ACV 25 C Evo Heat Master Instruction Manual

ACV 25 C Evo Heat Master

Product Information

Specifications

• Product Name: HeatMaster 25 C Evo
• Language: English
• Table of Contents Included
• General Information, User’s Guide, Technical Specifications, Installation, Maintenance Sections Available

Product Usage Instructions

General Information

This manual contains important information for the installation, starting up, and maintenance of the appliance. It must be provided to the user for careful reading and safekeeping.

Safety Instructions

Follow these essential safety instructions:

• If you smell gas, immediately isolate the gas supply, ventilate the area, and notify your gas supplier or installer.
• Avoid storing flammable or corrosive products near the appliance.
• Children and individuals with reduced capabilities should be supervised when using the appliance.
• Install carbon monoxide detectors in recommended areas for safety.

Installation

Follow these steps for installation:

1. Check required tools for starting up.
2. Perform checks before starting up.
3. Fill the system as instructed.
4. Start up the boiler and check/adjust the burner if
   necessary.

Maintenance

Regular maintenance is essential. Follow these steps:

• Refer to the maintenance section in the manual for detailed instructions.
• Perform scheduled maintenance tasks to ensure optimal performance.
• Keep the appliance clean and well-maintained.

FAQs

• What should I do if I smell gas?
  • If you smell gas, immediately isolate the gas supply, ventilate the area, and contact your gas supplier or installer for assistance.
• Can children use the appliance?
  • Children aged 8 years and above can use the appliance under supervision and with proper instruction on safety precautions.
• Where should carbon monoxide detectors be installed?
  • ACV recommends installing at least two hard-wired carbon monoxide detectors with alarms and battery back-up, one in the mechanical room and another in the living area outside the bedroom(s).

“`

HeatMaster
25 C Evo
Installation, Operation & Maintenance

A1010445-664Y8200 · B

Instructions for the User and the Installer
EN

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.

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3

General Information

MEANING OF SYMBOLS
Symbols on the packaging Fragile
Keep dry
Keep standing, up
Danger of tipping over
Hand truck or pallet truck required for transport
Symbols on the appliance Domestic Hot Water circuit Primary circuit Electricity
Symbols in the manual Essential 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 0.1 MPa (1 bar) when cold. If the pressure drops below 0.07 MPa (0.7 bar), the built-in pressure sensor blocks the appliance until the pressure exceeds 0.12 MPa (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.

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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 touch soft 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.

1

2

3

4

5

6

1 HeatMaster
2
84°C

CH

DHW

61°C

P3

P4

Target = 85°C

Boiler Protection

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5

User’s Guide

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 de-
crease 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 HeatMaster is ready to respond when a demand is received.
HeatMaster
84°C
61°C
Target = —
Stand-by
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).

Low Water
Water pressure has fallen below 0.7 bar. Increase pressure to normal range.
If problem persists, call for service
E37

Lockout message. Refer to “In case of Problem…” on page 7 for more information.
Body text. The first sentence describes the lockout, the second sentence gives a possible cure, and the third tells how to reset the lockout.
Lockout reference code. Refer to “In case of Problem…” on page 7 for more information.

The appliance is represented in the center of the Home Screen. Basic operating information such as supply and return temperatures are displayed as well as current burner status.

Radiator icon: indicates that a central heating call has been received. A small number 1 or 2 indicates which CH calls are active
A flame symbol is displayed when the unit is fired. The flame size changes to indicate the current firing rate.
Basic information: The user can toggle through items using the and soft keys to view Target, Supply, Return, Domestic, Outdoor and System temperatures, and System pressure.

1 HeatMaster
2
84°C

CH

DHW

61°C

P3

P4

Target = 85°C

Boiler Protection

Tap icon: indicates that a DHW call has been received. Circulator icons: indicate which circulators are currently powered.
Status line: displays the current operating state of the boiler. See next page.

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User’s Guide

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 built-in 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 45.

Fault code

Problem

Possible Cause(s)

Solution

The appliance does not turn – on when pressing the ON/OFF No power supply
Master switch

Check the power supply and that the appliance power plug is connected to the network.

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 operation.

E 34 Low voltage E 37 Low Water E 94 Internal Display Fault

Line voltage has fallen below an accept- The boiler will automatically reset once line

able operating level

voltage returns to normal.

Water pressure has fallen below an Refill the system to reach a normal range

acceptable operating level (0.07 MPa pressure. The boiler will automatically reset

[0.7 bar])

once water pressure returns to normal.

Display memory error

Turn appliance off and on to resume normal operation.

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7

User’s Guide

CONTROLLER SET-UP GUIDE Starting from the Home screen :

1 HeatMaster
2
84°C

CH

DHW

61°C

P3

P4

Target = 85°C

Boiler Protection

· 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

EZ Setup

CH / DHW Operation

Select Language

Boiler Information

Heating enabled

English
Français Nederlands Español Italiano Deutsch

Boiler Information

aababbcccddedeeffbfbbbbbbb b

aaabbbcccdddeeefffbbbbbbbbbb

b b

Lockout History

aaabbbcccdddeeeffbfbbbbbbb b

aaabbbcccdddeeefffbbbbbbbb

b b

Heating EZ Setup

DHW EZ Setup

EZ Setup Reset

Display EZ Setup

8

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User’s Guide

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)
EZ Setup

Heating EZ Setup
Select CH Demand
Thermostat & Setpoint Constant & Setpoint 0 – 10 V Power Modulation 0 – 10 V Temp. Modulation

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).

Select CH Demand

Thermostat & Outd. Curve Constant & Outdoor Curve Constant & Setpoint 0 – 10 V Power Modulation
0 – 10 V Temp. ModulatCioHn1 Setpoint
82°C

20°C

87°C

CH2 Setpoint

60°C

20°C

87°C

EZ Setup Complete

Heating EZ setup is complete. Additional changes can be made in
the Installer Menu if required.
Press OK to return to EZ Setup Menu

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 set-
point 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
point then touch Heating EZ Setup.

soft keys to adjust the temperature setto store the setting and complete the

CH1 Default: 82°C CH2 Default: 60°C

Select CH Demand
Thermostat & Setpoint Constant & Setpoint 0 – 10 V Power Modulation 0 – 10 V Temp. Modulation
EZ Setup Complete
Heating EZ setup is complete. Additional changes can be made in
the Installer Menu if required.
Press OK to return to EZ Setup Menu

0 – 10V Power Modulation – This option allows the HeatMaster firing rate to be controlled by an external control system.
0 – 10V Temp. Modulation – This option allows the appliance CH temperature to be controlled by an external control system.
Refer to the Installer’s Handbook for Evo Appliances for more information.

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9

User’s Guide

Select CH Demand (Outdoor sensor connected)

EZ Setup

Heating EZ Setup
Select CH Demand
Thermostat & Outd. Curve Constant & Outdoor Curve Constant & Setpoint 0 – 10 V Power Modulation 0 – 10 V Temp. Modulation

Select CH Demand prompts the installer to select how a CH Demand is generated. There are several Select 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).

Select CH Demand
Thermostat & Outd. Curve Constant & Outdoor Curve Constant & Setpoint
0 – 10 V Power MSodeulelactitoCnH1 Outd. Curve
0 – 10 V Temp. M82o°Cdulation MAX

27°C

Select CH2 Outd. Curve

186°C0°C

-12°C

Current Settings

Warm Weather Shutdown

27°C

Off

18°C

-12°C

Current Settings

Off

EZ Setup C25o°Cmplete

Heating EZ setup is complete. Additional changes can be made in
the Installer Menu if required.

Press OK to return to EZ Setup Menu

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 temperature 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.

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User’s Guide

DHW EZ SETUP
EZ Setup DHW EZ Setup

Select DHW Demand

Thermostat Sensor

DHW Boiler Setpoint
75°C

35°C

87°C

DHW EZ Setup

Select DHW Demand

Thermostat Sensor

DHW Setpoint 60°C

20°C

75°C

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 the Indirect Water Heater Sensor. The HeatMaster monitors the DHW storage temperature and generates a DHW call whenever the temperature drops below 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 Off

Off

120 min.

EZ Setup Complete

DHW EZ setup is complete. Additional changes can be made in
the Installer Menu if required.

Press OK to return to EZ Setup Menu

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

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EASY SETUP RESET
EZ Setup
EZ Setup Reset
EZ Setup Reset
Press OK to restore factory settings, any other button to keep current
settings.

User’s Guide
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
EZ Setup Display EZ Setup

English
Français Nederlands Español Italiano Deutsch

Select Unit

Fahrenheit Celsius

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.

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CH/DHW OPERATION
CH / DHW Operation Heating enabled DHW enabled

User’s Guide
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:

BOILER INFORMATION
Boiler Information

Boiler Information

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aaabbbcccdddeeefffbbbbbbbbbb

Boiler Information

Boiler Status Heating Call DHW Call Boiler Firing Rate Ionization current Boiler Setpoint

Standby No No -A —

b b

Lockout History

aaabbbcccdddeeeffbfbbbbbbb b

abc abc abc

dddeeefffbbbbbbbb

b b

Lockout History

1. Blower speed

5h ago

2. DHW Sensor Open 2h ago

3. Sensor Drift 4. No error

25 h ago 27 h ago

5. No error 6. No error

2L7ohckaogout Details
27 hBalogwoer speed

Boiler Status Heating Call DHW Call Boiler Firing Rate Ionization current

—44% 44A

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.

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User’s Guide

APPLIANCE DESCRIPTION HEATMASTER® 25 C EVO
The HeatMaster® 25 C Evo is a condensing combination boiler. The boiler combines ACV’s “Tank-inTank” 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.
The HeatMaster® 25 C Evo model is 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® 25 C Evo 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® 25 C Evo boiler 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 HeatMaster® 25C Evo boilers can also be set up in a cascade system, using an external controller. Refer to “Configuration and system set- up” on page 34 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 34), 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.

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Technical Specifications

COMBUSTION CHARACTERISTICS

Main Characteristics

Input (PCI)
Output at 100%
Efficiency at 100% Efficiency at 30% load (EN677) Combustion efficiency
NOx (Class 6) i.a.w. EN15502-1+A1:2016
CO
CO2 Max gas flow rate G20/G25

max min (80/60°C) (50/30°C) (80/60°C) (50/30°C)
at 100% Max. output Min. output Weighted Max. output Min. output Max. output Min. output 20 mbar 25 mbar

Max. gas flow rate G31

30/37/50 mbar

Normal

Temp of flue gases

Max.

Min.

Average temp. of combustion products

DHW mode

Mass flow rate* of flue gases

Normal Min. output

Standby loss

T = 45 K T = 30 K

• 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.

kW kW kW kW % % % %
mg/kWh
mg/kWh
mg/kWh
ppm ppm %CO2 %CO2 m³/h m³/h m3/h Kg/h °C °C °C °C g/s g/s
W W

HM 25 C Evo

G20/G25

G31

25.0 5.0 24.3 26.0 98.0 103.9 109.0 97.5 64 12 26.3 27 6 8.8 8.3 2.66 2.96 — — 62.0 120 32.9 52.6 11.6 2.45 124 79

25.0 5.0 24.3 26.0 98.0 103.9 109.0 97.5 — — — — — 10.1 9.3 — — 0.98 1.95 57.7 120 32.9 52.6 11.6 2.54 124 79

Main Characteristics
Rated voltage Rated frequency
Electrical consumption

V~ Hz Max. W Min. W

Electrical consumption at 30% load

W

Electrical consumption in standby

W

Rated current (Fuse)

A

Class

HM 25 C Evo 230 50 95 19
24
3 16 IP 20

EN A1010445-664Y8200 · B

15

Technical Specifications

ErP DATA (ECODESIGN)

Boiler type and model

HeatMaster

Condensing boiler Low temp boiler

Combination heater Useful heat output

at 30% of rated heat output

P1

kW

at rated output and high-temp re- P4 gime

kW

Useful efficiency

at 30% of rated heat output

1

%

at rated output and high-temp re- 4 gime

%

Auxiliary electricity consumption

At full load At part load

elmax

W

elmin

W

In standby mode Standby heat loss

PSB

W

Pstby

W

Product Fiche Data (i.a.w. Commission Delegated Regulation 811/2013)

Medium temperature application

Declared load profile for water heating

Seasonal space heating energy efficiency class

Water heating efficiency class

Rated heat output

kW

Annual energy consumption for space heating

kWh

Annual energy consumption for water heating

kWh

Seasonal space heating efficiency

%

Water heating efficiency

%

Sound power level indoors LWA

dB

Able to work only during off- peak hours

Y/N

25 C Evo
7.9 24.3
98.2 87.6
95 19 3 92
Condensation XXL A B 24 12031 8151 94 74 60 N

16

EN A1010445-664Y8200 · B

Technical Specifications

HYDRAULIC CHARACTERISTICS

Main Characteristics

Capacity (primary)

L

Capacity (DHW)

L

Water pressure drop (primary circuit) (t = 20 K) mbar

HeatMaster 25 C Evo 120 80
3

HYDRAULIC PRESSURE DROP CURVE OF THE BOILER (PRIMARY)

Pressure drop (mbar)

18

16

14

12 HeatMaster® 45 TC
10

8 HeatMaster® 35 TC
6

4 HeatMaster® 25 TC
2

0

0

500

1000

1500

2000

2500

3000

Water flow rate (l/h)

DHW PERFORMANCE

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

Operating conditions at 80°C

Constant flow at

40 °C [T = 30 K] L/h 60 °C [T = 50 K] L/h

Peak flow at

40 °C [T = 30 K] 60 °C [T = 50 K]

L/10′ L/10′

Peak flow 1st hour at

40 °C [T = 30 K] 60 °C [T = 50 K]

L/60′ L/60′

Reheat time from 10°C to 80°C

min.

DHW efficiency at T = 30 K

%

HeatMaster 25 C Evo 617 400
233.5 145 748 478 27 99.2

MAXIMUM OPERATING CONDITIONS
Maximum Service Pressure (tank full of water) * – Primary circuit : ……………………………………..0.3 MPa (3 bar) – DHW circuit : ………………………………….. 0.86 MPa (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.

EN A1010445-664Y8200 · B

17

Technical Specifications

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 is therefore isolated from the mains water. When maintaining the system or filling up the circuit, water renewal results in the addition of oxygen and carbonates in the primary circuit. The larger the water volume in the system, the larger the addition.
Hydraulic components without an oxygen barrier (PE pipes and connections) admit oxygen into the system.
Prevention Principles
1. Clean the existing system before installing a new 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 14868.

3. Limit the presence of oxygen and sludge in the water
A deaerator (on the appliance flow line) combined with a dirt separator (upstream of the appliance) must be installed according to the manufacturer’s 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.
4. Limit the carbonate concentration in the water
The fill water must be softened if its hardness is higher than 20° fH (11,2° dH).
Check regularly the water hardness and enter the values in the service log.
Water hardness table :

Water hardness Very soft Soft Fairly hard Hard Very hard

°fH 0 – 7 7 – 15 15 – 25 25 – 42 > 42

°dH 0 – 3.9 3.9 – 8.4 8.4 – 14 14 – 23.5 > 23.5

mmolCa(HCO3)2 / l 0 – 0.7 0.7 – 1.5 1.5 – 2.5 2.5 – 4.2 > 4.2

5. Control the water parameters
In addition to the oxygen and the water hardness, other parameters of the water must be checked.
Treat the water if the measured values are outside the range.

Acidity Conductivity Chlorides Iron Copper

6,6 < pH < 8,5 < 400 S/cm (at 25°C)
< 125 mg/l < 0,5 mg/l < 0,1 mg/l

18

EN A1010445-664Y8200 · B

Technical Specifications

CHIMNEY CHARACTERISTICS

Main Characteristics

concentric

mm

Air/flue pipe Ø

parallel

mm

HM 25 C Evo 80/125 80/80

Max. allowed flue pipe pressure drop

Pa

95

Max recommended length of concentric flue pipe (corresponding length in meters of straight pipes) Ø 80/125, terminal included Max recommended length of concentric flue pipe (corresponding length in meters of straight pipes) Ø 100/150, terminal included Max recommended length of dual flow (corresponding length in meters of straight pipes) *
Available connection types

60

130***

Rigid Ø 80

Flex. Ø 80

56

26

B23 – B23P – C13(x) – C33(x) – C43(x) – C53(x)** – C63(x) – C83(x), C93(x)

• See page 21 to calculate the flue pipe length. ** A C53 connection 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.

B23 C33

C43

C43

C43

C43

C13

C33

B23P

C93

C43

C43

C53

EN A1010445-664Y8200 · B

19

Technical Specifications

FLUE PIPE CONNECTION TYPES

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

B23p B23 C13(x)
C33(x)
C43(x)
C53(x) C63(x)

Connection to a combustion product exhaust system designed to operate with positive pressure.
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.
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.
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.
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.
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.
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 95 Pa.
· Condensate flow is allowed into the appliance.
· Maximum allowable recirculation rate of 10% under wind conditions.

C83(x) C93(x)

Connection using a single or double duct system. 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 fresh outdoor air. Please contact your ACV representative for the meters of flue pipes that can be used to connect the appliance(s).
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.

20

EN A1010445-664Y8200 · B

Technical Specifications

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 length 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

1 m straight pipe 90° elbow 45° elbow

Flue pipe length (L) (corresponding length in meters of straight pipe)

Concentric flue pipe Ø 80/125 mm (Terminal incl.)

Parallel flue pipe Ø 80 mm
(Terminal incl.)

1 m

1 m

2 m

2.3 m

1 m

1 m

1000 mm
L
2000 mm

2000 mm

1000 mm

L C33
L C13

Example of verification of the flue pipe length (L) in a concentric flue pipe system for HeatMaster 25 C Evo (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 (60 m).
This flue pipe length is within the recommended range.

Concentric connection
L C33
Parallel connection

EN A1010445-664Y8200 · B

21

Technical Specifications
CASCADE : CALCULATION OF THE MAXIMUM LENGTH OF FLUE PIPES

HeatMaster 25 C Evo cascade in a C43 chimney connection configuration

HeatMaster 25 C Evo 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.

Qty

Appliance type*

Maximum length in M.

2 to 6

HM 25 C Evo

Dn 150 30

Dn 150/200** 30

Dn 200 30

• 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

Elbow type
45° [M] 90° [M]

150

200

Equivalent Length

1.7m

3.8m

4.0m

5.8m

22

EN A1010445-664Y8200 · B

Technical Specifications
APPROVED CHIMNEY COMPONENTS

EN A1010445-664Y8200 · B

Connection type
Material / Ø mm

Terminals

Pipes

C93

PP Flex Ø 80

1. Set C93 Ø 80/125

13. Flexible PP PP Ø 80, 25 m

Extensions —

Components *

Bends

Measurement and condensate
recovery

Accessories

50. Connection

sheath for Ø

80/125, Ø 80

—

—

51. Connector FlexFlex PP Ø 80

Adapters —

2. Roof Terminal 14. Length 250 mm 30. Sliding extension, 34.43° – 45°

3. Wall terminal kit 15. Length 500 mm

straight + 50 to 35.87° – 90°

4. Wall terminal Kit 16. Length 1000 mm

130 mm

C13 C33

PP – Galva Ø 80/125

17. Length 2000 mm

44.Measuring tube 45.Measuring
T-piece with inspection

52. Weather Slate Steep
53. Bracket Ø 125 mm
54. Weather salte, flat roof Ø 390 mm

60. Expander SST/ Alu Ø 80/125 mm – 2 x Ø 80 mm
61. Expander PP/ ALU, Ø 60/100 mm – Ø 80/125 mm

• 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.

23

Installation

SAFETY INSTRUCTIONS FOR THE INSTALLATION

Essential instructions for safety
· The connections (electrical, flue pipe, hydraulic) must be carried out in accordance with local standards and regulations in force.
· Install the appliance on level base or vertically plumb support made of non- combustible materials and of sufficient strength to support its weight.
· 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.
· Do not use or store any flammable or corrosive products, such as paint, solvents, salts, chloride products and other detergent products near the appliance.
· Make sure that the condensate outlet is never obstructed and that a condensate neutralisation system is installed if required.
· 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

24

EN A1010445-664Y8200 · B

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 Instruc-
tions · 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 ac-
cordance with applicable local regulations.
BOILER PREPARATION

· Close the circulation tube end tap (1) (access from the bottom of the boiler)
1
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. Refer to the procedure provided with the condensate trap, or get it from www.acv.com (See page 4 for an access with QR code). · Install the safety valve : primary circuit safety valve at the back of the boiler

· Remove the bottom panel stored at the back of the boiler for transport. Install on the appliance when the boiler is in its final position. Refer to the ML Book for the correct installation procedure.

· Perform the gas conversion to propane as required. Refer to “Conversion to Propane” on page 32.

EN A1010445-664Y8200 · B

25

Installation

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 0.12 MPa (1.2 bar).
· Make sure to install a pressure reducing valve set at 0.45 MPa (4.5 bar) if the mains supply pressure is in excess of 0.6 MPa (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.

General remark
· At installation of domestic piping, ensure that the boiler connection elbow is correctly tightened before installing the pipes. Retighten as required.
· At commissioning and once the system is under pressure, check that there are no water leaks. Retighten as required.

26

A1010445-664Y8200 · B

Nm
MAX: 70 Nm
EN

Installation

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
(0.35 MPa [3.5 bar]) & expansion relief valve (0.6 MPa [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.

Discharge pipe from safety valves
The Building Regulation G3 requires that any discharge from an unvented system is conveyed to where it is visible, but will not cause danger to persons in or about the building.
The tundish and discharge pipes should be fitted in accordance with the requirements and guidance notes of Building Regulation G3.

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 (internal) 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 wiCtholdG3wareteqruire-

ments. above.

Also

referHtootiwnfaotremration

8 9 1

1 23

5

4

6 7

Cold water Hot water

EN A1010445-664Y8200 · B

27

Installation

For additional system configurations, refer to “Configuration and system set- up” on page 34 and to the Installer’s Handbook.

Typical connection – high temperature

Description

1. Isolating valve

2. Heating pump

3. Filling valve

4. Check valve

8

5. Safety valve (provided)

6. Expansion vessel

7. Drain valve

8. Automatic air vent (built-in)

9. Manometer

5

7
Cold water Hot water

1

9

3

4 6

1

2

Optional accessories Room thermostat High temperature kit DN 25

Description
Includes a heating pump, two isolating valves, a check valve and two thermometers.

28

EN A1010445-664Y8200 · B

Installation

Typical connection – low temperature

Description 1. Isolating valve 2. 3-way mixing valve 3. Heating pump 4. Safety valve (provided) 5. Filling valve 6. Check valve 7. Expansion vessel 8. Drain valve 9. Automatic air vent (built-in) 10. Manometer
6
5

9
10 4
7

8

12

1

3

Accessory Room thermostat Contact thermostat Low temperature kit DN 25
Servomotor

Description
Mandatory to protect all floor heating circuits. Includes a heating pump, two isolating valves, a check valve, two thermometers, a 3-way valve with built-in bypass and a servomotor. Motor for the 3-way valve provided with the low temperature kit.

EN A1010445-664Y8200 · B

29

Installation

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.

2,0 m

4

2,0 m

4 1

3

1,0 m

1 1,0 m

Slope = 3° 2

0,25 m

2,0 m

4
2
0,25 m

· 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

0,5 m

0,25 m

0,25 m

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.

· 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 19

30

EN A1010445-664Y8200 · B

Installation

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 by a qualified professional according to the provided procedure and requirements.

·

TsuhpepClyOp2a, rgaamsetfelorws

rate, air flow rate and air/gas 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 adjustment

pbrooicleerduCreO2anaddtjuhsetmteecnhtnic(raelfderatato).

the

A

EN A1010445-664Y8200 · B

31

Installation

CONVERSION TO PROPANE
General remark
According to the indication on the type plate, the boiler is factory preset to operate with natural gas (G20/G25). Converting the boiler to propane is done through the installation of an orifice and adjustments and shall be performed by a qualified professional. In Belgium, this conversion procedure can only be carried out by Groupe Atlantic Belgium personnel. Please contact Groupe Atlantic Belgium for further information.
Set-up conditions · External power supply isolated · Gas supply closed · Upper front panel and top cover of the boiler
open, refer to ML manual.

Evo Models 25 kW

Gas nat. orifice dia. (mm) —

Propane orifice dia. (mm) 5.2

Procedure of orifice installation
1. Release the gas pipe. 2. Remove the power supply plug from the gas valve (1). 3. Disconnect the compensation hose (7) from the gas
valve and air inlet. Retain for reinstallation. 4. Disconnect the air inlet (2) from the venturi (3). 5. Remove the gas valve/venturi assembly from the fan
by releasing two screws (5). Retain the screws for reinstallation. 6. Remove the gas valve (1) from the venturi (3) by releasing three screws (4). Retain the screws for reinstallation. 7. Install the orifice in the center of the O-ring (6).
Make sure you position the O-ring correctly.
8. Reassemble the gas valve/venturi assembly, following the same procedure in reverse order, and torque the three gas valve screws (4) and the 2 venturi screws (5) at 3.5 to 4 Nm.
9. Reinstall the air inlet (2). 10. Reconnect the compensation hose (7) to the gas
valve and air inlet. 11. Reconnect the gas pipe connection. 12. Reconnect the power supply plug(s) to the gas
valve. 13. Install the conversion stickers, see next page.

1 7
6
2

5

4

3

HM 25 – 35 – 45 – 70 – 85 TC Evo

32

EN A1010445-664Y8200 · B

Installation
Sticker Placement Make sure to place the stickers as requested. Failure to comply can cause injuries or damage to the equipment.
· Stick the yellow sticker at the back of the boiler and check the box to indicate the type of gas now used with the appliance.
· Stick the provided G31 data plate on the existing data plate (back of the appliance), or the corrective stickers (Belgium only).
Follow-on tasks 1. Start the boiler. Refer to “Starting up the Boiler” on
page 39. 2. Change the boiler code through the Installer menu,
refer to the “Installer’s handbook” 3. Carry out the CO2 adjustment, See “Checking and Adjusting
the Burner” on page 39. 4. Reseal the offset and the throttle on the gas valve, as
required. 5. Close all open panels, see the ML Book.

EN A1010445-664Y8200 · B

33

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

2 1
3
ACVMax

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.

ITEM

DESCRIPTION

QTY

ELECT. TERMINALS TO CONNECT TO**

1 Room thermostat

1

2 Outdoor temperature sensor, 12k

1

4321

X6 3&4
X6
X6 1&2

20 NTC 4

2

1

1

2 circuit manifold :

Max power : 70 kW, With built-in wall

1

—

mounts.

High temperature kit :

3

Includes: a circulator pump, two isolation valves, a check valve and two thermom-

2

eters.

By-pass kit :

To read the flow rate more easily. To be in-

1

stalled in the HT or LT circuit, as required.

87654321

LN
6
X100

Br

B

230 V

Y/Gr

B

Br

X100 3 to 8 —

• 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 15.

On the ACVMax Touch, set as follows:

EZ Setup

Heating EZ Setup

Select CH Demand
Thermostat & Outd. Curve Constant & Outdoor Curve Constant & Setpoint 0 – 10 V Power Modulation 0 – 10 V Temp. Modulation

34

EN A1010445-664Y8200 · B

Installation
Cascade Configuration, Controlled by EBV Controller
The control Unit (EBV Controller) is used to control a HeatMaster 25 C Evo 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.

15
123
123

16
12345 6 7 8 9 10
1 2 3 4 5 6 7 8 9 10

17

4

6

123
123456

W

W

W

W

W

W

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

W

Bk

R

W

W

W

W

W

W

Y

Y

Y

Y

Y

Y

Y

Y

Y

Y

W

R

Bk

10 11 12 13 14
7
X2
13 14

1 2 3 4 5 6 7 8 9 10
12345
X11
6 7 8 9 10

123456
123
X15
456

X16

ax

EBV Clip-in wiring
24
X18

X7
X4
Bk R
X6

X5

12 34

321

4321

21

321

Bus A
18 Bus – Ground
Bus B
19 NTC 3 20 NTC 4
1 21
22 0-10 Volt – Input
0-10 Volt – Ground

EN A1010445-664Y8200 · B

35

Installation

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 frequent and sudden opening/closing of valves, (e.g. car wash systems, etc.), devices should be installed in the system to counter this effect and prevent damage from occurring to the piping/appliance.
The water hammer effect is caused by shock waves running through the system when the flow rate is changed suddenly (e.g. when a valve is closed/opened suddenly). This induces a surge/sudden fall in pressure, which creates noise and sometimes movement in the system 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.

Expansion vessel Draw-off tap Ball valve

Thermostatic mixing valve Pneumatic valve Check valve

Cold water Hot water

Pressure reducing valve Safety valve

Piston water hammer arrestor Shock arrestor absorber

Primary filling valve with disconnection

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.

36

EN A1010445-664Y8200 · B

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
GAS pressure (mbar)

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.

EN A1010445-664Y8200 · B

37

Commissioning

FILLING THE SYSTEM

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

Set-up conditions

2

· External power supply isolated

1
DHW circuit filling procedure

1. Open the isolating valves (1) and the draw-off tap (2).

1

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 filling 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 filling valve (2).
5. Once the system is bled from air, bring the pressure to the static pressure between 0.15 and 0.2 MPa (1.5 and 2 bar).
6. Close the filling valve (2).
7. Disconnect filling device from water supply.*

Follow-on tasks

1. Check there is no leak.

3

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.

38

A1010445-664Y8200 · B

1 2
1
EN

Commissioning

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
Before operating the appliance, make sure that the primary circuit is full of water and has the minimum recommended pressure, even if no heating circuit is installed. Failure to comply can damage the equipment.
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 tem-
perature 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 val-
ue using the control panel. Refer to “Controller Set-up Guide” on page 8 and to the Installer’s Handbook. 7. After 5 minutes of operation, bleed the heating circuit until all air is evacuated and restore a 0.15 MPa (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 re-
turn temperature is equal or less than 20k. · If the Delta T is higher than 20k, check the pump set-
tings/specifications.

CHECKING AND ADJUSTING THE BURNER

When the burner operates at full power, the CthOe2treacthenmicuasltcbheawraicthteinritshtiecslim, (sitesem”eCnotmiobnuesdtioinn 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 us-

er’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 Install-

er’s Handbook).

3. Using a pressure tester, check that the dynamic gas pres-

sure at the gas valve is at least 18 mbar.

4. Allow the appliance to heat for a few minutes until it reach-

es at least 60°C.

5. Measure the burner combustion by placing the flue gas

analyzer probe in the measurement unit port on the flue

pthipoeseainnddiccoamtepdairnetthheecCoOmbaunsdtiConOc2 hvaarluaectsedriisstpiclasyteadblew.ith

IafdtjhuestCmOe2nvt amlueentdioifnfeerds

by more than 0.3%, carry in the procedure below.

out

the

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 burner combustion and compare the CO

aconmd bCuOst2iovnalcuheasradcitseprliastyiecsd

with table.

those

indicated

in

the

9. IcfutshteomCOer2’svasluupepdoirftfe. rs by more than 0.3% , contact ACV’s

CO2 Adjustment Procedure
To adjust the CO2 rate, rotate the throttle screw (1) in small steps : on the HM 25 C Evo:
· to the left (counterclockwise) to increase the CO2 rate. · to the right (clockwise) to decrease the CO2 rate.

1

Follow-on tasks Reinstall all removed access panels. See ML book

EN A1010445-664Y8200 · B

39

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
Description Burner flange screws Electrode screws Venturi screws Gas valve screws

Tightening torque (Nm)

Min.

Max

5

6

3

3.5

3.5

4

3.5

4

40

EN A1010445-664Y8200 · B

Maintenance

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.

GAS pressure (mbar)

PERIODIC BOILER MAINTENANCE TASKS

Tasks

Periodic inspection

End-user

1. Make sure that the primary water pressure is at least 0.1 MPa (1 bar) when cold. Top

up the system if necessary, adding small quantities of water at a time. In case of

X

repeated fills, call your installer.

2. Check that there is no water on the floor under the boiler. Call your installer if there is.

X

3. Check that no error code is displayed on the control panel. Call your installer if necessary.

X

4. Check that all gas, hydraulic and electrical connections are correctly fastened and tight.

5. Check the flue gas exhaust: correct fastening, correct installation, no leaks or clogging.

6. Check that there is no discoloured or cracked area on the burner chamber plate .

7. Check the combustion parameters (CO and CO2), see “Checking and Adjusting the Burner” on page 39.

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.

9. Check the electrode, see “Removal, Check and Installation of the Burner Electrode” on page 44.

10. Remove the burner and clean the exchanger, see “Removal and Installation of the Burner” on page 43 and “Cleaning the Exchanger” on page 44.

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 25.

12. If a condensate neutralisation system is installed, check it and have it cleaned.

X

Frequency 1 year 2 years
Professional X
X X X X X X
X
X
X X X

EN A1010445-664Y8200 · B

41

Maintenance

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).

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

2

1

Hot water

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.

The drain valve is located underneath and the front cover of the base needs to be removed to get access to it. Refer to “boiler Preparation” on page 25 for more information.
3
1
2

42

EN A1010445-664Y8200 · B

Maintenance

REMOVAL AND INSTALLATION OF THE BURNER
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 ig-
nition cable disconnected (refer to “Removal, Check and Installation of the Burner Electrode” on page 44) .
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 44. 7. If not removed previously, remove, check and reinstall the electrode, refer to “Removal, Check and Installation of the Burner Electrode” on page 44.

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 44.

Detail of the burner compo-

11

nents

1

1. Gas connection

2

2. Gas valve

3. Air inlet elbow(s)

4. Air inlet check valve

5. Venturi 10
6. Burner tube

7. Insulation

3

8. Burner hood

9

9. Burner hood insulation 5

8

10. Electrode 4

11. Fan assembly

7

6

EN A1010445-664Y8200 · B

43

Maintenance

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 · Front and 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.

1

2

Min. 3 mm

Max. 4 mm

3

CLEANING THE EXCHANGER
Set-up conditions
· Boiler shut down · External power supply isolated · Gas supply closed · Burner removed i.a.w. procedure “Removal and In-
stallation of the Burner” on page 43. · 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 25.
Follow-on tasks
1. Reinstall the burner according to procedure “Removal and Installation of the Burner” on page 43.
2. Restart the boiler in accordance with the next procedure.

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 and flue gas leaks.

Check the gas pressure and in accordance with “Checking

CO2 adjustment and Adjusting the

Burner” on page 39.

Follow-on tasks

None

44

EN A1010445-664Y8200 · B

Troubleshooting

Codes E 01 E 02 E 03
E 05
E 07 E 08 E 09 E 12 E 13 E 15 E 16
E 17
E 18 E19 E 21

Description of the fault
Failed ignition: The burner failed to light after 5 ignition attempts.
False flame: Flame detected prior to ignition. High Boiler temp. : The appliance temperature exceeds 105°C
Blower speed: Blower speed not correct or speed signal is not received by ACVMax.
High Flue temp.: Flue temperature exceeds high limit.
Flame Circuit Error: Flame circuit test failed
Gas valve circuit error: Gas valve circuit test failed. Internal Fault: EEPROM misconfiguration Reset limit reached: Resets are limited to 5 every 15 minutes. Sensor Drift: Supply or return sensor reading has drifted.
Supply Sensor Stuck: Supply sensor reading is not changing.
Return Sensor Stuck: Return sensor reading is not changing.
Sensor Failure: Supply or return sensor reading changed very rapidly.
Flame Failure: Flame failure during start up phase
Internal Control Fault: A / D conversion error.

Solution for the fault
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.
1. Check good electrical ground connection to unit. 2. Check electrode for pollution and deposition of dirt.
Correct condition which caused high temperature or limit to open. 1. Check water flow in the system (radiator valves). 2. Check Pump and pump electrical connections. 1. Check blower and 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. 1. Heat exchanger may require cleaning. 2. Appliance will automatically reset once flue temperature returns to normal range. 1. Turn appliance off. 2. Check and clean the electrode. 3. Check ignition and grounding cables are firmly connected. 1. Check the gas valve and wiring harness. 2. If the problem persists replace the “ACVMax” circuit board. 1. Turn unit off and on to resume normal operation. 2. If the problem persists replace the “ACVMax” circuit board. 1. Turn unit off and on to resume normal operation. 2. If the problem persists replace the “ACVMax” circuit board.
Check supply and return temperature sensors and wiring harness.
1. Check supply temperature sensor and wiring harness for shortcuts or other defects.
2. Check waterflow and the temperature balance in the system, because primary supply temperature does not change.
1. Check return temperature sensor and its position, check wiring harness for shortcuts or other defects.
2. Check waterflow and the temperature 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 !
Check supply and return temperature sensors and wiring harness.
Flame loss after start up of the appliance. 1. Check the flue system for blockage and check the adjustment of the appli-
ance. 2. Also check the Ignition / Ionisation rod (distance to the burner / pollution)
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 detected 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 harness. 3. After fixing the problem, reset the appliance and resume normal opera-
tion.

1. Check supply temperature sensor, connectors and wiring harness for an

Supply Sensor Open: An open circuit has

open circuit.

E 31 been detected in the appliance supply

2. If necessary replace the sensor, or the wire harness.

temperature sensor circuit

3. After fixing the problem reset the appliance and resume normal opera-

tion.

DHW Sensor Shorted: A short circuit has E 32 been detected in the DHW temperature
sensor circuit

1. Check DHW temperature 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 opera-
tion.

EN A1010445-664Y8200 · B

45

Troubleshooting

Codes E 33 E 34 E 37 E 43 E 44 E 45 E 46 E47 E 76

Description of the fault
DHW Sensor Open: An open circuit has been detected in the DHW temperature sensor circuit
Low Voltage: Line voltage has fallen below an acceptable operating level. Low Water: Water level has fallen below 0.07 MPa (0.7 bar). Return Sensor Shorted: A short circuit has been detected in the appliance return temperature sensor circuit.
Return Sensor Open: An open circuit has been detected in the appliance return temperature sensor circuit.
Flue Sensor Shorted: A short circuit has been detected in the appliance flue temperature sensor circuit
Flue Sensor Open: An open circuit has been detected in the appliance flue temperature sensor circuit.
Water pressure sensor error: Water pressure sensor is disconnected or broken
Gas pressure switch open
External Limit Open: An external automatic reset appliance limit has opened.

Solution for the fault
1. Check DHW 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 opera-
tion.
The appliance will automatically reset once line voltage returns to normal.
1. Increase pressure to normal range. 2. The appliance will automatically reset once water level returns to normal.
1. Check return temperature 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 opera-
tion. 1. Check return 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 opera-
tion. 1. Check flue temperature 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 opera-
tion. 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 opera-
tion. 1. Check water pressure sensor, connectors and wiring harness. 2. If necessary replace the sensor, or the wire harness. 3. After fixing the problem reset the appliance and resume normal opera-
tion. 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.
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 E 79 Mix-circuit sensor Open

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 opera-
tion.
1. Check Mix circuit temp. sensor 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 opera-
tion.

E 80

Return > Supply: Return temperature is higher than supply temperature.

Confirm water flows in appliance return and out appliance supply.

1. Check water is flowing through appliance.

E 81

Sensor Drift: Supply and return temperatures are not equal.

2. Wait a few minutes for the water to equalise the temperature, the appliance will automatically reset once temperatures become equal.
3. If appliance doesn’t reset, check the NTC’s 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 blockage and obstructions, unblock it as required. Re-
place if necessary.

E83

Delta T protection Lock-out – Lock-out due to Delta T value.

1. Verify flow in the system. 2. Check pump for blockage and obstructions, unblock it as required. Re-
place if necessary.

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 necessary

E 86 Pump hard fault: Pump Failure

Pump Failure, check if pump PWM-feedback wire is properly connected, replace pump when necessary

46

EN A1010445-664Y8200 · B

Troubleshooting

Codes E 87 E88 E 89 E 90 E 91
E 92
E 93 E 94 E 95
E 96 E 97 E 98 E 99

Description of the fault

Solution for the fault

External Limit Open: An external appliance 1. Correct condition which caused limit to open, then reset appliance.

limit has opened.

2. The appliance needs to be reset once external limit closes.

Pump Blocking: Pump attempts to restart.

Check pump for blockage and obstructions, unblock it as required. Replace if necessary.

Incorrect Setting: A parameter setting is outside the settings range.

1. Review primary/CH & DHW settings and correct as necessary. 2. The appliance will automatically reset once corrected.

Firmware Mismatch: Control module and display firmware versions are incompatible.
System Sensor Shorted: A short circuit has been detected in the system temperature sensor circuit
System Sensor Open: An open circuit has been detected in the system temperature sensor circuit.
Outdoor Sensor Shorted: A short circuit has been detected in the outdoor temperature sensor circuit.
Internal Display Fault: Display memory error
Supply Sensor Error: Supply sensor reading is invalid
Outdoor Sensor Open: An open circuit has been detected in the outdoor temperature sensor circuit.
Cascade Mismatch: Cascade configuration has changed.
Cascade Bus Error: Communication with other appliances has been lost.
Controller Bus Error: Communication between appliance display and control module has been lost.

One or several components are not compatible with the system. Replace mismatched component(s).
1. Check system 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 opera-
tion. 1. Check system 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 opera-
tion. 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 opera-
tion.
Turn unit off and on to resume normal operation.
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 opera-
tion. 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 opera-
tion. 1. Run autodetection if change was intentional, or else check wiring be-
tween appliances. 2. Appliance will automatically reset once repaired.
1. Check wiring between appliances. 2. Appliance will automatically reset once repaired.
1. Check wiring between components. 2. Appliance will automatically reset once repaired.

References

• ACV Excellence in hot water - ACV
• Que Faire de mes Déchets ? Découvrez les solutions pour tous vos déchets et nos conseils pour en produire moins.

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