to tighten field piping.
  Failure to support the appliance piping connections could damage piping or cause a leak.

• In the event of small amounts of hot water repeatedly being drawn off, a stratification effect can develop in the tank. The upper hot water layer may then reach very high temperatures.

• Hot water can cause scalding! The temperature of the domestic hot water can be adjusted up to 75 °C in the appliance. However, the temperature of the domestic hot water at the drawing off point must comply with local regulations.

• ACV recommends therefore the installation of a  pre-set thermostatic mixing valve in order to provide hot water at a maximum of 60°C.

• The risk of developing bacteria exists, including “Legionella pneumophila”, if  a  minimum temperature of 60°C is not maintained in both the DHW tank and the hot water distribution network.

• In order to avoid exposure to extremely hot water that can cause serious burns, never leave children, old people, disabled or handicapped people in the bath or shower alone.
  Never allow young children to turn on the hot water or fill their own bath.

Essential instructions for the correct operation of the appliance

• Make sure that the mains water used to fill the appliance has a minimum pressure of 1.2 bar.
• Make sure to install a pressure reducing valve set at 4.5 bar if the mains supply pressure is in excess of 6 bar.
• Flush the system before connecting the domestic hot water circuit. Refer to the installation instructions.
• If the appliance is not equipped with one, make sure to install an expansion vessel in the primary circuit, which is adapted to the appliance power/ size and the type of system.
• It is recommended to install an expansion vessel in the DHW circuit to prevent the safety valve from opening constantly and reduce the water hammer effect in the system.
• If the appliance is used as a domestic hot water preparation tank, a primary expansion vessel adapted to the boiler power/size and to the type of system must be fitted in the heating circuit (if there is no built-in expansion vessel, or if the builtin expansion  vessel size is not sufficient).

General remark

• If the water drawing off point is far from the tank, installing an auxiliary DHW loop can allow to get hot water more quickly at all times.
• The circuit illustrations are basic principle diagrams only.

G3 REQUIREMENTS AND GUIDANCE – UK ONLY

In the UK, for installation of Evo model appliances directly onto the mains supply of water, ACV offer bespoke unvented kits which have been sized to the requirements of each individual appliance, and contain all of the mandatory components you need to comply with Building Regulations.

Unvented kits provided for ACV Evo models include:

• a 25L expansion vessel & mounting bracket,
• a 28mm combined pressure reducing valve (3.5 bar) & expansion relief valve (6 bar),
• a tundish,
• a flexi hose.

For discharge pipe arrangements not covered by G3 Guidance advice should be sought from your local Building Control Officer. Main characteristics :

• Any discharge pipe connected to the pressure relief devices (Expansion Valve and Temperature/Pressure Relief Valve) must be installed in a continuously downward direction and in a  frost free environment.
• Water may drip from the discharge pipe of the pressure relief device.
• This pipe must be left open to the atmosphere.
• The pressure relief device is to be operated regularly to remove lime deposits and to verify that it is not blocked.

Essential instructions for safety

• The temperature/pressure relief valve should only be replaced by a competent person.
• No control or safety valves should be tampered with or used for any other purpose.
• The discharge pipe should not be blocked or used for any other purpose.
• The tundish should not be located adjacent to any electrical components.

CONNECTION OF THE DHW CIRCUIT

Typical installation with internal DHW tank

Description

1. Isolating valve
2. Pressure reducing valve
3. Check valve
4. DHW expansion vessel
5. Safety valve*
6.  Drain valve
7.  Grounding
8. Draw-off tap
9. Thermostatic mixing valve

*This appliance is equipped from factory with a Temperature and Pressure safety valve installed on the DHW circuit. In the UK, make sure to comply with G3 requirements. Also refer to information above.

CONNECTION OF THE HEATING CIRCUIT

For additional system configurations, refer to “Configuration and system set- up” on page 35 and to the Installer’s Handbook.

Typical connection – high temperature

Cold water
Hot water

Description

1. Isolating valve
2. Heating pump
3. Filling valve
4. Check valve
5. Safety valve
6. Expansion vessel
7. Drain valve
8. Automatic air vent (built-in)

isolating valves, a check valve and two thermometers.
High temperature kit DN 32 (HM 70 / 85 / 120 TC)| Includes a heating pump, two isolating valves, a check valve and two thermometers.

Typical connection – low temperature![ACV 25 TC Evo HeatMaster Gas Boiler

• low temperature](https://manuals.plus/wp-content/uploads/2023/10/ACV-25-TC- Evo-HeatMaster-Gas-Boiler-low-temperature.png) Description

  1. Isolating valve
  2. 3-way mixing valve
  3. Heating pump
  4. Safety valve
  5. Filling valve
  6. Check valve
  7. Expansion vessel
  8. Drain valve
  9. Automatic air vent (built-in)

isolating valves, a check valve, two thermometers, a
3-way valve with built-in bypass and a servomotor.
Low temperature kit DN 32 (HM 70 / 85 / 120 TC)| Includes a heating pump, two isolating valves, a check valve, two thermometers and a
3-way valve with built-in bypass.
Servomotor| Motor for the 3-way valve provided with the low temperature kit.

Applications with Water Hammer Effect (e.g. car wash)
When the appliance is used in applications where water hammer effect can be severe due to the frequentand sudden opening/closing of valves, (e.g. car washsystems, etc.), devices should be installed in the systemto counter this effect and prevent damage from occurring to the piping/appliance.
The water hammer effect is caused by shock wavesrunning through the system when the flow rate ischanged suddenly (e.g. when a valve is closed/openedsuddenly). This induces a surge/sudden fall in pressure,which creates noise and sometimes movement in thesystem piping.
The pressure wave created in these circumstances can be up to three times greater than the standing system pressure. This can damage the piping and the appliance.
It is therefore strongly recommended to install shock arrestor absorber and/or water hammer arrestor devices in the hydraulic system.
To determine the correct devices to be installed in the system for your application type and size, please contact your ACV representative. **** ACV / Groupe Atlantic shall not be liable for any special, indirect, incidental or consequential damages if the recommendations herein are not complied with at installation of the appliance in such systems.

CONFIGURATION AND SYSTEM SET-UP
Basic Configuration – HeatMaster 25 TC: High Temperature Heating Circuit Controlled by Room
Thermostat and Optional Outdoor Sensor.

BLOCK DIAGRAM
The heating system (radiators) is controlled by an On/Off room thermostat.
In this configuration, the boiler constantly adapts its operation to the outdoor temperature, if an outdoor temperature sensor is connected.
The heating pump is triggered as soon as the room thermostat generates a heat demand.
The priority of the internal domestic hot water tank of the boiler (DHW circuit not shown here) is always active.

• The illustrations are for information only. For more details on the required accessories, refer to the latest ACV price list.
  ** Refer to the ML book for the correct Wiring Diagrams, and to “Electrical Characteristics” on page 16.

On the ACVMax Touch, set as follows:

Cascade Configuration, Controlled by EBV Controller
The control Unit (EBV Controller) is used to control a HeatMaster TC Cascade. The connection is made through the EBV Clip-in wiring provided with the Control Unit.
Please connect on ACVMax board X18 and route wires to EBV equipment.

For additional information and specific system configurations, please contact your ACV representative.

Commissioning

SAFETY INSTRUCTIONS FOR STARTING UP

Essential instructions for safety

• The components inside the control panel 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.
• If there is a drain assembly, make sure that the condensate drain assembly is filled with water before starting up the boiler. Fill with water as necessary.
• Make sure that all connections are made and tight.

General remark
In normal operation, the burner starts automatically as soon as the boiler temperature drops below the preset temperature.

TOOLS REQUIRED FOR STARTING UP

CHECKS BEFORE STARTING UP

Essential recommendation for safety

• Check the tightness of the flue pipe connections.

Essential recommendation for the correct operation of the appliance

• Control the tightness of the hydraulic circuit connections.

FILLING THE SYSTEM

**** Put the DHW tank under pressure before pressurizing the heating (primary) circuit.

Set-up conditions

• External power supply isolated

DHW circuit filling procedure

1. Open the isolating valves (1) and the draw-off tap (2).
2. Once the water flow rate has stabilized and the air is totally evacuated from the system, close the draw-off tap (2).
3. Check all the connections for leaks.
   Cold water
   Hot water

Heating circuit fi lling procedure

1. Open boiler front panel (refer to applicable procedure in the manual).
2. Open the isolating valves (1).
3. Make sure that the drain valve (3) is tightly closed.
4. Open the fi lling valve (2).
5. Once the system is bled from air, bring the pressure to the static pressure between 1.5 bar and 2 bar.
6. Close the fi lling valve (2).
7. Disconnect fi lling device from water supply.*

Follow-on tasks

1. Check there is no leak.
   The drain valve is located underneath and the front cover of the base needs to be removed to get access to it.

• UK specific reference G24.1 & G24.2 of the Water Regulations Guide.

STARTING UP THE BOILER

Set-up conditions

• All connections made
• Gas conversion carried out as required
• Condensate trap full of water
• Electrical power supply on
• Gas supply open
• Hydraulic circuit(s) full of water

Procedure

1. Check that there is no gas leak.
2. Depress the ON/OFF master switch ( ).
3. If a room thermostat is installed, possibly increase the temperature set-point to generate a demand.
4. Check the gas pressure and allow the boiler to heat up for a few minutes
5. Check and adjust the burner according to local standards and regulations, refer to the procedure on the right.
6. Set the central heating temperature to the required value using the control panel. Refer to “Controller Set-up Guide” on page and to the Installer’s Handbook.
7. After 5 minutes of operation, bleed the heating circuit until all air is evacuated and restore a 1.5 bar pressure.
8. Bleed the central heating circuit once again and top it up with water to get the required pressure, if necessary.
9. Make sure that the central heating system is properly balanced and, if needed, adjust the valves to prevent certain circuits or radiators from getting a flow rate that is far above or below the set rate.

Follow-on tasks

1. Close the heating circuit filling valve and disconnect the filling connection as required.
2. Check that there are no leaks.
3. Check that the flow rate in the appliance is sufficient as follows :
   • Operate the boiler at maximum power
   • Once the temperatures are stable, read out the supply and return temperatures
   • Check that the difference between the supply and return temperature is equal or less than 20k.
   • If the Delta T is higher than 20k, check the pump settings/specifications.

CHECKING AND ADJUSTING THE BURNER

When the burner operates at full power, the CO2 rate must be within the limits mentioned in the technical characteristics, (see “Combustion characteristics” on page 15).

Set-up conditions

• Front top panel and top panel removed. See ML Book.
• Operating boiler

Procedure

1. Check if the ACVMAX parameters are set to meet the user’s requirements (refer to “Controller Set-up Guide” on page 8), and change them if required.
2. Put the boiler to maximum power mode (Refer to the Installer’s Handbook).
3. Using a pressure tester, check that the dynamic gas pressure at the gas valve is at least 18 mbar.
4. Allow the appliance to heat for a few minutes until it reaches at least 60°C.
5. Measure the burner combustion by placing the flue gas analyzer probe in the measurement unit port on the flue pipe and compare the CO and CO2 values displayed with those indicated in the combustion characteristics table.
6. If the CO2 value differs by more than 0.3% (HM 25 to 85 TC) or 0.2% (HM 120 TC), carry out the adjustment mentioned in the procedure below.
7. Then put the boiler to the minimum power mode (Refer to the Installer’s Handbook). Allow the boiler to stabilize for a few minutes.
8. Measure the CO2 level. It must be equal to the value at full power, or lower than that value by 0.5% maximum. If there is a significant deviation, please contact ACV’s customer’s support.

CO2 Adjustment Procedure
To adjust the CO2 rate, rotate the throttle screw (1) in small steps : on HM 25 to 85 TC:

• to the left (counterclockwise) to increase the CO2 rate.
• to the right (clockwise) to decrease the CO2 rate.

On HM 120 TC:

• to the right (clockwise) to increase the CO2 rate.
• to the left (counterclockwise) to decrease the CO2 rate.
  Follow-on tasks
  Reinstall all removed access panels. See ML book

Maintenance

SAFETY INSTRUCTIONS FOR MAINTENANCE

Essential instructions 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 instructions 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 burner components. The components could be damaged, resulting in unreliable or unsafe operation.
• Check the tightness of the flue pipe connections.

Essential instructions for the correct operation of the appliance

• It is recommended to have the boiler and the burner 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 and burner 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.
• To ensure maximum efficiency and reliability of the unit, it is recommended that the end-user perform the periodic checks mentioned in the Safety section of this manual.
• Control the tightness of the hydraulic circuit connections.
• Make sure to apply the correct torque value when tightening components, according to the table below.

TORQUE VALUES

| Tightening torque
---|---
Description| (Nm)| Max
Burner flange screws| 5| 6
Electrode screws| 3| 3.5
Venturi screws| 3.5| 4
Gas valve screws| 3.5| 4

TOOLS REQUIRED FOR MAINTENANCE

BOILER SHUT DOWN FOR MAINTENANCE

1. Switch the boiler off using the ON/OFF master switch and isolate the external power supply.
2. Close the gas supply valve of the boiler.

PERIODIC BOILER MAINTENANCE TASKS

| | Frequency| Frequency
---|---|---|---
| Tasks| Periodic
inspection
End-user| 1 year 2 years
Professional
1.| Make sure that the system water pressure is at least 1 bar when cold. Top up the system if necessary, adding small quantities of water at a time. In case of repeated fills, call your installer.| X| X|
2.| Check that there is no water on the floor under the boiler. Call your installer if there is.| X| X|
3.| Check that no error code is displayed on the control panel. Call your installer if necessary.| X| X|
4.| Check that all gas, hydraulic and electrical connections are correctly fastened and tight.| | X|
5.| Check the flue gas exhaust: correct fastening, correct installation, no leaks or clogging.| | X|
6.| Check that there is no discoloured or cracked area on the burner chamber plate .| | X|
7.| Check the combustion parameters (CO and CO2), see “Checking and Ad-justing the Burner” on page 39.| | X|
8.| Check visually the heating body: no evidence of corrosion, soot deposits or damages. Carry out all required cleaning tasks, repairs and replacements that might be required.| | X|
9.| Check the electrode, see “Removal, Check and Installation of the Burner Electrode” on page 43.| | | X
10.| Remove the burner and clean the exchanger, see “Removal and Installation of the Burner – HM 25 to 85 TC” on page 44 or or “Removal and lnstalla-
tion of the Burner – HM 120 TC” on page 45 and “Cleaning the Exchanger” on page 46.| | | X
11.| Check that the condensate trap is not clogged. If it is, remove it, clean it, and reinstall it i.a.w. “boiler Preparation” on page 27| | X|
12.| If a condensate neutralisation system is installed, check it and have it cleaned.| X| X|

DRAINING THE BOILER

Essential instructions for safety

• Before draining the DHW tank, drain the heating (primary) circuit or bring its pressure to 0 bar.
• Water flowing out of the drain valve may be extremely hot and could cause severe scalding. Keep people away from the hot water discharge.

Set-up conditions

• Boiler switched off using the ON/OFF master switch
• External power supply isolated
• Fuel/gas supply closed

Heating circuit draining procedure

1. Close the isolating valves (1).
2. Connect the drain valve (2) to the sewer with a hose.
3. Open the drain valve (2) to empty the heating circuit of the boiler.
4. Close the drain valve (2) once the heating circuit of the boiler is empty.
   Cold water
   Hot water

The drain valve is located underneath and the front cover of the base needs to be removed to get access to it.

DHW circuit draining procedure
**** Before draining the DHW tank, make sure that the heating (primary) circuit pressure is null.

1. Open fully a draw-off tap (3) for about 60 minutes to make sure that the DHW tank has cooled down.
2. Close the isolating valves (1).
3. Connect the drain valve (2) to the sewer with a hose.
4. Open the drain valve (2) and drain the DHW tank water to the sewer.
5. Open the draw-off tap (3) to accelerate the draining process. If it is located lower than the tank connection, open a draw-off tap located higher in the system.
6. Close the drain valve (2) and the draw-off tap (3) once the DHW tank of the boiler is empty.

REMOVAL, CHECK AND INSTALLATION OF THE BURNER ELECTRODE
Remove the electrode to control it in case of ignition problems.

Set-up conditions

• Boiler shut down
• External power supply isolated
• Gas supply closed
• Top panel open, refer to ML Book.

Removal procedure

1. Disconnect the electrode grounding cable from the electrode.
2. Disconnect the electrode ignition cable from the electrical box.
3. Remove two mounting screws (1) and retain them for reinstallation.
4. Remove the electrode (2) and the gasket (3).
5. Check the correct alignment of the electrode ends and that the gap corresponds to the values indicated on the figure below.
6. If the electrode is in bad condition, replace it.

Installation procedure

1. Install a new gasket (3).
2. Install the electrode (2) using the two screws (1), torque i.a.w. “Torque Values” on page 40.

Follow-on tasks

1. Reconnect the grounding cable to the electrode.
2. Reconnect the ignition cable to the electrical box.

REMOVAL AND INSTALLATION OF THE BURNER – HM 25 TO 85 TC

Set-up conditions

• Boiler shut down
• External power supply isolated
• Gas supply closed
• Front and top panels removed (refer to ML Book).
• Electrode removed or electrode grounding cable and ignition cable disconnected (refer to “Removal, Check and Installation of the Burner Electrode” on page 43)

Removal procedure

1. Disconnect all plugs from the fan assembly (11) and the gas valve (2) and any grounding cable, as required.
2. Disconnect the air inlet elbow (3).
3. Release the gas connection (1).
4. Using a socket wrench, release the burner hood (8) attaching hex. screws and retain them for reinstallation.
5. Lift the burner assembly and pull it out of the exchanger.
6. If required, clean the exchanger, see “Cleaning the Exchanger” on page 46.
7. If not removed previously, remove, check and reinstall the electrode, refer to “Removal, Check and Installation of the Burner Electrode” on page 43.

Installation procedure

1. Reinstall the burner assembly with its insulation block into the exchanger.

2. Install the retaining screws of the burner hood (8) and fasten them in a crosswise pattern at the required tightening torque (refer to “Torque Values” on page 40).

3. Reconnect the gas connection (1).
   When connecting the air inlet, make sure that the check valve (4) is correctly located at the elbow (3) end.

4. Reconnect the air inlet elbow (3).

5. Reconnect the plugs to the gas valve (2) and the fan assembly (11), and any disconnected grounding cable.

Follow-on tasks

1. Install the electrode, or reconnect the electrode grounding cable and ignition cable, as required. Refer to “Removal, Check and Installation of the Burner Electrode” on page 43.

Detail of the burner components

REMOVAL AND INSTALLATION OF THE BURNER – HM 120 TC

Set-up conditions

• Boiler shut down
• External power supply isolated
• Gas supply closed
• Front and top panels removed (refer to ML Book).
• Electrode removed or electrode grounding cable and ignition cable disconnected (refer to “Removal, Check and Installation of the Burner Electrode” on page 43)

Removal procedure

1. Disconnect all plugs from the fan assembly (11) and the gas valve (2) and any grounding cable, as required.
2. Release clamp and remove air inlet hose from elbow (3).
3. Disconnect the air inlet elbows (3) from the venturi (5).
4. Disconnect the gas connection (1) flange from the gas valve (2) by releasing four screws. Retain hardware for reinstallation.
5. Discard O-ring.
6. Using a socket wrench, release the burner hood (8) attaching hex. screws and retain them for reinstallation.
7. Lift the burner assembly and pull it out of the exchanger with its insulation.
8. If required, clean the exchanger, see “Cleaning the Exchanger” on page 46.
9. If not removed previously, remove, check and reinstall the electrode, refer to “Removal, Check and Installation of the Burner Electrode” on page 43.

Installation procedure

1. Reinstall the burner assembly with its insulation into the exchanger.
2. Install the retaining screws of the burner hood (8) and fasten them in a crosswise pattern at the required tightening torque (refer to “Torque Values” on page 40).
3. Install a new O-ring on the gas connection (1) flange.
4. Reconnect the gas connection (1) flange to the gas valve (2) using four retained screws. When connecting the air inlet, make sure that the check valve (4) is correctly located at  the elbow (3) end.
5. Reconnect the air inlet elbows (3).
6. Install the air inlet hose on the elbow (3) and secure with retained clamp.
7. Reconnect the plugs to the gas valve (2) and the fan assembly (11), and any disconnected grounding cable.

Follow-on tasks

1. Install the electrode, or reconnect the electrode grounding cable and ignition cable, as required. Refer to “Removal, Check and Installation of the Burner Electrode” on page 43.

CLEANING THE EXCHANGER

Set-up conditions

• Boiler shut down
• External power supply isolated
• Gas supply closed
• Burner removed i.a.w. procedure “Removal and Installation of the Burner – HM 25 to 85 TC” on page 44, or “Removal and Installation of the Burner -HM 120 TC” on page 45.
• Front and top panels open, refer to ML Book .

Procedure

1. Brush and vacuum clean the chamber.
2. Pour some water in the chamber to flush away any foreign deposits that may be present in the heat exchanger.
3. Remove and clean the condensate trap.
4. Reinstall the condensate trap, refer to “boiler Preparation” on page 27.

Follow-on tasks

1. Reinstall the burner according to procedure “Removal and Installation of the Burner – HM 25 to 85 TC” on page 44 or “Removal and Installation of the Burner – HM 120 TC” on page 45.
2. Restart the boiler in accordance with the next procedure “Restarting after Maintenance”.

RESTARTING AFTER MAINTENANCE

Set-up conditions

• All removed components reinstalled
• All connections made
• Power supply
• Gas supply open
• Hydraulic circuit(s) full of water

Procedure

1. Make sure there is no gas leak at the gas connections.
2. Switch the appliance on using the ON/OFF master switch.
3. Set the appliance at maximum power and check the absence of gas leaks.
4. Check the gas pressure and CO2 adjustment in accordance with “Checking and Adjusting the Burner” on page 39.

Follow-on tasks
None

Troubleshooting

1.Check gas supply to appliance.
2.Check Ignition cable connection in control box.
3.Check electrode for defects, and distance between the pins.
4.Check gas valve and electrical connections to gas valve.
E 02| False flame Flame detected prior to ignition.| 1.Check good electrical ground connection to unit
2.Check electrode for pollution and deposition of dirt.
E 03| High Boiler temp. :The ap- pl lance temperature exceeds 105°C| Correct condition whkh caused high temperature or limit to open.
1.Check water flow in the system (radiator valves).
2.Check Pump and pump electrical connections.
E 05| Blower speed: Blower speed not correct or speed signal is not received by ACVMax.| 1.Check blowerand wiring harness.
2.Under normal condition if actual fan speed is 1000 rpm different from set fan speed an error is displayed (after 60sec in running and after 30 sec. at startup).
3.Only exception when actual fan speed > 3000 rpm at max. PWM.
E 07| High Flue temp.: Flue tem- perature exceeds hig h limit| 1.Heat exchanger may require cleaning.
2.Appliance will automatically reset once flue temperature retums to normal range.
E 08| Flame Circuit Error Flame circuit test failed| 1.Tum appliance off.
2.Check and clean the electrode.
3.Check ignition and grounding cables are firmly connected.
E 09| Gas valve circuit error: Gas valve circuit test failed.| 1.Check the gas valve and wiring hamess.
2.If the problem persists replace theACVMax° circuit board.
E 12| Internal Fault EEPROM mis- configuration| 1.Tum unitoff and onto resume normal operation.
2.If the problem persists replace thes’ACVMaxicircuit board.
E 13| Reset limit reached: Resets are limited to 5 every 15
minutes .| 1.Tum unit off and onto resume normal operation.
2.If the problem persists replace thefrACVMaecircuit board.
E 15| Sensor Drift: Supply or return sensor reading has drifted.| Check supply and return temperature sensors and wiring harness.
E 16| Supply Sensor Stuck: Supply sensor reading is not chang-ing.| 1.Check supply temperature sensor and wiring harness for shortcuts or other defects.
2.Checkwaterflow and thetemperature balance in the system, because primarysupply temperature does not change.
 E 17| Return Sensor Stuck: Return sensor reading is not chang-ing.| 1.Check return temperature sensor and its position, check wiring harness for shortcuts or otherdefects.
2.Checkwaterflow and thetemperature balance in the system, because primary return temperature does not change.
3.Failure may happen at low output capacity when supplying from a big tank I
E 18| Sensor Failure: Supply or re-turn sensor reading changed very rapidly.| Check supply and return temperature sensors and wiring hamess.
E19| Flame Failure: Flame failure during start up phase| Flame loss after start up of the appliance.
1.Check the flue system for blockage and check the adjustment of the appliance (CO2 high 8.8+/-0.2%, CO2 low 86+/-0.296 measured with from casing open).
2.Also check the ignition /Ionisation rod (distance to the burner/ pollution)
E 21| Internal Control Fault A/ D conversion error.| Turn unit off and on then press OK to resume normal operation.
E 25| Internal Control Fault: CRC check error.| Turn unit off and on to resume normal operation.
E 30| Supply Sensor Shorted: A short circuit has been detect-ed in the appliance supply temperature sensor circuit| 1.Check supply temperature sensor and wiring harness for a short circuit.
2.If necessary replace the sensor, or the wire hamess.
3.Afterfixing the problem, reset the appliance and resume normal operation.
E 31| Supply Sensor Open: An open circuit has been detect-ed in the appliance supply temperature sensor circuit| 1.Check supply temperature sensor, connectors and wiring hamess for an open circuit.
2.If necessary replace the sensor, or the wire hamess.
3.Afterfixing the problem reset the appliance and resume normal operation.
E 32| DHW Sensor Shorted:A
short circuit has been detect-ed in the DHW temperature sensor circuit| 1.Check DHW temperature sensor and wiring harness fora short circuit
2.If necessary replace the sensor or the wire hamess.
3.Afterfixing the problem reset the appliance and resume normal operation.
E 33| DHW Sensor Open: An open circuit has been detected in the DHW temperature sensor circuit| 1.Check DHW temperature sensor, connectors and wiring harness for an open circuit
2.If necessary replace the sensor, or the wire hamess.
3.Afterfixing the problem reset the appliance and resume normal operation.
Codes| Description of the fault| Solution for the fault
---|---|---
E 34| Low Voltage: Line voltage has fallen below an acceptable operating level.| The appliance will automatically reset once I inevoltage returns to normal.
E 37| LowWater:Water level has fallen below 0.7 bar.| 1. Increase pressure to normal range.
2. The appliance will automatically reset once water level returns to normal.
E 43| Return Sensor Shorted: A short circuit has been detect-ed in the appliance retum temperature sensor circuit.| 1.Check return temperature sensor and wiring harness fora short circuit
2.If necessary replace the sensor, or thew ire hamess.
3.After fixing the problem, reset the appliance and resume normal operation.
E 44| Return Sensor Open: An open circuit has been detect-ed in the appliance return temperature sensor circuit.| 1.Check return temperature sensor, connectors and wiring harness for an open circuit.
2.If necessary replace the sensor, or thew ire harness.
3.After fixing the problem, reset the appliance and resume normal operation.
E 45| Flue Sensor Shorted: A short circuit has been detected In the appliance flue tempera-ture sensor circuit| 1.Check flue temperature sensor and wiring harness fora short circuit
2.If necessary replace the sensor, or thewire harness.
3.After fixing the problem reset the appliance and resume normal operation.
E 46| Flue Sensor Open: An open circuit has been detected in the appliance flue tempera-ture sensor circuit.| 1.Check flue temperature sensor, connectors and wiring harness for an open circuit.
2.If necessary replace the sensor, or the wire harness.
3.After fixing the problem reset the appliance and resume normal operation.
E47| Water pressure sensor error: Water pressure sensor is disconnected or broken| 1.Check water pressure sensor, connectors and wiring harness.
2.If necessary replace the sensor, or thew ire harness.
3.After fixing the problem reset the appliance and resume normal operation.
E 76| Gas pressure switch open| 1. Check both the static and the dynamic gas pressures.
2 Correct condition which caused the pressure switch to open
3. Appliance will automatically reset once the pressure switch is closed.
External Limit Open: An external automatic reset appi lance limit has opened.| 1.Correct condition which caused limit to open.
2.Appliance will automatically reset once external limit closes
E 77| High temperature mixing circuit| Check if the mixing valve functions correctly.
E 78| Mix circuit sensor shorted| 1.Check Mix circuit temp. sensor and wiring harness for a short circuit.
2.If necessary replace the sensor, or the wire harness.
3.After fixing the problem reset the appliance and resume normal operation.
E 79| Mix-circuit sensor Open| 1.Check Mix circuit temp. sensor and wiring harness for an open circuit.
2.If necessary replace the sensor, or thewire harness.
3.Afterfixing the problem reset the appliance and resume normal operation.
E 80| Return > Supply: Return temperature is higher than supply temperature.| Confirm water flows in appliance return and out appliance supply.
E 81| Sensor Drift: Supply and return temperatures are not equal.| 1.Check water is flowing through appliance
2.Wait a few minutes for thewater to equalise thetemperature, the appliance will auto-matically reset oncetemperatures become equal.
3.If appliance doesn’t reset, check the NTes and check the wire harness, replace if necessary.
E82| Delta T protection blocking – Delta T too high| 1.Verify flow in the system.
2. Check pump for bbckageand obstructions, unblock it as required. Replace if neccessary.
E83| Delta T protection Lock-out –
Lock-out due to Delta T value.| 1.Verify flow in the system.
2.Check pump for blockageand obstructions, unblock it as required. Replace if neccessary.
E 85| Pump operation: warning – Appliance pump is running out of limits.| Pump is running out of its limits. Check pump for blockage and obstructions, replace if neccessary
E 86| Pump hard fault Pump Failure| Pump Failure, check if pump PWM-feedback wire is properly connected, replace pump when neccessary
E 87| External LimitOpen: An external appliance limit has opened.| 1.Correct condition which caused limit to open, then reset appliance
2.The appliance needs to be reset once external limit closes.
E88| Pump Blocking: Pump at- tempts to restart| Check pump for blockage and obstructions, unblock it as required. Replace if neccessary.
E 89| Incorrect Setting: A Darn eter setting is outside the settings range.| 1.Review primary/CH & DHW settings and correct as necessary.
2.The appliance will automatically reset once corrected.
E 90| Firmware Mismatch: Control module and display firmware versions are incompatible.| One or several components are not compatible with the system. Replace mismatched component(s).
Codes| Description of the fault| Solution for the fault
---|---|---
E 91| System Sensor Shorted: A short circuit has been detect-ed in the system temperature sensor circuit| 1.Check system temperature sensor and wiring for a short circuit.
2. if necessary replace the sensor, or the wire ha mess.
3.After fixing the problem reset the appliance and resume normal operation.
E 92| System Sensor Open: An open circuit has been detect- ed in the system temperature sensor circuit| 1. Check system temperature sensor and wiring for an open circuit. 2.11 necessary replace the sensor, or the wire ha mess.
3.After fixing the problem reset the appliance and resume normal operation.
E 93| Outdoor Sensor Shorted: A short circuit has been detect- ed in the outdoor tempera- ture sensor circuit| 1.Check outdoor temperature sensor and wiring for a short circuit.
2.if necessary replace the sensor, or the wire harness.
3.After fixing the problem reset the appliance and resume normal operation.
E 94| Internal Display Fault Display memory error| Tum unit off and on to resume normal operation.
E 95| Supply Sensor Error: Supply sensor reading is invalid| 1.Check wiring between display and control module.
2.If necessary replace the sensor, or the wire harness.
3.After fixing the problem reset the appliance and resume normal operation.
E 96| Outdoor Sensor Open: An open circuit has been detect- ed in the outdoor tempera- ture sensorcircuit| 1.Check outdoor temperature sensor and wiring for an open circuit.
2.If necessary replace the sensor, or the wire harness.
3.After fixing the problem reset the appliance and resume normal operation.
E 97| Cascade Mismatch: Cascade configuration has changed.| 1.Run autodetection if change was intentional, or else check wiring between appliances.
2.Appliance will automatically reset once repaired.
E 98| Cascade Bus Error: Commu- nication with other applianc- es has been lost.| 1.Check wiring between appliances.
2.Appliance will automatically reset once repaired.
E 99| Controller Bus Error. Communication between appliance display and control module has been lost.| 1.Check wiring between components.
2.Appliance will automatically reset once repaired.

Service Log

ACV International
Oude Vijverweg, 6
B-1653 Dworp
Belgium
belgium.service@acv.com
www.acv.com
HeatMaster
25 – 35 – 45 – 70 – 85 – 120 TC Evo

| Fragile
---|---
| Keep dry
| Keep standing up
| Danger of tipping over
| Hand truck or pallet truck required for transport
| Gas Connection
| Condensate trap (ball syphon)
| Domestic Hot Water circuit
| Primary circuit
| Electricity
| Alarm
****| Essential instruction for safety (of persons and equipment)
---|---
| Essential instruction for electrical safety (electrical hazard)
| Essential instruction for the correct operation of the appliance or the system
| General remark
| Safety valve connected to the sewage system
| Connection to the sewage system
| Dimensions
| Wiring diagrams
| information
| Assembly

The part number (Code) and serial number (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.HM 25 – 35 – 45 TC HM 70 – 85 – 120 TC

HeatMaster® 25 -35-45-70-85-120TC

GAS CATEGORIES

Isolate the external power supply

HEATMASTER® 25-35-45 TC

1. 230 V power supply plug
2. Ground – Masse – Aarding
3. ON/OFF master switch
4. Gas valve rectified
5. Burner power supply
6. Terminal block for optional items
7. Terminal block for optional items:
8. Modulating pump PWM
9. Burner PWM plug
10. NTC5 flue gas temperature sensor
11.NTC2 return sensor
12. NTC1supply sensor
13. NTC – Low temperature circuit| 14. High limit switch
15. Low water pressure sensor
16. PCB (Display)
17. ACV Max programmation plug
18. A&B Modbus (option)
19. NTC3 DHW sensor
20. NTC4 outdoor temperature sensor (option)
21. Room thermostat 1 (option)
22. Q-10 Volt (option)
23. Room thermostat 2 (option)
24. Connection for interface control unit
25. Ignition and ionization cable
26. 5AT slow-blow fuse (3x) for internal and optional circuits*
27. 10A fuse, 250V, Dim: 5×20 mm
---|---

HEATMASTER® 70-85 TC

1. 230 V power supply plug
2. Ground – Masse
3. ON/OFF master switch
4. Gas valve rectified
5. Burner power supply
6. Terminal block for optional items
7. Terminal block for optional items:
8. Burner PWM plug — Fiche PWM du
9. NTC5 flue gas temperature sensor
10. NTC2 return sensor
11. NTC1supply sensor
12. Gas pressure switch
13. NTC – Low temperature circuit
14. High limit switch| 15. Low water pressure sensor
16. PCB (Display)
17. ACV Max programmation plug
18. A&B Modbus (option)
19. NTC3DHW sensor
20. NTC4 outdoor temperature sensor (option)
21. Room thermostat 1 (option)
22. Q-10 Volt (option)
23. Room thermostat 2 (option)
24. Connection for interface control unit
25. Ignition and ionization cable
26. 5AT slow-blow fuse (3x) for internal and optional circuits*
27. Modulating pump PWM
28. 10A fuse, 250V, Dim: 5×20 mm
---|---

HEATMASTER® 120 TC

1. 230 V power supply plug
2. Ground
3. ON/OFF master switch
4. Gas valve rectified
5. Burner power supply
6. Terminal block for optional items
7. Terminal block for optional items:
8. Burner PWM plug
9. NTC5 flue gas temperature sensor
10. NTC2 return sensor
11. NTC1supply sensor
12. Gas pressure switch
13. NTC – Low temperature circuit
14. High limit switch| 15. Low water pressure sensor
16. PCB (Display)
17. ACV Max programmation plug
18. A&B Modbus (option)
19. NTC3 DHW sensor
20. NTC4 outdoor temperature sensor (option)
21. Room thermostat 1 (option)
22. QO-10 Volt (option)
23. Room thermostat 2 (option)
24. Connection for interface control unit
25. Ignition and ionization cable
26. 5AT slow-blow fuse (3x) for internal and optional circuits*
27. Modulating pump PWM
28. 10A fuse, 250V, Dim: 5×20 mm
---|---

HEATMASTER® 25 – 35 – 45 TC

1. Concentric flue gas/air inlet box
2. Flue gas exhaust tube
3. Combustion chamber
4. Stainless steel heat exchanger
5. Stainless steel “Tank-in-Tank” hot water production tank
6. Primary circuit separation disc
7. Indirect water pre-heater
8. Insulation
9. Condensate recovery dish + NTC5 sensor (flue gas)
10. High efficiency circulator pump
11. NTC2 sensor (CH return)| 12. Electrical panel (with spare fuses at the back)
13. ACV Max Touch Control panel
14. On-Off switch
15. DHW tank dry well (Dip tube with temperature sensor)
16. Automatic air vent
17. Gas pipe
18. NTC1 sensor (CH supply)
19. Gas valve
20. DHW safety valve / (T&P relief valve – UK only)
21. Modulating air/gas premix burner with fan
22. Air inlet
---|---

HEATMASTER® 70 – 85 – 120 TC

1. Concentric flue gas/air inlet box
2. Flue gas exhaust tube
3. Combustion chamber
4. Stainless steel heat exchanger
5. Stainless steel “Tank-in-Tank” hot water production tank (primary +DHW)
6. Primary circuit separation disc
7. Indirect water pre-heater
8. Insulation
9. Condensate recovery dish + NTC5 sensor (flue gas)
10. High efficiency circulator pump
11. NTC2 sensor (CH return)| 12. Electrical panel (with spare fuses at the back)
13. ACVMax Touch Control panel
14. On-Off switch
15. DHW tank dry well (Dip tube with temperature sensor)
16. Automatic air vent
17. Gas pressure switch
18. NTC1 sensor (CH supply)
19. Gas valve
20. DHW safety valve / (T & P relief valve – UK only)
21. Modulating air/gas premix burner with fan
22. Air inlet
---|---

1. Discharge for built-in DHW safety valve / (T & P relief valve – UK only) outlet to be connected to the sewage system
2. Gas connection [M] 3. Grommets for electrical wires (low voltage control)
4. Domestic Hot Water outlet [M] 5. Heating supply connection ([F]| 6. Connection for provided heating safety valve (to be installed).
7. Heating return connection [F] (HM 70 – 85 – 120 TC only)
8. Heating return connection (HM 25 – 35 – 45 TC) / Heating return for
low temp circuit (HM 70 – 85 – 120 TC only)
9. Grommets for electrical wires (230 V)
10. Domestic Hot Water inlet [M] 11. Flue connection
---|---

DECLARATION OF CONFORMITY TO STANDARDS

Oude Vijverweg, 6
B-1653 Dworp
Belgium
This declaration of conformity is issued under the sole responsibility of the manufacturer.
Mo d el:| HeatMaster 25 C Evo
HeatMaster 25 TC Evo
HeatMaster 35 TC Evo
HeatMaster 45 TC Evo
HeatMaster 70 TC Evo
HeatMaster 85 TC Evo
HeatMaster 120 TC Evo

We declare hereby that the appliance specified above is conform to the following regulations and directives:

09.03.2016
2009/125/EC| Ecodesign Directive (implemented by EU regulation 813/2013)| 21.10.2009
2014/35/EU| Low Voltage Directive| 26.02.2014
2014/30/EU| Electromagnetic Compatibility Directive| 26.02.2014

Relevant harmonized standards:

The notified body, (KIWA Nederlands B.V., Wilmersdorf 50, PO Box 137, 7300 AC APEL-DOORN, The Netherlands (0063]) performed a Type Examination and issued the certificate(s) Nb 17GR0164/01, ID # 0063CQ3618

Signed for and on behalf of
ACV International SA/NV

Dworp, 15/11/2021
Date

R&D Director
Celine Coupain

ACV International Oude Vijverweg, 6
B-1653 Dworp, Belgium
belgium.service@acv.com
www.acv.com

Cross-Reference Table – Evo Models

APPLICABILITY :

| 664Y8100 – Rev A – HeatMaster 25 – 35 – 45 – 70 -85 – 120 TC Evo
---|---
| 664Y8200 – Rev A – HeatMaster 25C Evo
| 664Y8300 – Rev A – WaterMaster 25 (X) – 35 – 45 (X) – 70- 85 – 120 Evo
Ref.| ACV| Groupe Atlantic| Ref.| ACV| Groupe Atlantic
---|---|---|---|---|---
1| 537D6287| 786251| 33| 537D6202| 786210
2| 537D6184| 786195| 34| 537D6190| 786201
3| 537D6185| 786196| 35| 537D6191| 786202
4| 10800301| 784474| 36| 537D6306| 786263
5| 537D6290| 786254| 37| 537D6307| 786264
6| 537D6300| 786257| 38| 537D6219| 786225
7| 537D6301| 786258| 39| 537D6220| 786226
8| 537D6211| 786217| 40| 537D6221| 786227
9| 537D6212| 786218| 41| 537D6222| 786228
10| 537D6213| 786219| 42| 537D6203| 786211
11| 537D6197| 786205| 43| 537D6204| 786212
12| 537D6198| 786206| 44| 537D6193| 786203
13| 537D6275| 786249| 45| 537D6229| 786231
14| 537D6186| 786197| 46| 537D6308| 786265
15| 537D6187| 786198| 47| 537D6310| 786267
16| 537D6188| 786199| 48| 537D6223| 786229
17| 537D6516| 786362| 49| 537D6226| 786230
18| 537D6271| 786248| 50| 537D6266| 786246
19| 537D6302| 786259| 51| 537D6448| 786301
20| 537D6303| 786260| 52| 537D6182| 786193
21| 537D6304| 786261| 53| 537D6183| 786194
22| 537D6517| 786363| 54| 537D6194| 786204
23| 537D6214| 786220| 55| 37D6267| 786247
24| 537D6215| 786221| 56| 537D6451| 786303
25| 537D6216| 786222| 57| 537D6209| 786215
26| 537D6217| 786223| 58| 537D6210| 786216
27| 537D6199| 786207| 59| 537D6208| 786214
28| 537D6200| 786208| 60| 537D6231| 786232
29| 537D6201| 786209| 61| 537D6405| 786287
30| 537D6189| 786200| 62|  537D6207| 786213
31| 537D6305| 786262| 63| 537D6293| 786256
32| 537D6218| 786224| 64| 537D6172| 786191

Chimney components – Evo: A1008961 – ADD8120 • A

References

• ACV Excellence in hot water - ACV

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