INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS

Transcription

1 INSTALLATION, OPERATION AND MAINTANCE INSTCTIONS for the Installer and the User HeatMaster TC A D

2 Adddum - iring Diagrams - Detail of X00 Terminal APICAIL : Rev D - Installer's Handbook - olume Rev D - Prestige 4- Solo/Excellce, Installation, Operation and Maintance Instructions Rev D - HeatMaster TC, Installation, Operation and Maintance Instructions Rev - HeatMaster 5C, Installation, Operation and Maintance Instructions Rev C - atermaster , Installation, Operation and Maintance Instructions Prestige 4- Solo/Excellce Prestige Solo HeatMaster TC HeatMaster 5C atermaster X Or /Gr /Gr r /Gr r /Gr r 0 L N Or /Gr /Gr r /Gr r /Gr r 0 L N X Or /Gr /Gr /Gr r 0 L N r X00 X00 X00 Adddum X00 Terminal: A ADD0050

3 Adddum - Additional Safety Instructions for Gas Appliances APICAIL : Rev E - Delta Pro S -Pro Pack, Installation, Operation and Maintance Instructions Rev - HeatMaster (), Installation, Operation and Maintance Instructions Rev - HeatMaster 00N, Installation, Operation and Maintance Instructions Rev D - Prestige 4- Solo/Excellce, Installation, Operation and Maintance Instructions Rev D - HeatMaster TC, Installation, Operation and Maintance Instructions Rev - HeatMaster 5C, Installation, Operation and Maintance Instructions Rev - Compact Conds , Installation, Operation and Maintance Instructions Rev C - atermaster , Installation, Operation and Maintance Instructions Make sure that the appliance is connected to the earth. eiller à ce que l appareil soit raccordé à la terre. Zorg ervoor dat het toestel is geaard. Asegúrese de que el aparato esté conectado a tierra. Assicurarsi che l apparecchio sia elettricamte collegato alla messa a terra dell impianto. Stell Sie sicher, dass das Gerät geerdet ist. Upewnij się, że urządzie jest uziemione. Убедитесь, что прибор заземлен. Check that the gas type and pressure from the distribution network are compatible with the appliance settings. érifier que le type de gaz et la pression du réseau de distribution sont compatibles avec les réglages de l appareil. Controleer of het type gas de druk van het distributietwerk in overestemming zijn met de toestelinstelling. Compruebe que el tipo de gas y la presión de la red de distribución son compatibles con los ajustes del aparato. Controllare che il tipo di gas e la pressione della rete di distribuzione siano compatibili con le impostazioni dell apparecchio. Stell Sie sicher, dass die Gasart und der Druck des erteilungsnetzes mit d Geräteinstellung kompatibel sind. Sprawdzić, czy typ gazu i ciśniie sieci dystrybucyjnej są zgodne z ustawiiami urządzia. Убедитесь, что тип газа и давление в распределительной сети совместимы с настройками прибора. Adddum Gas Appliances : A ADD0000

4 TALE OF CONTTS GERAL RECOMMDATIONS... Safety Instructions... USER S GUI...4 Meaning of Symbols...4 oiler Marking...5 Control Panel and Display...6 Stand-by Scre...7 Lockout Scre...7 Status Messages...7 hat to Check on a Regular asis...8 In case of Problem...8 oiler Setup Guide...8 APIANCE SCRIPTION...5 Models - HeatMaster TC...5 Configuration in a system...5 HeatMaster TC overview...5 HeatMaster TC overview...6 Connections - at the back...7 TECHNICAL CHARACTERISTICS...8 Dimsions...8 Clearance...9 gas categories (All models)...9 Combustion characteristics... 0 Chimney connection characteristics... Calculation of the flue pressure drop in the flue pipes... Cascade : calculation of the maximum lgth of flue pipes... Electrical Characteristics HeatMaster TC...4 Electrical Characteristics HeatMaster TC... 6 Electrical Characteristics HeatMaster 0 TC... 8 Hydraulic Characteristics... 0 Hydraulic Pressure Drop Curve of the oilers... 0 DH performance... 0 Maximum Operating Conditions... 0 Recommdations for the Prevtion of Corrosion and Scaling in Heating Systems... G Requiremts and Guidance - UK Only... INSTALLATION...4 Safety Instructions for the Installation... 4 Package contts...5 Tools Required for the Installation... 6 oiler preparation... 6 Hydraulic Connections... 6 DH connection... 6 Heating Connection...7 Removal and Installation of the Front and Top Panels... 8 Gas Connection... 8 Conversion to Propane...9 CONFIGURATION AND SSTEM SET-UP...40 asic Configuration - HeatMaster 5 TC 5: High Temperature Heating Circuit Controlled by Room Thermostat and Optional Outdoor Ssor Cascade Configuration, Controlled by E Controller... 4 STARTING UP...4 Safety Instructions for Starting up...4 Tools Required for Starting up...4 Checks before Starting up...4 Filling the system...4 Starting up the oiler...4 Checking and Adjusting the urner...4 MAINTANCE...44 Safety Instructions for the oiler Maintance Tools Required for Maintance oiler shut down for Maintance Periodic oiler Maintance Tasks Draining the oiler Removal, Check and Installation of the urner Electrode Removal and Installation of the urner Torque alues...47 Cleaning the Exchanger Restarting after Maintance LOCKING COS...49 SERICE LOG...5 CLARATION OF CONFORM...5 PRODUCT FICHE...54 HeatMaster TC : A D

5 GERAL RECOMMDATIONS NOTE This manual contains important information with respect to the installation, the starting up and the maintance of the appliance. This manual must be provided to the user, who will read it carefully and keep it in a safe place. e accept no liability should any damage result from the failure to comply with the instructions contained in this technical manual. SAFET INSTCTIONS If you smell gas: - Immediately isolate the gas supply. - Op windows and doors to vtilate the area. - Do not use any electrical appliances and do not operate any switches. - Immediately notify your gas supplier and/or your installer. Esstial recommdations for safety It is prohibited to carry out any modifications to the appliance without the manufacturer s prior and writt agreemt. The product must be installed by a qualified gineer, 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 vironmtal pollution. The manufacturer declines all liability for any damage caused as a result of incorrect installation or in the evt of the use of appliances or accessories that are not specified by the manufacturer. Esstial recommdations for the correct operation of the appliance In order to sure that the appliance operates correctly, it is esstial to have it serviced by a certified installer or maintance contractor every year. In case of anomaly, please call your service gineer. Faulty parts may only be replaced by guine factory parts. Geral 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. In spite of the strict quality standards that AC applies to its appliances during production, inspection and transport, faults may occur. Please immediately notify your approved installer of any faults. Esstial recommdations for safety Do not store any flammable or corrosive products, paint, solvts, salts, chloride products and other detergt products near the appliance. Make sure that the condsate outlet is never obstructed and that a condsate neutralisation system is installed if required. This appliance is not intded for use by persons (including childr) with reduced physical, ssory or mtal capabilities, or lack of experice and knowledge, unless supervised or unless they have be giv instruction concerning the use of the appliance by a person responsible for their safety. Childr should be supervised to sure that they do not play with the appliance. Geral remarks The d user is only allowed to carry out the basic set-up operations mtioned in "oiler Setup 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 d 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 ACMax interface, refer to the installerspecific settings and the detailed error codes, in the Installer's Handbook provided with the boiler. HeatMaster TC : A D

6 USER S GUI MEANING OF SMOLS Symbols on the packaging Meaning Fragile Keep dry Symbols in the manual Meaning Esstial recommdation for safety (of persons and equipmt) Esstial recommdation for electrical safety (electrical hazard) Keep standing, up Esstial recommdation for the correct operation of the appliance or the system Danger of tipping over Geral remark Hand truck or pallet truck required for transport Safety valve connected to the sewage system Symbols on the appliance Meaning Gas connection Connection to the sewage system Condsate trap (ball syphon) Domestic Hot ater circuit Primary circuit Electricity Alarm 4 HeatMaster TC : A D

7 USER S GUI OILER MARKING Location: ack panel The part number (Code) and serial number (N ) of the appliance are indicated on its rating plate and must be provided to AC in case of warranty claim. Failure to do so will make the claim void. HeatMaster 5 TC HeatMaster 5 TC HeatMaster 70 TC HeatMaster 85 TC HeatMaster 45 TC HeatMaster 0 TC HeatMaster TC : A D 5

8 USER S GUI CONTROL PANEL AND DISA 4 5 Main Icons of ACMAX display Ctral Heating - indicates information related to the CH circuit. DH - indicates information related to the Domestic Hot ater circuit. Home - to go back to the main mu scre. ack - to go back to the previous scre. arm weather shutdown - displays on the home scre wh the outdoor temperature reaches the arm eather Shutdown preset temperature. Reset - to reset the system to the factory settings. Parameters - to access to the setup of controller parameters (language, units, etc.). Easy setup - Indicates parameters that can be accessed through the EZ setup. Panel Description. Pressure gauge - Indicates the primary circuit pressure (min. bar wh cold).. ACMAX 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 scres, each showing information and/or icons. The main icons are detailed on the right.. Installer button - Allows the installer to access the mus of the ACMAX controller to set up the system. 4. Arrow keys and OK key - to browse through the scres of the ACMAX controller, set up the boiler, increase and decrease the displayed values and validate the selections and access the Easy set-up scres. The OK key is also used to RET the boiler after a locking (follow the instructions on the scre). 5. ON/OFF master switch of the boiler - To turn the appliance ON and OFF. Main settings of ACMAX Display Scre backlight - it will illuminate wh any button is depressed, and remain illuminated for five minutes. Scre contrast - it can be adjusted at the Home scre by pressing and holding the OK button, th pressing and holding the LEFT button along with the OK button. Press the UP and DON button to increase or decrease the contrast while holding the OK and LEFT buttons depressed. All buttons must be released and the procedure performed again to switch betwe increasing and decreasing contrast. CH/DH operation - To able/disable the concerned circuit. Information - To get information on the boiler. Typical items appearing on the Home scre: The boiler type is indicated at the top of the scre. The type and model are factory preset. The boiler is represted in the ctre of the Home Scre. asic operating information such as supply and return temperatures are displayed as well as currt burner status. Radiator icon: indicates that a ctral heating call has be received. A small number or indicates which CH calls are active A flame symbol is displayed wh the unit is fired. The flame size changes to indicate the currt firing rate. asic information. The user can toggle the items using the LEFT and RIGHT keys and view target, Supply, Return, Domestic, Outdoor and System temperatures. CH P HeatMaster 84 C 6 C Target = 85 C oiler Protection DH P4 Tap icon: indicates that a DH call has be received. Circulator icons: indicate which circulators are currtly powered. Status line: displays the currt operating state of the boiler. See Status Messages on page 7. 6 HeatMaster TC : A D

9 USER S GUI STAND- SCRE STATUS MSAG This scre is displayed at start-up. It indicates that the HeatMaster is ready to respond wh a demand is received. Stand-by Indicates that the HeatMaster is ready to respond wh a demand is received. CH Demand A ctral heating call has be received. HeatMaster 84 C DH Demand CH / DH Demand A domestic hot water call has be received. Ctral heating and domestic hot water calls are being received simultaneously. oth calls are being satisfied simultaneously because domestic hot water priority has be disabled. Target = -- 6 C Stand-by DH Priority Priority Timeout External Demand Manual Operation Ctral heating and domestic hot water calls are being received simultaneously. Domestic hot water call is being satisfied first because it has priority over ctral heating calls. Ctral heating and domestic hot water calls are being received simultaneously. The domestic hot water priority time limit has be exceeded. Priority will now switch back and forth betwe ctral heating and domestic hot water calls until one call is satisfied. An external modulation call has be received. The burner or circulators have manually be abled in the Installer Mu. CH urner Delay The burner will not fire until the call blocking time has elapsed. LOCKOUT SCRE DH urner Delay The burner will not fire until the call blocking time has elapsed. If a problem occurs, the Lockout scre replaces the Home scre. The backlight also remains on as long as the problem is not solved. Pressing any arrow button will return to the Home scre. Using the code located in the right bottom corner of the scre, troubleshoot the problem, either with the table located in paragraph In case of Problem... on page 8, or with the Lockout code table in the Installer s Handbook (for the installer only). Lockout message. Refer to In case of Problem... on page 8 for more information. CH Setpoint Reached DH Setpoint Reached CH Post Pump The burner is not fired because the supply/system water temperature exceeds the setpoint. The ctral heating circulator continues to operate and the burner will fire again once the supply/system water temperature drops below the setpoint. The burner is not fired because the supply/system water temperature exceeds the setpoint. The domestic circulator continues to operate and the burner will fire again once the supply/system water temperature drops below the setpoint. The ctral heating circulator is running to remove heat from the HeatMaster at the completion of a call. Low ater ater pressure has fall below 0.7 bar. Increase pressure to normal range. If problem persists, call for service ody text. The first stce describes the lockout, the second stce gives a possible cure, and the third tells how to reset the lockout. DH Post Pump Freeze Protection oiler Protection Lockout Description The domestic hot water circulator is running to remove heat from the HeatMaster at the completion of a call. The burner is fired because the freeze protection feature has be activated. Freeze protection will d once the supply/system water temperature is raised to6 C. The burner firing rate is being reduced because of an excessive differce betwe the boiler supply and return temperatures. The firing rate will begin increasing once the temperature differce is less than5 C. The lockout which currtly has the HeatMaster shut down is displayed E7 Lockout referce code. Refer to In case of Problem... on page 8 for more information. HeatMaster TC : A D 7

10 USER S GUI HAT TO CHECK ON A REGULAR ASIS Esstial recommdations for the correct operation of the appliance AC recommds to check the system at least every 6 months as follows: Check that the system water pressure is at least bar wh cold. If the pressure drops below 0.7 bar, the built-in pressure ssor blocks the appliance until the pressure exceeds. bar. If it is required to top up the system to maintain the minimum recommded 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 condsate neutralisation system is installed, check it and have it cleaned regularly. Check regularly that there is no error message (lockout) on the scre. A typical lockout scre is explained on the previous page. Refer also to the Troubleshooting table below or call your installer as required. IN CASE OF PROLEM... 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 Locking codes on page 49. OILER SETUP GUI The main parameters of the HeatMaster boilers can be set up using the EZ (easy) setup function of the ACMax controller. The EZ setup function allows the user/installer to quickly setup the appliance for immediate operation according to the system configuration*. Geral remarks To navigate on the scre, use the UP, DON, LEFT and RIGHT keys, th the OK key to validate a selection. A selection is marked by a black background under the selected icon/text. To increase/decrease values, use the UP and DON keys or the LEFT and RIGHT keys according to the situation. CH P HeatMaster 84 C 6 C Target = 85 C oiler Protection DH P4 EZ Setup Fault code - Problem Possible Cause(s) Solution The appliance does not turn on wh pressing the ON/OFF Master switch No power supply Check the power supply and that the appliance power plug is connected to the network. Heating EZ Setup E 0 Failed ignition The burner failed to light after 5 ignition attempts Check gas supply to the boiler. E Reset limit reached Resets are limited to 5 every 5 minutes Turn unit OFF and ON to resume normal operation. E 4 Low voltage Line voltage has fall below an acceptable operating level The boiler will automatically reset once line voltage returns to normal. DH EZ Setup EZ Setup Reset Display EZ Setup E 7 Low ater ater pressure has fall below an acceptable operating level (0.7 bar) Refill the system to reach a normal range pressure. The boiler will automatically reset once water pressure returns to normal. E 94 Internal Display Fault Display memory error Turn appliance off and on to resume normal operation. * In case of complex systems, the setup must be performed by an approved installer using the Installer s Handbook. 8 HeatMaster TC : A D

11 USER S GUI Heating Easy setup (no outdoor ssor connected) To navigate on the scre, use the UP, DON, LEFT and RIGHT keys, OK EZ Setup Use the OK key to validate a selection. To increase/decrease values, use the UP and DON keys, or LEFT and RIGHT, according to the situation Heating EZ Setup Select CH Demand Thermostat & Setpoint Constant & Setpoint 0-0 Modulation Signal Select CH Demand prompts the installer to select how a CH Demand is gerated. There are three Select CH Demand options, among which the installer must make a selection. Thermostat & Setpoint - This option is only displayed wh no outdoor temperature ssor is connected. A ctral heating call from a thermostat or zone panel will able the HeatMaster and the setpoint will be fixed for ctral heating calls. h Thermostat & Setpoint is selected, the CH Setpoint scre appears. 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. h Constant & Setpoint is selected, the CH Setpoint scre appears. Select CH Demand Thermostat & Setpoint Constant & Setpoint 0-0 Modulation Signal CH Setpoint 8 C 0 C 87 C CH Setpoint 60 C 0 C 87 C EZ Setup Complete Heating EZ setup is complete. Additional changes can be made in the Installer Mu if required. Press OK to return to EZ Setup Mu CH Setpoint prompts to ter the fixed setpoint for a CH heating call wh a Setpoint option is chos in Select CH Demand. Press on LEFT or RIGHT button to adjust the required temperature setpoint th press OK to store the setting. The CH Setpoint scre appears. CH Setpoint prompts to ter the fixed setpoint for a CH heating call wh a Setpoint option is chos in Select CH Demand. Press on LEFT or RIGHT button to adjust the required temperature setpoint th press OK to store the setting and complete the Heating setting. CH Default: 8 C. CH Default: 60 C Select CH Demand Thermostat & Setpoint Constant & Setpoint 0-0 Modulation Signal EZ Setup Complete Heating EZ setup is complete. Additional changes can be made in the Installer Mu if required. 0-0 Modulation Signal - This option allows the HeatMaster firing rate to be controlled by an external control system. Refer to Installer s Handbook, olume, for more information. Press OK to return to EZ Setup Mu HeatMaster TC : A D 9

12 USER S GUI Heating Easy Setup (outdoor ssor connected) EZ Setup Heating EZ Setup Select CH Demand Thermostat & Outd. Curve Constant & Outdoor Curve Constant & Setpoint 0-0 Modulation Signal Select CH Demand prompts the installer to select how a CH Demand is gerated. There are several Select CH Demand options, among which the installer must make a selection. Thermostat & Outd. Curve This option is only displayed wh the outdoor temperature ssor is connected. A ctral heating call from a thermostat or zone panel will able the boiler and the setpoint will vary with the outdoor temperature for ctral heating calls.. Constant & Outdoor Curve - This option is only displayed wh the outdoor temperature ssor 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 ctral heating calls. Select CH Demand Thermostat & Outd. Curve Constant & Outdoor Curve Constant & Setpoint 0-0 Modulation Signal 8 C 7 C Select CH Outd. Curve MAX 8 C - C Currt Settings Select CH Outd. Curve prompts to select an outdoor curve for a CH heating call wh an Outdoor Reset option is chos 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 Mu (refer to Installer s Handbook). Press on UP or DON button to select the outdoor reset curve appropriate for the type of heating system, th press OK to store the setting. Default: Systems with a temperature betwe 7 C and 8 C. 60 C 7 C Select CH Outd. Curve 8 C - C Currt Settings Select CH Outd. Curve prompts to select an outdoor curve for a CH heating call wh an Outdoor Reset option is chos 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 Mu (refer to Installer s Handbook). Press on UP or DON button to select the outdoor reset curve appropriate for the type of heating system, th press OK to store the setting. Default: Systems with a temperature betwe 7 C and 60 C arm eather Shutdown Off Off 5 C EZ Setup Complete Heating EZ setup is complete. Additional changes can be made in the Installer Mu if required. Press OK to return to EZ Setup Mu arm eather Shutdown allows to ter an optional outdoor temperature at which to disable the ctral heating function. The HeatMaster will continue to respond to a domestic hot water call or a 0-0 Modulation Signal wh the outdoor temperature exceeds the arm eather Shutdown Temperature setting. Press the LEFT or RIGHT buttons to adjust the arm eather Shutdown Temperature th press the OK button to store the setting and complete the Heating setting. The arm eather Shutdown icon ( ) is displayed on the home scre wh the outdoor temperature reaches the arm eather Shutdown preset temperature. Default: OFF. 0 HeatMaster TC : A D

13 USER S GUI EZ Setup Heating EZ Setup Select CH Demand CH Setpoint CH Setpoint arm eather Shutdown EZ Setup Complete Thermostat & Outd. Curve Constant & Outdoor Curve Constant & Setpoint 0-0 Modulation Signal 8 C 0 C 87 C 60 C 0 C 87 C Off Off 5 C Heating EZ setup is complete. Additional changes can be made in the Installer Mu if required. Refer to page 9 for scre descriptions Press OK to return to EZ Setup Mu Select CH Demand EZ Setup Complete Thermostat & Outd. Curve Constant & Outdoor Curve Constant & Setpoint 0-0 Modulation Signal Heating EZ setup is complete. Additional changes can be made in the Installer Mu if required. Refer to page 9 for scre descriptions Press OK to return to EZ Setup Mu HeatMaster TC : A D

14 USER S GUI DH Setup EZ Setup DH EZ Setup Select DH Demand Thermostat Ssor Select DH Demand prompts the installer to select how a DH Demand is gerated. There are two Select DH Demand options, among which the installer must make a selection. h Thermostat is selected in Select DH Demand, a domestic hot water call from an aquastat or dry contact switch will able the HeatMaster with a fixed setpoint for a domestic hot water call.. h Ssor is selected in Select DH Demand, it requires the use of an optional Indirect ater Heater Ssor. The HeatMaster monitors the DH storage temperature and gerates a DH call whever the temperature drops below the DH storage setpoint by C. Default : Ssor Select DH Demand Thermostat Ssor DH oiler Setpoint 75 C 5 C 87 C DH oiler Setpoint prompts to ter the fixed boiler setpoint temperature during a hot water call wh the Thermostat option is selected. Press on LEFT or RIGHT button to adjust the required temperature setpoint th press OK to store the setting. Default: 75 C. DH Setpoint DH Storage Setpoint prompts to ter the DH storage setpoint temperature. 60 C Press on LEFT or RIGHT button to adjust the required temperature setpoint th press OK to store the setting. 0 C 75 C Default: 60 C. The DH Storage Setpoint will automatically be set 5 C higher than the DH Setpoint setting DH Priority Timeout Off Off 0 min. EZ Setup Complete DH EZ setup is complete. Additional changes can be made in the Installer Mu if required. Press OK to return to EZ Setup Mu DH Priority Timeout prompts to ter an optional time limit that a domestic hot water call has priority over ctral heating call. Press on LEFT or RIGHT button to adjust the required timeout value, if required, th press OK to store the setting and complete the DH setting. Default: Off HeatMaster TC : A D

15 USER S GUI Starting from the Home scre : Easy Setup Reset EZ Setup HeatMaster 84 C CH 6 C DH EZ Setup Reset EZ Setup Reset Press OK to restore factory settings, any other button to keep currt settings. EZ Setup Reset allows to reset all EZ setup settings back to the original factory defaults. Follow the on-scre instructions to reset all EZ setup settings. P P4 Target = 85 C oiler Protection EZ Setup Display Easy Setup EZ Setup Display EZ Setup English Français Nederlands Español Italiano Deutsch Display EZ Setup allows to select the interface language (Nine differt languages: English, Frch, Dutch, Spanish, Italian, German, Czech, Polish and Russian). Press on UP or DON button to select the required language th press OK to store the setting. CH / DH Operation oiler Information Select Language Fahrheit Celsius Select Unit Display EZ Setup allows to select the interface temperature unit. Press on UP or DON button to select the required unit th press OK to store the setting. Selecting this icon and validating the selection with the OK key allows to access directly to the language selection page (see on the left) HeatMaster TC : A D

16 USER S GUI CH/DH Operation CH / DH Operation Heating abled DH abled CH/DH Operation provides a simple way to able/disable either the CH or the DH function of the Heat- Master. Press on LEFT or RIGHT button to select the object (CH or DH icon), th press OK to toggle betwe the abled/disabled status. The status of the circuit is displayed at the top of the scre. Using the arrow keys, select the HOME or RETURN icon at the bottom of the scre to go back either to the home page or to the previous scre respectively. Default: oiler Information oiler Information oiler Information abc de f bbb b abc de f bb abc de f bbb b abc de f bbb b abc de f bb abc de f bbb b oiler Information oiler Status Standby Heating Call No DH Call No oiler Firing Rate -- Ionization currt μa oiler Setpoint -- oiler Information scre provides real time operating information of the HeatMaster. Each line contains an information item followed by its currt value. Six lines are displayed on the scre at one time. Press on UP or DON button to scroll through the items. For more information, refer to the Installer s Handbook of the HeatMaster boilers. oiler Information abc de f bbb b abc de f bb abc de f bbb b abc de f bbb b abc de f bb abc de f bbb b Lockout History. lower speed 5h ago. DH Ssor Op h ago. Ssor Drift 5 h ago 4. No error 7 h ago 5. No error 7 h ago 6. No error 7 h ago Lockout Details lower speed oiler Status -- Heating Call -- DH Call -- oiler Firing Rate 44% Ionization currt 44μA Lockout History records the last eight lockouts. Six lines are displayed on the Lockout History scre at one time. Each line contains a lockout description followed by how long ago the lockout occurred. Press on UP or DON button to scroll through the items and on OK to select any of them and get more details through the Lockout Details scre. For more information, refer to the Installer s Handbook of the HeatMaster boilers. 4 HeatMaster TC : A D

17 APIANCE SCRIPTION MOLS - HEATMASTER TC HEATMASTER TC OERIE The HeatMaster TC series is a range of condsing combination boilers. The boilers combine AC's "Tank-in-Tank" concept with a double primary circuit to reach the high performance of a TOTAL CONN- SATION, double-circuit boiler All the HeatMaster TC models are equipped with a high efficicy charging pump and with an AC air/ gas premix burner with low NOx emissions. During operation, the burner starts automatically as soon as the boiler temperature gets lower than the preset temperature and stops as soon as the preset temperature is reached. The HeatMaster TC series features a built-in frost protection mechanism: as soon as the flow temperature [NTC probe] drops below 7 C, the ctral heating pumps are activated. As soon as the flow temperature is at 5 C, the burner starts up until the flow temperature rises above 5 C. The pumps continue to run for around 0 minutes. The function can be abled or disabled through the installer mu. h the frost protection is disabled, only the pumps operate. An anti-freeze function is also available if an outdoor temperature ssor is connected, the pumps are activated wh the outside temperature drops below the threshold defined through the Freeze protection function in the installer mu. In order to able the HeatMaster boiler to protect the whole system against freezing, all the valves of the radiators and the convectors should be completely op. CONFIGURATION IN A SSTEM The HeatMaster TC boilers can be set up in differt types of systems, either high or low temperature, or both, with or without external Domestic Hot ater tank. The HeatMaster TC boilers can also be set up in a cascade system, using an external controller. Refer to Configuration and system set-up on page 40 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 40), with the required accessories, required electrical connections and ACMax 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 mtioned in either manuals, please contact your AC represtative Conctric flue gas/air inlet box. Flue gas exhaust tube. Combustion chamber 4. Stainless steel heat exchanger 5. Stainless steel Tank-in-Tank hot water production tank 6. Primary circuit separation disc 7. Indirect water pre-heater 8. Condsate recovery dish + NTC5 ssor (flue gas) 9. High efficicy circulator pump 0. NTC ssor (CH return). Pressure ssor. Heating circuit. Electrical panel (with spare fuses at the back) 4. ACMax Control panel 5. DH tank dry well (Dip tube with temperature ssor) 6. Automatic air vt 7. Gas pipe 8. NTC ssor (CH supply) 9. Gas valve 0. DH safety valve / (T & P relief valve - UK only). Modulating air/gas premix burner with fan. Air inlet HeatMaster TC : A D 5

18 APIANCE SCRIPTION HEATMASTER TC OERIE Conctric flue gas/air inlet box. Flue gas exhaust tube. Combustion chamber 4. Stainless steel heat exchanger 5. Stainless steel Tank-in-Tank hot water production tank 6. Primary circuit separation disc 7. Indirect water pre-heater 8. Condsate recovery dish + NTC5 ssor (flue gas) 9. High efficicy circulator pump 0. NTC ssor (CH return). Pressure ssor. Heating circuit. Electrical panel (with spare fuses at the back) 4. ACMax Control panel 5. DH tank dry well (Dip tube with temperature ssor) 6. Automatic air vt 7. Gas pressure switch 8. NTC ssor (CH supply) 9. Gas valve 0. DH safety valve / (T & P relief valve - UK only). Modulating air/gas premix burner with fan. Air inlet HeatMaster TC 6 HeatMaster TC : A D

19 APIANCE SCRIPTION CONNECTIONS - AT THE ACK HeatMaster 0 TC 8. Discharge for built-in DH safety valve / (T & P relief valve - UK only) outlet to be connected to the sewage system. Gas connection [M]. Grommets for electrical wires (low voltage control) 4. Domestic Hot ater outlet [M] 5. Heating supply connection ([F] 6. Connection for provided heating safety valve (to be installed). 7. Connection for low temperature heating circuit return (HM TC only) 8. Heating return connection [F] 9. Grommets for electrical wires (0 ) 0. Domestic Hot ater inlet [M]. Flue connection HeatMaster TC : A D 7

20 TECHNICAL CHARACTERISTICS DIMSIONS oiler Dimsions HM TC HM TC HM 0 TC A mm mm C mm D mm E mm F mm G mm H mm J ( ) mm K ( ) mm L ( ) mm M (aux. circulation loop) mm N ( ) mm O ( ) mm 7 Heating Connection [F]././ DH Connection [M] Auxiliary connection [F]././ Gas connection [M] /4 /4 /4 min. of flue pipe mm Drained weight Kg A C E D G F H K J L O N M 8 HeatMaster TC : A D

21 TECHNICAL CHARACTERISTICS CLEARANCE GAS CATEGORI (All models) oiler Clearance A (mm) (mm) C (mm) D (mm) A C HeatMaster TC Recommded 400 Minimum 00 Recommded 800 Minimum 600 Recommded 400 Minimum 50 Recommded 600 Minimum 400 Front view iew from the top D Gas type G0 G5 G0 G5 G Pressure (mbar) Country code Category AT II HP I E(S) * E I E(R) ** I P CH II HP CZ II HP II EP II ELLP II HP FI II HP II ErP G II HP GR II HP HR II HP IE II HP II HP LT II HP LU II EP L I H II LP II EP PT II HP RO II HP SI II HP SK II HP * HM 5 / 5 / 45 / 70 TC ** HM 85 / 0 TC HeatMaster TC : A D 9

22 TECHNICAL CHARACTERISTICS COMUSTION CHARACTERISTICS Main Characteristics HM 5 TC HM 5 TC HM 45 TC G0/G5 G G0/G5 G G0/G5 G Main Characteristics HM 70 TC HM 85 TC HM 0 TC G0/G5 G G0/G5 G G0/G5 G Input (PCI) Output at 00% Efficicy at 00% max k min k (80/60 C) k (50/0 C) k (80/60 C) % (50/0 C) % Efficicy at 0% load (677) % Combustion efficicy NOx (Class 5) CO CO Max gas flow rate G0/G5 Max. gas flow rate G Temp of flue gases Average temp. of combustion products Mass flow rate* of flue gases Standby loss at 00% % Max. output mg/kh Min. output mg/kh eighted mg/kh 9 9 Max. output ppm Min. output ppm Max. output %CO / Min. output %CO / mbar m³/h mbar m³/h /7/50 mbar m /h Kg/h Normal C Max. C Min. C DH mode C Normal g/s Min. output g/s T = 45 K T = 0 K Input (PCI) Output at 00% Efficicy at 00% max. k min. k (80/60 C) k (50/0 C) k (80/60 C) % (50/0 C) % Efficicy at 0% load (677) % Combustion efficicy NOx (Class 5) CO CO Max gas flow rate G0/G5 Max. gas flow rate G Temp of flue gases Average temp. of combustion products Mass flow rate* of flue gases Standby loss at 00% % Max. output mg/kh Min. output mg/kh 6 eighted mg/kh Max. output ppm Min. output ppm Max. output %CO / /9.. Min. output %CO / mbar m³/h mbar m³/h /7/50 mbar m/h Kg/h Normal C Max. C Min. C DH Mode C Normal g/s Min. output g/s T = 45 K T = 0 K * Mass flow rate values were calculated for G0 and G with an air factor of.. 0 HeatMaster TC : A D

23 TECHNICAL CHARACTERISTICS CHIMNE CONNECTION CHARACTERISTICS Main Characteristics HM 5 TC HM 5 TC HM 45 TC HM 70 TC HM 85 TC HM 0 TC Air/flue pipe Ø conctric mm 80/5 80/5 80/5 00/50 00/50 00/50 dual flow mm 80/80 80/80 80/80 00/00 00/00 00/00 Max. allowed flue pipe pressure drop Pa Max recommded lgth of conctric flue pipe (corresponding lgth in meters of straight pipes) * Ø 80/5 Max recommded lgth of conctric flue pipe (corresponding lgth in meters of straight pipes) * Ø 00/50 4 Max recommded lgth of dual flow Twin Flex Twin Flex Twin Flex Twin Flex Twin Flex Twin Flex (corresponding lgth in meters of straight Ø 80 Ø 80 Ø 80 Ø 80 Ø 80 Ø 80 Ø 00 Ø 00 Ø 00 Ø 00 Ø 00 Ø 00 pipes) * Available connection types * See next page to calculate the Flue pipe pressure drop. ** A C5 connection of the HeatMaster TC boilers requires an optional accessory. - P - C(x) - C(x) - C4(x) - C5(x)** - C6(x) - C8(x), C9(x) It is mandatory to vtilate the boiler room. The high or low air vt oping dimsions depd on the boiler power and the boiler room size. Refer to the local regulations in force. FLUE PIPE CONNECTION TP P: It is mandatory to use AC flue systems to connect the appliance. : 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. C(x) : Connection using pipes fitted with a horizontal terminal that simultaneously takes in combustion air for the burner and discharges combustion products outside through opings that are either conctric or close ough together to be subjected to similar wind conditions, i.e. opings shall fit inside a square of 50 cm for boilers up to 70 k and inside a square of 00 cm for boilers above 70 k. C(x) : Connection using pipes fitted with a vertical terminal that simultaneously takes in fresh air for the burner and discharges combustion products outside through opings that are either conctric or close ough together to be subjected to similar wind conditions, i.e. opings shall fit inside a square of 50 cm for boilers up to 70 k and inside a square of 00 cm for boilers above 70 k. C4(x) : Connection using two pipes to a collective duct system serving more than one appliance; this system of collective ducts features two pipes connected to a terminal unit that simultaneously takes in fresh air for the burner and discharges the combustion products outside through opings that are either conctric or close ough together to be subjected to similar wind conditions. C4(x) boilers are suitable for a connection to a natural draught chimney only. C5(x) : Connection to separate ducts for supplying combustion air and discharging combustion products; these ducts may d in zones with differt pressure levels, but are not allowed to be installed on opposite walls of the building. C6(x) : Type C boiler meant to be connected to a system for supplying combustion air and discharging combustion products, that is approved and sold separately (Prohibited in some countries (e.g. elgium) - 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 00 Pa. Maximum allowable pressure differce betwe combustion air inlet and flue gas outlet (including wind pressures) is as follows: 95 Pa (HM 5 TC), 0 Pa (HM 5-45 TC), 0 Pa (HM 70 TC), 60 Pa (HM 85 TC) and 70 Pa (HM 0 TC). Condsate flow is allowed into the appliance. Maximum allowable recirculation rate of 0% under wind conditions. C8(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 AC represtative for the meters of flue pipes that can be used to connect the appliance(s). C 4 C 4 C9(x) : Connection using an individual system whose combustion product exhaust duct is installed in an exhaust duct that is integral with the building. The appliance, the exhaust duct and the terminal units are certified as an inseparable assembly. Minimum usable diameter for the vertical duct supplying the combustion air is 00 mm. C C 4 C 4 C The C9 configuration ables airtight operation in a pre-existing chimney. The combustion air crosses the space betwe 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 equivalt to the area that would have be provided by separate conctric ducts or air intake ducts. C P C 9 C 4 C 4 C 5 HeatMaster TC : A D

24 TECHNICAL CHARACTERISTICS CALCULATION OF THE FLUE PRSURE DROP IN THE FLUE PIP h connecting the flue pipes, make sure not to exceed the maximum flue pressure drop value, recommded for the product, otherwise the system pressure might decrease. The flue pipe dimsions can be calculated using the method shown below. Please refer to the tables below indicating the pressure drop values, applied to each of the connection componts. Th compare the calculation result to the recommded maximum flue pressure drop indicated in the table on previous page. Conctric flue pipe Ø 80/5 mm Flue pressure drop values (Pa) Conctric flue pipe Ø 00/50 mm HM 5 TC HM 5 TC HM 45 TC HM 70 TC HM 85 TC HM 0 TC m straight pipe elbow elbow ertical terminal Horizontal terminal Pressure drop for pipes equipped with a measuremt unit is equal to pressure drop for a meter pipe Example of verification of the pressure drop for a specific lgth of conctric flue pipes for a HeatMaster 5 TC (80/5) - The method is explained through an example. Figure : The assembly is comprised of: pipe with a measuremt unit + x 90 elbows + 6 meters of straight pipes + x 45 elbows + vertical terminal. 000 mm 000 mm Method : a) Calculate the pressure drop (Pa) of the whole flue pipe assembly, taking the values from the above table:.0 + ( x 5.) + (6 x.0) + ( x.6) +.5 = mm 000 mm b) Compare the resulting value with the recommded value (0 Pa). The pressure drop for this flue pipe lgth is within the recommded range. Fig. HeatMaster TC : A D

25 TECHNICAL CHARACTERISTICS CASCA : CALCULATION OF THE MAXIMUM LGTH OF FLUE PIP HeatMaster TC cascade in a chimney connection configuration HeatMaster 5-5 TC cascade in a C4 chimney connection configuration Elbow type L. Eq. L. Eq. 45 [M] [M] Qty Appliance type* Maximum lgth in M. Dn 50 Dn 50/00** Dn 00 HM TC HM 0 TC 0 0 HM TC HM 70 TC HM 85 TC HM 0 TC HM TC HM 70 TC 0 0 HM 85 TC 0 0 HM 0 TC HM TC HM 70 TC 0 0 HM 85 TC 6 0 HM 0 TC HM 5-5 TC HM 45 TC HM 70 TC 0 HM 85 TC HM 0 TC * This table is for systems comprised of boilers with idtical power. For any other configuration, please refer to your AC represtative. **Dn 50/00 : Hor. = 50 mm, ert.=00 mm HeatMaster TC : A D

26 TECHNICAL CHARACTERISTICS ELECTRICAL CHARACTERISTICS HEATMASTER TC HeatMaster TC Main Characteristics Rated voltage ~ Rated frequcy Hz Electrical consumption Max Min Electrical consumption at 0% load Electrical consumption in standby Rated currt (Fuse) A Class IP 0 IP 0 IP 0 CALE ROUTING These grommets are intded for low voltage electrical wires (e.g. NTC ssors, etc.) These grommets are intded for high voltage electrical wires (e.g. boiler and pump power supply) Key. 0 power supply plug. Ground. ON/OFF master switch 4. Gas valve rectified 5. urner power supply 6. Terminal block for optional items : Alarm (ERR) 7. Terminal block for optional items: 0 AC OUTPUT! : DH circuit circulator pump (DH) : Pump (P and P4 terminals) 0 AC OUTPUT! : Flame terminal (versatile connection according to configuration) 8. Modulating pump PM 9. urner PM plug 0. NTC5 flue gas temperature ssor. NTC return ssor. NTC supply ssor. NTC - Low temperature circuit For low temp circuit operation, black wires from X, terminals & 6 must be routed to X0, terminals & High limit switch 5. Low water pressure ssor 6. PC (Display) 7. ACMax programmation plug 8. A & Modbus (option) 9. NTC DH ssor 0. NTC4 outdoor temperature ssor (option). Room thermostat (option). 0-0 olt (option). Room thermostat (option) 4. Connection for interface control unit 5. Ignition and ionization cable 6. 5AT slow-blow fuse (x) for internal and optional circuits* * 5AT slow-blow fuse (x) for internal circuits and connection of CH, DH and Flame output + 5AT slow-blow fuse (x) for connection of Alarm, P and P4 (connector P4) spare 5AT slow-blow fuses are located on the back side of the electrical box, for fuse replacemt, if required. 4 HeatMaster TC : A D

27 TECHNICAL CHARACTERISTICS 0 /Gr r X00 /Gr P4 FL 0 P r r /Gr r X00 8 PUMP PM M C /Gr r k r R k NTC 5 0 NTC R R NTC 4 5 X0 k k R r k R k R k Or k k Or k R Harness code: A k r /Gr /Gr r X X r Or k /Gr F00 X0 X X9 P4 P X X AC Max X X X5 4 X6 4 ON / OFF r /Gr r N L N L /Gr r 0 ~ 50Hz N L 5 /Gr /Gr /Gr /Gr /Gr /Gr /Gr /Gr /Gr k k k k R k. lue k. lack r. rown G. Grey O. Orange R. Red. iolet. hite /Gr. ellow/gre /Gr Or r /Gr 5AT Fuse 5AT Fuse 5AT Fuse 6 X8 X7 X4 X6 X us A us - Ground us NTC NTC olt - Input 0-0 olt - Ground X0 HeatMaster TC : A D 5

28 TECHNICAL CHARACTERISTICS ELECTRICAL CHARACTERISTICS HEATMASTER TC HeatMaster TC Main Characteristics Rated voltage ~ 0 0 Rated frequcy Hz Electrical consumption Electrical consumption at 0% load Electrical consumption in standby Max Min Rated currt (Fuse) A 6 6 Class IP 0 IP 0 Key. 0 power supply plug. Ground. ON/OFF master switch 4. Gas valve 5. urner power supply 6. Terminal block for optional items : Alarm (ERR terminal) 7. Terminal block for optional items: : DH circuit circulator pump (DH terminal) : Pump (P and P4 terminals) 0 AC OUTPUT! : Flame terminal (versatile connection according to configuration) 8. urner PM plug 9. NTC5 flue gas temperature ssor 0. NTC return ssor. NTC supply ssor. Gas pressure switch. NTC - Low temperature circuit For low temp circuit operation, black wires from X, terminals & 6 must be routed to X0, terminals & High limit switch 5. Low water pressure ssor 6. PC (Display) 7. ACMax programmation plug 8. A & Modbus (option) 9. NTC DH ssor 0. NTC4 outdoor temperature ssor (option). Room thermostat (option). 0-0 olt (option). Room thermostat (option) 4. Ignition and ionization cable 5. Connection for Interface Control Unit (option) 6. 5AT slow-blow fuse (x) for internal and optional circuits* 7. Modulating pump PM 0 AC OUTPUT! * 5AT slow-blow fuse (x) for internal circuits and connection of CH, DH and Flame output + 5AT slow-blow fuse (x) for connection of Alarm, P and P4 (connector P4). spare 5AT slow-blow fuses are located on the back side of the electrical box, for fuse replacemt, if required. 6 HeatMaster TC : A D

29 0 /Gr r X00 /Gr r r 4 5 X0 k k R r R K R k k k Or k R Harness code: A00 k X F00 X0 X X9 P4 P X X AC Max X X X5 5 X6 4 ON / OFF r /Gr r N L N L /Gr r N L 0 ~ 50Hz 4 /Gr /Gr /Gr /Gr /Gr /Gr /Gr Or /Gr /Gr 7 X /Gr /Gr TECHNICAL CHARACTERISTICS 0 P4 FL P /Gr r PUMP PM M /Gr k C r R k NTC 5 9 NTC 0 R R NTC Or k k k k R k. lue k. lack r. rown G. Grey O. Orange R. Red. iolet. hite /Gr. ellow/gre K r /Gr /Gr r X r r r Or k /Gr 5AT Fuse 5AT Fuse 5AT Fuse 6 X8 X7 X4 X6 X us A us - Ground us NTC NTC olt - Input 0-0 olt - Ground X0 HeatMaster TC : A D 7

30 TECHNICAL CHARACTERISTICS ELECTRICAL CHARACTERISTICS HEATMASTER 0 TC HeatMaster TC Main Characteristics 0 Rated voltage ~ 0 Rated frequcy Hz 50 Electrical consumption Max. 7 Min. 70 Electrical consumption at 0% load 74 Electrical consumption in standby 4 Rated currt (Fuse) A 6 Class IP 0 Key. 0 power supply plug. Ground. ON/OFF master switch 4. Gas valve 5. urner power supply 6. Terminal block for optional items : Alarm (ERR terminal) 7. Terminal block for optional items: : DH circuit circulator pump (DH terminal) : Pump (P and P4 terminals) 0 AC OUTPUT! : Flame terminal (versatile connection according to configuration) 8. urner PM plug 9. NTC5 flue gas temperature ssor 0. NTC return ssor. NTC supply ssor. Gas pressure switch. NTC - Low temperature circuit For low temp circuit operation, black wires from X, terminals & 6 must be routed to X0, terminals & High limit switch 5. Low water pressure ssor 6. PC (Display) 7. ACMax programmation plug 8. A & Modbus (option) 9. NTC DH ssor 0. NTC4 outdoor temperature ssor (option). Room thermostat (option). 0-0 olt (option). Room thermostat (option) 4. Ignition and ionization cable 5. Connection for Interface Control Unit (option) 6. 5AT slow-blow fuse (x) for internal and optional circuits* 7. Modulating pump PM 0 AC OUTPUT! * 5AT slow-blow fuse (x) for internal circuits and connection of CH, DH and Flame output + 5AT slow-blow fuse (x) for connection of Alarm, P and P4 (connector P4). spare 5AT slow-blow fuses are located on the back side of the electrical box, for fuse replacemt, if required. 8 HeatMaster TC : A D

31 TECHNICAL CHARACTERISTICS /Gr r X00 P4 FL P /Gr r r /Gr r X00 PUMP PM M 7 C /Gr k r R k NTC 5 9 NTC 0 R R NTC 4 5 X0 k Or k k k k R k. lue k. lack r. rown G. Grey O. Orange R. Red. iolet. hite /Gr. ellow/gre k R K R K R k k k Or k R 5 4 k L N L N r /Gr /Gr r r r r r Or k /Gr F00 X0 X X9 P4 P X X AC Max X X X X6 4 ON / OFF r /Gr r N L N L /Gr r N L 0 ~ 50Hz /Gr /Gr /Gr /Gr /Gr /Gr /Gr r Or /Gr /Gr /Gr /Gr Harness code: A X0 X AT Fuse 5AT Fuse 5AT Fuse 6 5 X8 X7 X4 X6 X us A us - Ground us NTC NTC olt - Input 0-0 olt - Ground X0 4 6 HeatMaster TC : A D 9

32 TECHNICAL CHARACTERISTICS HDRAULIC CHARACTERISTICS HEATMASTER TC Main Characteristics Capacity (primary) L Capacity (DH) L ater pressure drop (primary circuit) (Δt = 0 K) mbar HDRAULIC PRSURE DROP CURE OF THE OILERS HeatMaster TC DH PERFORMANCE Domestic hot water performance* (cold drink water at 0 C) Operating conditions at 80 C HM 5 TC HM 5 TC HM 45 TC 40 C [ T = 0 K] L/h 788,04,90 Constant flow at 45 C [ T = 5 K] L/h ,9 60 C [ T = 50 K] L/h C [ T = 0 K] L/ Peak flow at 45 C [ T = 5 K] L/ C [ T = 50 K] L/ C [ T = 0 K] L/60,08,8,60 Peak flow st hour at 45 C [ T = 5 K] L/60 865,7,66 60 C [ T = 50 K] L/ Reheat time from 0 C to 80 C min. 5 6 DH efficicy at T = 0 K % Pressure drop (mbar) Perte de charge (mbar) HeatMaster 45 TC 0 8 HeatMaster 5 TC 6 4 HeatMaster 5 TC ater flow rate (l/h) Domestic hot water performance* (cold drink water at 0 C) Operating conditions at 80 C HM 70 TC HM 85 TC HM 0 TC 40 C [ T = 0 K] L/h,087,54,40 Constant flow at 45 C [ T = 5 K] L/h,789,7,98 60 C [ T = 50 K] L/h,5,50, C [ T = 0 K] L/ Peak flow at 45 C [ T = 5 K] L/ C [ T = 50 K] L/ C [ T = 0 K] L/60,455,895,60 Peak flow st hour at 45 C [ T = 5 K] L/60,08,456, C [ T = 50 K] L/60,9,68,847 Reheat time from 0 C to 80 C min. 7 4 DH efficicy at T = 0 K % HeatMaster 0 TC HeatMaster TC Perte de charge (mbar) MAXIMUM OPERATING CONDIONS Maximum Service Pressure (tank full of water) * - Primary circuit :... bar - DH circuit : bar Pressure drop (mbar) HeatMaster 85 TC HeatMaster 70 TC Maximum Operating Temperatures - Maximum temperature (primary) :...87 C - Maximum temperature (DH) : C ater Quality See "Recommdations for the Prevtion of Corrosion and Scaling in Heating Systems" on the following page Débit (litres/heure) ater flow rate (l/h) * The hydraulics of the boiler have be tested according to -550, and the boiler is classified as a pressure class appliance. 0 HeatMaster TC : A D

33 TECHNICAL CHARACTERISTICS RECOMMDATIONS FOR THE PRETION OF CORROSION AND SCALING IN HEATING SSTEMS How oxyg and carbonates can affect the heating system Oxyg and dissolved gasses in the water of the primary circuit contribute to the oxidation and the corrosion of the system componts that are made of ordinary steel (radiators,...). The resulting sludge is th deposited in the boiler 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 boiler 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 oxyg and carbonates in the heating circuit The primary circuit is a closed circuit; the water it contains is therefore isolated from the mains water. h maintaining the system or filling up the circuit, water rewal results in the addition of oxyg and carbonates in the primary circuit. The larger the water volume in the system, the larger the addition. Hydraulic componts without an oxyg barrier (PE pipes and connections) admit oxyg into the system. Prevtion Principles. Clean the existing system before installing a new boiler - efore the system is filled, it must be cleaned in accordance with standard 46. Chemical cleaning agts can be used. - If the circuit is in bad condition, or the cleaning operation was not efficit, or the volume of water in the installation is substantial (e.g. cascade system), it is recommded to separate the boiler from the heating circuit using a plate-to-plate exchanger or equivalt. In that case, it is recommded to install a hydrocyclone or magnetic filter on the installation side.. Limit the fill frequcy - Limit fill operations. In order to check the quantity of water that has be added into the system, a water meter can be installed on the filling line of the primary circuit. - Automatic filling systems are not recommded. - If your installation requires frequt water refilling, make sure your system is free of water leaks. - Inhibitors may be used in accordance with standard Limit the presce of oxyg and sludge in the water - A deaerator (on the boiler flow line) combined with a dirt separator (upstream of the boiler) must be installed according to the manufacturer's instructions. - AC recommds using additives that keep the oxyg in solution in the water, such as Fernox ( and Stinel ( products. - The additives must be used in accordance with the instructions issued by the manufacturer of the water treatmt product. 4. Limit the carbonate conctration in the water - The fill water must be softed if its hardness is higher than 0 fh (, dh). - Check regularly the water hardness and ter the values in the service log. - ater hardness table : ater hardness fh dh mmolca(hco) / l ery soft Soft Fairly hard Hard ery hard > 4 >.5 > Control the water parameters - In addition to the oxyg and the water hardness, other parameters of the water must be checked. - Treat the water if the measured values are outside the range. Acidity 6,6 < ph < 8,5 Conductivity Chlorides Iron Copper < 400 μs/cm (at 5 C) < 5 mg/l < 0,5 mg/l < 0, mg/l HeatMaster TC : A D

34 TECHNICAL CHARACTERISTICS G REQUIREMTS AND GUIDANCE - UK O Discharge pipe from safety valves The uilding Regulation G requires that any discharge from an unvted 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 requiremts and guidance notes of uilding Regulation G. The G Requiremts and Guidance sections are detailed below. For discharge pipe arrangemts not covered by G Guidance advice should be sought from your local uilding Control Officer. Main characteristics : Any discharge pipe connected to the pressure relief devices (Expansion alve and Temperature/ Pressure Relief alve) must be installed in a continuously downward direction and in a frost free vironmt. ater may drip from the discharge pipe of the pressure relief device. This pipe must be left op to the atmosphere. The pressure relief device is to be operated regularly to remove lime deposits and to verify that it is not blocked. A typical discharge pipe arrangemt is shown on next page. Geral remarks Discharge pipe-work D can now be a plastic pipe but only pipes that have be tested to a minimum 0 C must be used. Discharge pipe D can now be plumbed into the soil stack but only soil stacks that can handle temperatures of 99 C or greater should be used. Extract from The uilding Regulation G : Discharge pipe D.50 Safety devices such as temperature relief valves or combined temperature and pressure and pressure relief valves (see paragraphs. or.8) should discharge either directly or by way of a manifold via a short lgth of metal pipe (D) to a tundish..5 The diameter of discharge pipe (D) should be not less than the nominal outlet size of the temperature relief valve..5 here a manifold is used it should be sized to accept and discharge the total discharge from the discharge pipes connected to it..5 here valves other than the temperature and pressure relief valve from a single unvted hot water system discharge by way of the same manifold that is used by the safety devices, the manifold should be factory fitted as part of the hot water storage system unit or package. Tundish.54 The tundish should be vertical, located in the same space as the unvted hot water storage system and be fitted as close as possible to, and lower than, the valve, with no more than 600mm of pipe betwe the valve outlet and the tundish. Note: To comply with the ater Supply (ater Fittings) Regulations, the tundish should incorporate a suitable air gap. UK.55 Any discharge should be visible at the tundish. In addition, where discharges from UK safety devices may not be appart, e.g. in dwellings occupied by people with impaired vision or mobility, consideration should be giv to the installation of a suitable safety device to warn wh discharge takes place, e.g. electronically operated. Discharge pipe D.56 The discharge pipe (D) from the tundish should: (a) have a vertical section of pipe at least 00mm long below the tundish before any elbows or bds in the pipework; and (b) be installed with a continuous fall thereafter of at least in The discharge pipe (D) should be made of: (a) metal; or (b) other material that has be demonstrated to be capable of safely withstanding temperatures of the water discharged and is clearly and permantly marked to idtify the product and performance standard (e.g. as specified in the relevant part of S 79).58 The discharge pipe (D) should be at least one pipe size larger than the nominal outlet size of the safety device unless its total equivalt hydraulic resistance exceeds that of a straight pipe 9m long, i.e. for discharge pipes betwe 9m and 8m the equivalt resistance lgth should be at least two sizes larger than the nominal outlet size of the safety device; betwe 8 and 7m at least sizes larger, and so on; bds must be tak into account in calculating the flow resistance. See figure, table and the worked example..59 here a single common discharge pipe serves more than one system, it should be at least one pipe size larger than the largest individual discharge pipe (D) to be connected..60 The discharge pipe should not be connected to a soil discharge stack unless it can be demonstrated that that the soil discharge stack is capable of safely withstanding temperatures of the water discharged, in which case, it should: (a) contain a mechanical seal, not incorporating a water trap, which allows water into the branch pipe without allowing foul air from the drain to be vtilated through the tundish; (b) be a separate branch pipe with no sanitary appliances connected to it; (c) if plastic pipes are used as branch pipes carrying discharge from a safety device they should be either polybutale (P) to Class S of S 79-:006 or cross linked polyethyle (PE-X) to Class S of S 79-:006; and (d) be continuously marked with a warning that no sanitary appliances should be connected to the pipe. Note:. Plastic pipes should be joined and assembled with fittings appropriate to the circumstances in which they are used as set out in S ISO here pipes cannot be connected to the stack it may be possible to route a dedicated pipe alongside or in close proximity to the discharge stack. Termination of discharge pipe.6 The discharge pipe (D) from the tundish should terminate in a safe place where there is no risk to persons in the vicinity of the discharge..6 Examples of acceptable discharge arrangemts are: (b) to a trapped gully with the d of the pipe below a fixed grating and above the water seal; (c) downward discharges at low level; i.e. up to 00mm above external surfaces such as car parks, hard standings, grassed areas etc. are acceptable providing that a wire cage or similar guard is positioned to prevt contact, whilst maintaining visibility; and (d) discharges at high level: e.g. into a metal hopper and metal downpipe with the d of the discharge pipe clearly visible or onto a roof capable of withstanding high temperature discharges of water and m from any plastic guttering system that would collect such discharges. HeatMaster TC : A D

35 TECHNICAL CHARACTERISTICS.6 The discharge would consist of high temperature water and steam. Asphalt, roofing felt and non-metallic rainwater goods may be damaged by such discharges. UK orked example of discharge pipe sizing Figure on the left shows a G/ temperature relief valve with a discharge pipe (D) having 4 No. elbows and lgth of 7m from the tundish to the point of discharge. From Table: UK temperature relief valve to tundish Maximum resistance allowed for a straight lgth of mm copper discharge pipe (D) from a G/ temperature relief valve is 9.0m. 600mm maximum Tundish Subtract the resistance for 4 No. mm elbows at 0.8m each =.m Therefore the permitted lgth equates to: 5.8m 5.8m is less than the actual lgth of 7m therefore calculates the next largest size. 00mm minimum Maximum resistance allowed for a straight lgth of 8mm pipe (D) from a G/ temperature relief valves equates to 8m. Subtract the resistance of 4 No. 8mm elbows at.0m each = 4.0m Therefore the maximum permitted lgth equates to: 4m Metal discharge pipe (D) tundish with continuous fall. See.56, Table G and worked example Figure G: Typical discharge pipe arrangemt Discharge below fixed grating (.6 gives alternative points of discharge) Fixed grating Trapped gulley As the actual lgth is 7m, a 8mm (D) copper pipe will be satisfactory. Esstial recommdations for safety The temperature/pressure relief valve should only be replaced by a compett 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 adjact to any electrical componts Table G Sizing of copper discharge pipe D for common temperature relief valve outlet sizes alve outlet size Minimum size of discharge pipe D Minimum size of discharge pipe D from tundish mm Maximum resistance allowed, expressed as a lgth of straight pipe (i.e. no elbows or bds) Up to 9m Resistance created by each elbow or bd. 0.8m G½ 5mm 8mm Up to 8m.0m 5mm Up to 7m.4m 8mm Up to 9m.0m G¾ mm 5mm Up to 8m.4m 4mm Up to 7m.7m 5mm Up to 9m.4m G 8mm 4mm Up to 8m.7m 54mm Up to 7m.m HeatMaster TC : A D

36 INSTALLATION SAFET INSTCTIONS FOR THE INSTALLATION Geral remarks The connections (electrical, flue pipe, hydraulic) must be carried out in accordance with local standards and regulations in force. If the water drawing off point is far from the tank, installing an auxiliary DH loop can allow to get hot water more quickly at all times. Esstial recommdations for the correct operation of the appliance The boiler must be installed in a dry and protected area, with an ambit temperature comprised betwe 0 and 45 C. Install the appliance to sure easy access at all times. To avoid any risk of corrosion, connect the stainless steel DH production tank directly to the earth. Make sure that the mains water used to fill the boiler has a minimum pressure of. bar. Make sure to install a pressure reducing valve set at 4.5 bar if the mains supply pressure is in excess of 6 bar. The DH circuit must be fitted with an approved safety group, comprised of a 7 bar safety valve, a check valve and a shut-off valve. If works need to be performed (in the boiler room or close to the air vts), make sure to turn off the boiler to prevt dust from tering and accumulating in the boiler heating system. Esstial recommdations for safety Install the boiler on a base made of non-combustible materials. Do not store any corrosive products, paint, solvts, salts, chloride products and other detergt products near the appliance. Make sure that all air vts are unobstructed at all times. A condsation outlet connected to the sewer must be fitted close to the boiler to prevt the condsation products from the flue pipe from running into the boiler. Install a condsate neutralisation system if required by national and/or local regulations and have it cleaned regularly. The horizontal flue pipes must be installed with a slight slope of 5 cm per meter, so that the acid condsation water flows to a condsate recovery container and does not damage the heating body. Only use AC flue systems to connect this appliance to sure that the pipe and connection diameters all match. Hot water can cause scalding! In the evt of small amounts of hot water repeatedly being drawn off, a stratification effect can develop in the tank. The upper hot water layer may th reach very high temperatures. The temperature of the domestic hot water can be adjusted up to 75 C in the boiler. However, the temperature of the domestic hot water at the drawing off point must comply with local regulations. AC recommds using 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 DH tank and the hot water distribution network. ater heated to wash clothes, dishes and for other uses can cause serious burns. In order to avoid exposure to extremely hot water that can cause serious burns, never leave childr, old people, disabled or handicapped people in the bath or shower alone. Never allow young childr to turn on the hot water or fill their own bath. Esstial recommdations for the electrical safety Only an approved installer is authorized to carry out the electrical connections. Install a -way switch and a fuse or circuit breaker of the recommded rating outside the appliance, so as to be able to shut power down wh 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 intded for use by persons (including childr) with reduced physical, ssory or mtal capabilities, or lack of experice and knowledge, unless supervised or unless they have be giv instruction concerning the use of the appliance by a person responsible for their safety. * For UK specific requiremts for the discharge from safety valves, refer to «G Requiremts and Guidance - UK Only» on page. 4 HeatMaster TC : A D

37 INSTALLATION PACKAGE CONTTS The HeatMaster TC boilers are delivered assembled and packaged. At product reception and after removal of packaging, check the package contts and that the appliance is free of damages. Contts oiler Installation, Operation and Maintance Instructions Installer's Handbook on electronic support Orifice for the natural gas to propane conversion + sticker all condsate trap to be installed. Safety valve kit to be installed, comprised of: A primary safety valve Ø /" F HeatMaster TC : A D 5

38 INSTALLATION TOOLS REQUIRED FOR THE INSTALLATION HDRAULIC CONNECTIONS Geral remark The circuit illustrations are basic principle diagrams only. Esstial recommdations for safety The hot water output may reach temperatures in excess of 60 C, which can cause scalding! It is therefore necessary to install a thermostatic mixing valve after the appliance. The system must be fitted with an approved safety group, comprised of a 7 bar safety valve, a check valve and a shut-off valve.* GAS pressure (mbar) OILER PREPARATION efore placing the boiler in its final position, install: The ball condsate trap The safety valve kit : Primary circuit safety valve at the back of the boiler Esstial recommdations for the correct operation of the appliance Flush the system before connecting the domestic hot water circuit. Refer to the installation instructions. Make sure to install a pressure reducing valve set at 4.5 bar if the mains supply pressure is in excess of 6 bar. It is recommded to install an expansion vessel in the DH circuit to prevt the safety valve from oping 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 sufficit). Typical installation with internal DH tank DH CONNECTION Description. Isolating valve. Pressure reducing valve. Check valve 4. DH expansion vessel 5. Safety valve 6. Drain valve 7. Grounding 8. Draw-off tap 9. Thermostatic mixing valve Cold water Hot water 6 7 Fit the condsate trap, complete with the ball, making sure to install the items in the correct sequce and connect the hose to the drain using a connection that can be inspected. Fill the trap with clean water. Make sure to prevt any risk of the condsates freezing. * For UK specific requiremts for the discharge from safety valves, refer to «G Requiremts and Guidance - UK Only» on page. 6 HeatMaster TC : A D

39 INSTALLATION HEATING CONNECTION Typical connection - low temperature Typical connection - high temperature Description. Isolating valve. Heating pump. Filling valve 4. Check valve 5. Safety valve 6. Expansion vessel 7. Drain valve 8. Automatic air vt (built-in) 8 5 Description. Isolating valve. -way mixing valve. Heating pump 4. Safety valve 5. Filling valve 6. Check valve 7. Expansion vessel 8. Drain valve 9. Automatic air vt (built-in) Cold water Hot water 8 Cold water Hot water Optional accessories to control a regular low temperature heating circuit.for more information, refer to the Installer's Handbook. Optional accessories to control a regular high temperature heating circuit.for more information, refer to the Installer's Handbook. Accessory Room thermostat Description Accessory Room thermostat Description Contact thermostat Low temperature kit DN 5 (HM 5 / 5 / 45 TC) Mandatory to protect all floor heating circuits. Includes a heating pump, two isolating valves, a check valve, two thermometers, a -way valve with built-in bypass and a servomotor. High temperature kit DN 5 (HM 5 / 5 / 45 TC) Includes a heating pump, two isolating valves, a check valve and two thermometers. Low temperature kit DN (HM 70 / 85 / 0 TC) Includes a heating pump, two isolating valves, a check valve, two thermometers and a -way valve with built-in bypass. High temperature kit DN (HM 70 / 85 / 0 TC) Includes a heating pump, two isolating valves, a check valve and two thermometers. Servomotor Motor for the -way valve provided with the low temperature kit. For additional system configurations, refer to "Configuration and system set-up" on page 40 and to the Installer's Handbook. HeatMaster TC : A D 7

40 INSTALLATION REMOAL AND INSTALLATION OF THE ONT AND TOP PANELS GAS CONNECTION Set-up conditions External power supply isolated Removal Procedure Upper front panel. Release two bolts (), one on the left and one on the right. Retain for reinstallation. Pull the top of the panel towards you to disgage the upper studs. Lower front panel. Release two bolts (), one on the left and one on the right. Retain for reinstallation. Pull the bottom of the panel towards you to disgage the lower studs. Top panel Esstial recommdations 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. The gas burners are factory preset for use with natural gas [equivalt to G0]. The natural gas to propane conversion or the reverse is not authorized in certain countries such as elgium. Refer to the table of gas categories in the technical characteristics of this manual. The CO, gas flow rate, air flow rate and air/gas supply parameters are factorypreset and may not be modified in elgium, except for type I E(R) boilers. Do not change the OFFSET (A) setting of the gas valve: it is factory-preset and sealed. A. Release 7 screws and retain them for reinstallation.. Remove top panel. Installation procedure Top panel. Put top panel in position on the boiler.. Install and tight 7 screws. HeatMaster TC HeatMaster 0 TC Lower front panel. Push panel in position, gaging the studs in their corresponding slots until a click is heard.. Install both bolts () and tight them. Upper front panel. Push panel in position, gaging the studs in their corresponding slots until a click is heard.. Install both bolts () and tight them. Follow-on tasks None Esstial recommdations for the correct operation of the appliance Refer to the technical characteristics of this manual or to the burner documtation to know the connection diameters. leed the gas duct and check thoroughly if all the boiler tubes, both internal and external, are tight. Check the system gas pressure. Refer to the table containing all relevant data in the section "Technical characteristics". Check the boiler electrical connection, the boiler room air vt system, the tightness of flue gas outlet pipes and of the burner chamber plate. Control the gas pressure and consumption at appliance start up. Check the boiler CO adjustmt (refer to the adjustmt procedure and the technical data). 8 HeatMaster TC : A D

41 INSTALLATION CONERSION TO PROPANE Geral remark According to the indication on the type plate, the boiler is factory preset to operate with natural gas (G0/G5). Converting the boiler to propane is done through the installation of an orifice and adjustmts. The conversion is prohibited in elgium. Set-up conditions External power supply isolated Gas supply closed Upper front panel and top panel of the boiler op, refer to Removal and Installation of the Front and Top Panels on page 8 Procedure of orifice installation (HM TC). Unscrew the gas pipe.. Remove the plug from the gas valve ().. Disconnect the air inlet () from the vturi (). 4. Remove the gas valve/vturi assembly by releasing two screws (5). Retain the screws for reinstallation. 5. Remove the gas valve () from the vturi () by releasing screws (4). Retain the screws for reinstallation. 6. Install the orifice in the cter of the O-ring (6). Make sure you position the O-ring correctly. Follow-on tasks Stick the sticker provided with the conversion kit on the boiler and check the box to indicate the type of gas to be now used with the boiler. Reconnect the gas pipe connection. Reconnect the plug(s) to the gas valve (). Restart the boiler. Change the boiler code through the Installer mu, refer to the Installer s handbook Carry out the CO adjustmt, (refer to Checking and Adjusting the urner on page 4). Reseal the offset and the throttle on the gas valve (), as required Reassemble the gas valve/vturi assembly, following the same procedure in reverse order, and torque the gas valve screws (4) and the vturi screws (5). Refer to "Torque alues" on page 47. HeatMaster TC 8. Reinstall the air inlet (). Procedure of orifice installation (HM 0 TC) 4. Remove the plugs from the gas valve ().. Unscrew the union (4) of the gas pipe.. Release 4 screws from the gas pipe flange () and retain for reinstallation. 4. Install the orifice in the flange (). HeatMaster TC Propane orifice dia. (mm) Make sure you position the orifice correctly (shouldered face turned towards the gas pipe, flat face turned towards the gas valve). 5. Install the O-ring () on the flange Install the flange () on the gas valve () using 4 retained screws. HeatMaster 0 TC HeatMaster TC : A D 9

42 4 CONFIGURATION AND SSTEM SET-UP ASIC CONFIGURATION - HEATMASTER 5 TC 5: HIGH TEMPERATURE HEATING CIRCU CONTROLLED ROOM THERMOSTAT AND OPTIONAL OUTDOOR SSOR. EM SCRIPTION QT ELECT. TERMINALS TO CONNECT TO** Room thermostat X6 &4 X6 NTC 4 0 Outdoor temperature ssor, kω X6 & circuit manifold : Max power : 70 k, ith builtin wall mounts. -- High temperature kit : Includes: a circulator pump, two isolation valves, a check valve and two thermometers. X /Gr r 0 ACMax y-pass kit : To read the flow rate more easily. To be installed in the HT or LT circuit, as required. X00 to 8 -- LOCK DIAGRAM The heating system (radiators) is controlled by an On/Off room thermostat. EZ Setup In this configuration, the boiler constantly adapts its operation to the outdoor temperature, if an outdoor temperature ssor is connected. The heating pump is triggered as soon as the room thermostat gerates a heat demand. The priority of the internal domestic hot water tank of the boiler (DH circuit not shown here) is always active. Heating EZ Setup Select CH Demand * The illustrations are for information only. For more details on the required accessories, refer to the latest AC price list. Thermostat & Outd. Curve Constant & Outdoor Curve Constant & Setpoint 0-0 Modulation Signal ** For electrical detail, refer to wiring diagram in Electrical Characteristics HeatMaster TC on page HeatMaster TC : A D

43 CONFIGURATION AND SSTEM SET-UP CASCA CONFIGURATION, CONTROLLED E CONTROLLER The control Unit (E Controller) is used to control a HeatMaster TC Cascade. The connection is made through the E Clip-in wiring provided with the Control Unit. Please connect on ACMax board X8 and route wires through X0, terminals and 4 as shown below. Existing wiring (low temperature circuit ssor) is to be disconnected first. X k R k k k R k k k Or k R X X X5 4 X6 Max E Clip-in wiring 4 X8 k R X7 X4 X6 4 us A us - Ground us NTC NTC For additional information and specific system configurations, please contact your AC represtative. HeatMaster TC : A D 4

44 STARTING UP SAFET INSTCTIONS FOR STARTING UP Geral remark FILLING THE SSTEM Put the DH tank under pressure before pressurizing the heating (primary) circuit. In normal operation, the burner starts automatically as soon as the boiler temperature drops below the preset temperature. Set-up conditions External power supply isolated Esstial recommdations for safety The componts 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. DH circuit filling procedure. Op the isolating valves () and the drawoff tap ().. Once the water flow rate has stabilized and the air is totally evacuated from the system, close the draw-off tap (). TOOLS REQUIRED FOR STARTING UP. Check all the connections for leaks. Cold water Hot water Heating circuit filling procedure GAS pressure (mbar). Op boiler front panel (refer to applicable procedure in the manual).. Op the isolating valves ().. Make sure that the drain valve () is tightly closed. CHECKS EFORE STARTING UP Esstial recommdation for safety 4. Op the filling valve (). 5. Once the system is bled from air, bring the pressure to the static pressure betwe.5 bar and bar. 6. Close the filling valve (). Check the tightness of the flue pipe connections. Esstial recommdation for the correct operation of the appliance 7. Disconnect filling device from water supply.* Follow-on tasks Control the tightness of the hydraulic circuit connections.. Check there is no leak. * UK specific referce G4. & G4. of the ater Regulations Guide. 4 HeatMaster TC : A D

45 STARTING UP STARTING UP THE OILER Set-up conditions All connections made Gas conversion carried out as required Condsate trap full of water Electrical power supply on Gas supply op Hydraulic circuit(s) full of water Procedure. Check that there is no gas leak.. Push in the ON/OFF master switch ( ).. If a room thermostat is installed, possibly increase the temperature set-point to gerate 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 Checking and Adjusting the urner on page Set the ctral heating temperature to the required value using the control panel. Refer to oiler Setup 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.5 bar pressure. 8. leed the ctral heating circuit once again and top it up with water to get the required pressure, if necessary. 9. Make sure that the ctral heating system is properly balanced and, if needed, adjust the valves to prevt certain circuits or radiators from getting a flow rate that is far above or below the set rate. CHECKING AND ADJUSTING THE URNER h the burner operates at full power, the CO rate must be within the limits mtioned in the technical characteristics, (see Combustion characteristics on page 0). Set-up conditions Operating boiler Procedure. Check if the ACMAX parameters are set to meet the user's requiremts (refer to oiler Setup Guide on page 8), and change them if required.. Put the boiler to maximum power mode (Refer to the Installer s Handbook).. Using a pressure tester, check that the dynamic gas pressure at the gas valve is at least 8 mbar. 4. Allow the appliance to heat for a few minutes until it reaches at least 60 C. 5. Measure the burner combustion by placing the flue gas analyzer probe in the measuremt unit port on the flue pipe and compare the CO and CO values displayed with those indicated in the combustion characteristics table. 6. If the CO value differs by more than 0.%, carry out the adjustmt mtioned in the procedure below. 7. Th put the boiler to the minimum power mode (Refer to the Installer's Handbook provided with the boiler). Allow the boiler to stabilize for a few minutes. 8. Measure the CO level. It must be equal to the value at full power, or lower than that value by 0.5% maximum. If there is a significant deviation, please contact AC's maintance departmt. CO adjustmt procedure To adjust the CO rate, rotate the throttle screw () : to the left (counterclockwise) to increase the CO. rate. to the right (clockwise) to decrease the CO. rate. Follow-on tasks. Close the heating circuit filling valve and disconnect the filling connection as required.. Check that there are no leaks.. Check that the flow rate in the appliance is sufficit as follows : Operate the boiler at maximum power Once the temperatures are stable, read out the supply and return temperatures Check that the differce betwe the supply and return temperature is equal or less than 0k. If the Delta T is higher than 0k, check the pump settings/specifications. HeatMaster TC HeatMaster 0 TC The CO adjustmt screw () of the HM 0 TC is a worm screw, whose rotation in a direction causes the CO rate to cyclically increase to the maximum, th decrease to the minimum, th increase again, and so on. To adjust, monitor the value change on the analyzer to determine whether the rotation in the selected direction causes the CO value to increase or decrease. Follow-on tasks None HeatMaster TC : A D 4

46 MAINTANCE SAFET INSTCTIONS FOR THE OILER MAINTANCE PERIODIC OILER MAINTANCE TASKS Esstial recommdations for the electrical safety 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 measuremts or perform system setup. Esstial recommdations for safety Tasks Periodic inspection End-user Frequcy year years Professional ater flowing out of the drain valve may be extremely hot and could cause severe scalding. Check the tightness of the flue pipe connections.. Make sure that the system water pressure is at least bar wh cold. Top up the system if necessary, adding small quantities of water at a time. In case of repeated fills, call your installer. X X Esstial recommdations for the correct operation of the appliance. Check that there is no water on the floor under the boiler. Call your installer if there is. X X It is recommded to have the boiler and the burner serviced at least once a year or every,500 hours. More frequt servicing may be required depding on boiler use. Please consult your installer for advice. The boiler and burner maintance will be carried out by a qualified gineer, and the defective parts may only be replaced by guine factory parts. Control the tightness of the hydraulic circuit connections. Make sure to replace the gaskets of the removed items before reinstalling them. Make sure to apply the correct torque value wh tighting componts. Refer to "Torque alues" on page 47. TOOLS REQUIRED FOR MAINTANCE. Check that no error code is displayed on the control panel. Call your installer if necessary. 4. Check that all gas, hydraulic and electrical connections are correctly fasted and tight. 5. Check the flue gas exhaust: correct fasting, 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 CO), see Checking and Adjusting the urner on page 4. X X X X X X 8. Check visually the heating body: no evidce of corrosion, soot deposits or damages. Carry out all required cleaning tasks, repairs and replacemts that might be required. X 9. Check the electrode, see Removal, Check and Installation of the urner Electrode, page 45. X GAS pressure (mbar) 0. Remove the burner and clean the exchanger, see Removal and Installation of the urner, page 46 and Cleaning the Exchanger on page 48. X OILER SHUT DON FOR MAINTANCE. Switch the boiler off using the ON/OFF master switch and isolate the external power supply.. Close the gas supply valve of the boiler.. Check that the condsate trap is not clogged. If it is, remove it, clean it, and reinstall it i.a.w. oiler preparation on page 6.. If a condsate neutralisation system is installed, check it and have it cleaned. X X X 44 HeatMaster TC : A D

47 MAINTANCE DRAINING THE OILER Esstial recommdations for safety efore draining the DH tank, drain the heating (primary) circuit or bring its pressure to 0 bar. ater 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 oiler switched off using the ON/OFF master switch External power supply isolated Fuel/gas supply closed Heating circuit draining procedure. Close the isolating valves ().. Connect the drain valve () to the sewer with a hose.. Op the drain valve () to empty the heating circuit of the boiler. 4. Close the drain valve () once the heating circuit of the boiler is empty. DH circuit draining procedure Cold water Hot water REMOAL, CHECK AND INSTALLATION OF THE URNER ELECTRO Esstial recommdations for the correct operation of the appliance Remove the electrode to control it in case of ignition problems. Set-up conditions oiler shut down External power supply isolated Gas supply closed Top panel op, refer to Removal and Installation of the Front and Top Panels on page 8. Removal procedure. Disconnect the electrode grounding cable from the electrode.. Disconnect the electrode ignition cable from the electrical box.. Remove two mounting screws () and retain them for reinstallation. 4. Remove the electrode () and the gasket (). 5. Check the correct alignmt of the electrode ds 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. Install a new gasket ().. Install the electrode () using the two screws (), torque i.a.w. Torque alues on page 47. Follow-on tasks. Reconnect the grounding cable to the electrode.. Reconnect the ignition cable to the electrical box. efore draining the DH tank, make sure that the heating (primary) circuit pressure is null.. Op fully a draw-off tap () for about 60 minutes to make sure that the DH tank has cooled down.. Close the isolating valves ().. Connect the drain valve () to the sewer with a hose. 4. Op the drain valve () and drain the DH tank water to the sewer. 5. Op the draw-off tap () to accelerate the draining process. If it is located lower than the tank connection, op a draw-off tap located higher in the system. 6. Close the drain valve () and the draw-off tap () once the DH tank of the boiler is empty. HeatMaster TC Min. mm Max. 4 mm HeatMaster TC HeatMaster TC : A D 45

48 MAINTANCE REMOAL AND INSTALLATION OF THE URNER Set-up conditions oiler shut down External power supply isolated Gas supply closed Front and top panels removed (refer to Removal and Installation of the Front and Top Panels on page 8). Electrode removed or electrode grounding cable and ignition cable disconnected (refer to Removal, Check and Installation of the urner Electrode on page 45). 0 Removal procedure. Disconnect all plugs from the fan assembly () and the gas valve () and any grounding cable, as required.. Disconnect the air inlet elbow ().. Release the gas connection (). 4. Using a socket wrch, 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 If not removed previously, remove, check and reinstall the electrode, refer to Removal, Check and Installation of the urner Electrode on page 45. Installation procedure. Reinstall the burner assembly with its insulation block into the exchanger.. Install the retaining screws of the burner hood (8) and fast them in a crosswise pattern at the required tighting torque (refer to Torque alues on page 47).. Reconnect the gas connection (). 0 9 HeatMaster TC h connecting the air inlet, make sure that the check valve (4) is correctly located at the elbow () d. 4. Reconnect the air inlet elbow (). 5. Reconnect the plugs to the gas valve () and the fan assembly (), and any disconnected grounding cable Follow-on tasks. Install the electrode, or reconnect the electrode grounding cable and ignition cable, as required. Refer to Removal, Check and Installation of the urner Electrode on page HeatMaster TC 46 HeatMaster TC : A D

49 MAINTANCE TORQUE ALU Tighting torque (Nm) Description Min. Max 0 urner flange screws 5 6 Electrode screws.5 turi screws (except HM 0 TC) Gas valve screws (except HM 0 TC) HeatMaster 0 TC Detail of the burner componts. Gas connection. Gas valve. Air inlet elbow 4. Air inlet check valve 5. turi 6. urner tube 7. Insulation 8. urner hood 9. urner hood insulation 0. Electrode. Fan assembly HeatMaster TC : A D 47