Heatmaster Water Heater 200 N User Manual

®
HeatMaster  
Installation, Operating and  
Servicing Instructions  
®
HeatMaster 200 N  
®
HeatMaster 200 F  
excellence in hot water  
04/03/2004 - 66412600  
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INDEX  
INTRODUCTION  
INTRODUCTION  
1
TARGET GROUP  
Target group  
Symbols  
Certification  
Information and safety instructions  
1
1
1
2
This manual is intended for the use of:  
- final users of the appliance;  
- the engineer installing and starting up the appliance;  
- the engineering and design department;  
- the installer responsible for servicing or maintaining the appliance.  
USER GUIDE  
2
SYMBOLES  
Use of the boiler  
2
The following symbols are used in this manual:  
DESCRIPTION  
3
Operating principle  
Packing  
Construction features  
3
3
4
Essential instruction for operating the system  
correctly.  
TECHNICAL SPECIFICATION  
5
Effective dimensions  
5
5
6
6
6
General characteristics  
Hot water output data  
Limits of operating conditions  
Burner chamber plate  
INSTALLATION  
7
Essential instruction for personal safety or  
environmental protection.  
Boiler room  
7
7
8
9
9
Chimney connections  
Hot water connections  
Heating connection  
Oil supply connections  
Electrical connections  
Wiring diagram  
10  
10  
COMMISSIONING  
11  
Danger of electrocution.  
D A N G E R  
Filling the hot water and heating circuits  
11  
MAINTENANCE  
11  
Service intervals  
11  
11  
11  
11  
12  
Servicing the boiler  
Servicing the safety devices  
Servicing the burner  
Draining the boiler  
HOT  
SAFETY MODE  
12  
Placing the burner in safety mode  
Placing the boiler in safety mode  
12  
12  
Risk of scalding.  
SPARE PARTS  
13  
CERTIFICATION  
Jackets  
Accessories  
13  
13  
The appliances carry the “CE” mark, in accordance with the  
standards in force in the various countries (European Directive  
92/42/CEE “Efficiency”).  
SERVICE RECORD  
14  
Details of the installation  
Service notes  
14  
14  
1
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INTRODUCTION  
USER GUIDE  
GENERAL INFORMATION  
USING THE BOILER  
AND SAFETY INSTRUCTIONS  
General information  
It is compulsory to have your system serviced every  
year by a competent engineer. In the event of heavy  
use of the boiler, it may require servicing on a more  
regular basis than once a year. In this case, contact  
your installer for advice.  
This documentation forms part of the items delivered with the  
appliance and must be given to the user to keep in a safe place!  
This appliance must be serviced and repaired by an approved  
installer, in accordance with current standards in force.  
Starting the burner  
ACV declines all liability for any damage caused as a result of  
incorrect installation or as a result of the use of components or  
connections that are not approved by ACV for this application.  
In conditions of normal operation, the burner starts automatically if  
the temperature of the boiler is below the set point and goes off  
when this value is reached.  
Temperatures  
Control panel  
This boiler is designed for central heating systems  
D A N G E R  
with a maximum outlet temperature of 90°C.  
Therefore, the central heating pipelines and the  
radiators must reach this temperature.  
HOT  
Manual reset high  
limit thermostat  
Combined temperature  
and pressure gauge  
Burner  
lockout  
indicator  
The waste-gas pipe lines must reach  
temperatures in excess of 100°C.  
Time clock  
The hot water can reach temperatures in excess  
of 60°C.  
Installation  
I
O
Before installing and commissioning the boiler, first  
carefully read this manual.  
®
Position the HeatMaster according to the safety rules and  
Primary circuit low  
standards in force. You must comply with the ventilation  
requirements for the room where appliances of this type are  
installed. All air vents must remain unobstructed at all times.  
water pressure  
indicator  
ON / OFF  
switch  
Control  
thermostat  
It is prohibited to modify the interior of the appliance in any way,  
without the manufacturer’s prior written agreement.  
High limit cutoff  
indicator  
Summer / Winter switch  
Service  
In order to ensure the appliance operates safely and correctly, it is  
important to have it serviced and reconditioned every year by an  
installer or an approved service company.  
The user must not attempt to gain access to the  
components inside the control panel.  
Faults  
Despite the strict quality standards imposed on its appliances by  
ACV during production, inspection, and transport, faults may occur.  
Please immediately inform your approved installer about such faults.  
Remember to give the fault code as it appears on the screen.  
1. On/Off switch  
This turns the HeatMaster on or off.  
Only genuine factory parts may be used as replacement parts.  
Please go to page 13 for a list of spare parts and their ACV  
reference numbers.  
2. Control thermostat - 60 to 90°C  
When using the HeatMaster as a hot water generator only, the  
®
temperature can be set between 60°C and 90°C.  
If the HeatMaster is used for both hot water and central heating, the  
control thermostat would normally be set at 80°C to achieve optimum  
®
Important note: ACV reserves the right to change the technical  
characteristics and specification of its products without notice.  
operating conditions.  
3. Summer/Winter switch  
This turns the heating pump (if fitted) on or off.  
4. Manual reset high limit thermostat  
If the boiler temperature exceeds 103°C this safety device will  
activate and the high temperature indicator will light up. To reset -  
first allow the boiler to cool to below 60°C, unscrew the cap and  
press the reset button using a pencil or similar pointed device,  
replace the cap. If the fault persists, turn the boiler off and call an  
engineer.  
2
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USER GUIDE  
DESCRIPTION  
5. Time clock  
OPERATING PRINCIPLE  
®
This allows the HeatMaster to be timed on and off and operates on  
a 24 hour sequence. Around the outside of the clock there are a  
number of white tabs, these allow 15 minute switching periods. To  
set the time clock simply push outwards the number of tabs required  
for ON period.  
®
The HeatMaster is a high performance, direct fired hot water  
storage heater, which has indirect heat transfer due to its Tank-in-  
Tank construction.  
®
At the heart of the HeatMaster is a stainless steel cylinder through  
Remember:  
TAB IN = HeatMaster OFF  
TAB OUT = HeatMaster ON  
which the flue tubes pass. This is surrounded by a mild steel shell  
containing the primary water (neutral fluid). The outer shell extends  
down to the combustion chamber and even around the flue tubes.  
The area of the heat transfer surface is therefore much greater than  
that of standard direct fired water heaters.  
6. Temperature and pressure gauge  
This gauge indicates both the temperature of the HeatMaster and  
the pressure within the primary circuit.  
The temperature should not exceed 90°C - if it does, switch the  
boiler off and check the thermostat setting. If the fault persists, call  
an engineer.  
®
A circulating pump fitted to the primary circuit moves the water  
around the tank, heating it faster and maintaining an even  
temperature across the primary jacket.  
The pressure should not fall below 1bar, if it does the please see the  
'Heating System Pressure' paragraph later in this section.  
The burner, either gas or oil, fires onto the primary water which  
indirectly heats the stainless steel cylinder containing the DHW. As  
with all Tank-in-Tanks, this is corrugated over its full height and  
suspended in the HeatMaster by its hot and cold water  
connections.  
®
7. Low primary water pressure indicator  
®
If this indicator lights up, the primary circuit of the HeatMaster  
requires topping up with water. Please see the 'Heating System  
Pressure' paragraph later in this section.  
The cylinder expands and contracts during use and this, together  
with the fact that cold water does not come into contact with the  
intense heat of the burner flame, means that limescale buildup is  
prevented.  
Heating-system pressure  
The heating circuit may require a top-up of water. The pressure  
gauge, located beside the display, gives the pressure.  
This scale resistant feature, along with the corrosion resistance of  
stainless steel, eliminates the need for sacrifical anodes.  
®
The HeatMaster has one very major advantage over other direct  
fired water heaters - because it heats the DHW with a primary  
circuit, this primary water can be used to provide central heating as  
well.  
In the case of repeated fills, contact your installer.  
The pressure of the primary circuit must be at least 1 bar and must  
be regularly checked by the end user. If the pressure falls below  
0.5 bar, the low-water-level pressure switch locks the appliance until  
the pressure in the system returns to above 0.8 bar.  
®
By connecting two, three, four or more HeatMaster together in a  
module, most hot water and heating demands can be met.  
Indeed, when used in conjunction with HR and Jumbo hot water  
storage tanks the HeatMaster can supply even the largest hot water  
requirement.  
®
The HeatMaster 200 N / 200 F is fitted with a purpose-designed fill  
set (see Fig. A and B). Always make sure that the appliance is  
switched off when filling the system.  
To do this, turn the On/Off switch on the left of the control panel to  
Off.  
Standard equipment  
The HeatMaster 200 has the following items as standard:  
For more information, please ask your installer when delivering the  
system.  
- On/off switch  
- Summer/Winter switch  
The appliance is fitted with a safety valve. If the system pressure  
exceeds 3 bars, this valve opens and drains the water from the  
system. In this case, contact your installer.  
- Control thermostat (60 - 90°C)  
- Thermal reset high-limit thermostat (95°C)  
- Manual reset high-limit thermostat  
- Hot water priority thermostat  
- Primary circulating shunt pump  
- Primary expansion vessels  
- Primary safety valve  
- Pressure and temperature gauge  
- Drain valve  
- Body completely insulated in rigid polyurethane foam  
PACKING  
The HeatMaster is delivered in separate packages.  
Fig. A  
(cover)  
Fig. B  
(rear panel)  
• Package No. 1:  
Foam-insulated body, hydraulic accessories,  
and control panel.  
• Package No. 2:  
• Package No. 3:  
Chimney reducing pipe.  
Wooden protective casing (jacket and  
accessory).  
• Package No. 4:  
“RIELLO” RG4S 396 T1 burner (HM 200 F only).  
3
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DESCRIPTION  
CONSTRUCTION FEATURES  
5
1
Outer body  
The outer body, containing the primary water, is made from STW 22  
carbon steel.  
TANK-IN-TANK heat exchanger  
The ring-shaped inner tank with its large heating surface for  
producing domestic hot water is built of Chrome/Nickel 18/10  
stainless steel. It is corrugated over its full height by an exclusive  
production process and entirely argon arc welded by the TIG  
(Tungsten Inert Gas) method.  
6
2
Combustion gas circuit  
The combustion gas circuit is paint-protected and comprises:  
• Flue pipes  
7
8
®
Depending on output, HeatMaster 200 models contain  
several steel flue pipes with an internal diameter of 64 mm.  
Each pipe is fitted with a baffle of special steel designed to  
improve heat exchange and reduce flue gas temperature.  
3
4
• Combustion chamber  
The combustion chamber on HeatMaster models is entirely  
water cooled.  
®
Insulation  
The boiler body is fully insulated by rigid polyurethane foam with a  
high thermal insulation coefficient, sprayed on without the use of  
CFCs.  
Casing  
The boiler is covered by a steel jacket which has been scoured and  
phosphated before being stove enamelled at 220°C.  
9
Burner  
The HM 200 F model is always delivered with a “RIELLO” RG4S 396  
T1 fuel oil burner.  
15  
16  
10  
11  
Legend  
1. “Tank-in-Tank” type storage exchanger  
2. Flue ways  
3. Primary circuit  
4. Combustion chamber  
5. Turbulators  
6. Heating outlet  
17  
18  
7. Stainless steel pocket  
8. Heating return  
9. Boiler drain cock  
10. Hot water priority thermostat bulb  
11. Cold water inlet  
12  
13  
12. Bulbs of the thermal reset high-limit 95°C thermostat and the  
manual reset high-limit 103°C thermostat  
13. Insulation  
14. Low-water-level pressure switch  
15. Hot water outlet  
19  
20  
16. Chimney reducer  
17. Steam trap  
18. T&P valve (optional)  
14  
19. Thermostat-pressure gauge bulb  
20. 60 - 90°C control thermostat bulb  
21. Flange of the burner chamber plate  
21  
4
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