ACV HeatMaster 201

HeatMaster®
Installation, Operating and

Servicing Instructions
HeatMaster® 201
excellence in hot water

20/08/2004 - 66402500
INDEX INTRODUCTION
INTRODUCTION 1 TARGET GROUP

Target group 1 This manual is intended for the use of:
Symbols 1 - final users of the appliance;
Certification 1 - the engineer installing and starting up the appliance;
General information and safety instructions 2 - the engineering and design department;
- the installer responsible for servicing or maintaining the appliance.
USER GUIDE 2
Using the boiler 2 SYMBOLS

Setting the parameters 3
The following symbols are used in these instructions:
DESCRIPTION 4
Operating principle 4
Packing 4
Construction features 4
TECHNICAL SPECIFICATION 6 Essential instruction for operating the system

correctly.
Effective dimensions 6
General characteristics 6
Maximum operating conditions 7
Domestic hot water performances 7
HeatMaster® setting instructions 7
INSTALLATION 8
Boiler room 8
Chimney connections 8
Hot water connections 9 Essential instruction for personal safety or
Heating connection 10 environmental protection.
Electrical connections 10
COMMISSIONING 12
Filling the hot water and heating circuits 12
BURNER FEATURES 12
ACV BG 2000-M modulating premix gas burner 12

Danger of electrocution.
MAINTENANCE 14
Service intervals 14
Servicing the boiler 14
Servicing the safety devices 14
Servicing the burner 14
Draining the boiler 14
MCBA FOR SPECIALISTS: INSTALLER,

SERVICE ENGINEER 15
Pilot mode 15
Safety stop (Error mode) 16
Setting the parameters 17 Risk of scalding.
Entering the code 20
Information on the installation 20
Communication mode (with code) 21
Error mode 21
CERTIFICATION
SPARE PARTS 22 The appliances carry the “CE” mark, in accordance with the
standards in force in the various countries (European Directives
Jackets 22 92/42/CEE “Efficiency” and 90/396/CEE “Gas Appliances”). They
Accessories 22 also carry the labels, “HR+”.
Setting and electrical accessories 22
Burner 22
SERVICE RECORD 23
Installation details 23
Service notes 23
1
INTRODUCTION
GENERAL INFORMATION AND USING THE BOILER

SAFETY INSTRUCTIONS
Starting the burner
IF YOU SMELL GAS: During operation, the burner starts automatically as soon as the
- Immediately shut off the gas supply. temperature of the boiler is below the set point and goes off when
- Ventilate the boiler room. this value is reached.
- Do not use electrical appliances and do not switch anything on or
off. Control panel
- Immediately notify your gas company and/or your installer.
General information Summer/Winter switch

This documentation forms part of the items delivered with the
appliance and must be given to the user to keep in a safe place!
Main switch
This appliance must be serviced and repaired by an approved
installer, in accordance with current standards in force.
Display – MCBA controller
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. Thermostat-pressure gauge
Temperatures
This boiler is designed for central heating systems

with a maximum outlet temperature of 90°C.
Therefore, the central heating pipelines and the
radiators must reach this temperature.
The waste-gas pipe lines must reach

temperatures in excess of 100°C. The user must not attempt to gain access to the components
inside the control panel.
The hot water can reach temperatures in excess
of 60°C.
Heating system pressure
Installation From time to time you may need to top up the heating
system pressure. This pressure is indicated by the combined
temperature and pressure gauge on the boiler control panel.
The minimum pressure when the boiler is cold should be 1 bar. The
Before installing and commissioning the boiler, first precise operating pressure required depends on the height of the
carefully read this manual. building, and your installer will have informed you of this value at the
Position the HeatMaster® according to the safety rules and time of installation (see Commissioning Section - Filling the hot water and
standards in force. You must comply with the ventilation heating circuits).
requirements for the room where appliances of this type are If the pressure falls below 1 bar, the boiler water pressure switch will
installed. All air vents must remain unobstructed at all times. turn the boiler off until pressure is restored.
To re-pressurise, the system needs to be topped up with water.
It is prohibited to modify the interior of the appliance in any way, First, switch the boiler OFF on the on/off switch and isolate the
without the manufacturer’s prior written agreement. external electrical supply. The fill valves A and B are located at the
rear of the HeatMaster® (see photo A and B below). Open both valves
and allow thesystem to fill. When the combined temperature and
Service
pressure gauge shows the required pressure, close both valves.
In order to ensure the appliance operates safely and correctly, it is
Replace the casing top front panel. Restore the power supply and
important to have it serviced and reconditioned every year by an
switch the boiler on.
installer or an approved service company.
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. (See
also the list of faults on page 16)
Only genuine factory parts may be used as replacement parts.

Please go to page 22 for a list of spare parts and their ACV
reference numbers.
A B
Note: ACV reserves the right to change the technical characteristics

and specification of its products without notices. Safety Valves
If water discharges from any of the safety valves, switch the boiler
off and call a service engineer.
2
USER GUIDE
SETTING THE PARAMETERS Setting the temperature of the hot water
Stand by mode
1X 1X
Mode Store
1X 2X
Stand
by
mode
Step Mode
1X
Setting the temperature of the hot water: Store
(Temperature of the hot water)

- Press “Mode”: “PARA” comes up on the screen.
- Press “Step”: the first digit is 1 and the last two digits indicate the
current temperature setting for the hot water.
- To change this temperature, press the “+” or “-” keys until the Enabling and disabling hot water mode
temperature indicated by the last two digits is the desired
temperature. Stand by mode
- Press “Store” to save the setting.
- Press “Mode” twice to return to Standby mode (normal operating 1X 1X
mode).
Mode Store
2X 2X
Stand
Enabling and disabling hot water mode: by
(hot water) Mode
mode
Step
- Press “Mode”: “PARA” comes up on the screen. 1X
- Press “Step” twice: the first digit is 2 and the last two digits
indicate the current setting: Store
00 = disabled; 01 = enabled.
- To change this parameter, press the “+” or “-” keys until you reach
the desired value:
- Press “Store” to save the setting. Enabling and disabling central heating mode
- Press “Mode” twice to return to Standby mode (normal operating
mode).
Stand by mode
Enabling and disabling central heating mode: 1X 1X

(heating)
- Press “Mode”: “PARA” comes up on the screen. Mode Store
- Press “Step” three times: the first digit is 3 and the last two digits 3X 2X
Stand
indicate the current setting: by
mode
00 = disabled; 01 = enabled. Step Mode
1X
- To change this parameter, press the “+” or “-” keys until you reach
the desired value:
Store
- Press “Store” to save the setting.
- Press “Mode” twice to return to Standby mode (normal operating
mode).
Setting the temperature of the central heating: Setting the temperature of the central heating
(the maximum temperature for the heating circuit)
- Press “Mode”: “PARA” comes up on the screen. Stand by mode
- Press “Step” four times: the first digit is 4 and the last two digits
1X 1X
indicate the current temperature setting for the central heating.
- To change this temperature, press the “+” or “-” keys until the
Mode Store
temperature indicated by the last two digits is the desired 2X
4X Stand
temperature. by
- Press “Store” to save the setting. Step Mode
mode
- Press “Mode” twice to return to Standby mode (normal operating 1X
mode).
Store
Fault:
The temperature setting of the appliance and the safety functions of its
parts are constantly monitored by a microprocessor controller (MCBA).
In the event of a fault, this MCBA disables the appliance and displays
an error code: the screen flashes and the first character is an “E”
Fault Reset the appliance
followed by the fault code, (see the list of faults on page 16).
Reset the appliance:

- Press “Reset” on the screen.
- If the fault code appears again, contact your installer.
Status T°
1 Reset
3
DESCRIPTION
OPERATING PRINCIPLE CONSTRUCTION FEATURES
The HeatMaster® is a high performance, direct fired hot water Outer body
storage heater, which has indirect heat transfer due to its Tank-in- The outer body containing the primary fluid is made of thick STW 22
Tank construction. steel.
At the heart of the HeatMaster® is a stainless steel cylinder through TANK-IN-TANK heat exchanger
which the flue tubes pass. This is surrounded by a mild steel shell The ring-shaped inner tank with its large heating surface for
containing the primary water (neutral fluid). The outer shell extends producing domestic hot water is built of Chrome/Nickel 18/10
down to the combustion chamber and even around the flue tubes. stainless steel. It is corrugated over its full height by an exclusive
The area of the heat transfer surface is therefore much greater than production process and entirely argon arc welded by the TIG
that of standard direct fired water heaters. (Tungsten Inert Gas) method.
A circulating pump fitted to the primary circuit moves the water Combustion gas circuit
around the tank, heating it faster and maintaining an even The combustion gas circuit is paint-protected and comprises:
temperature across the primary jacket.
• Flue pipes
The burner heats the primary water, which indirectly heats the The HeatMaster® 201 range has 15 steel flue ways with an
stainless steel tank containing the hot water. As in all Tank-in-Tank inside diameter of 64 mm. Each flue way has turbulators
systems, the tank is corrugated over its full height and suspended in made of special stainless steel designed to improve the heat
the HeatMaster® by its hot- and cold water connections. exchange and reduce the flue-gas outlet temperature.
The cylinder expands and contracts during use and this, together
with the fact that cold water does not come into contact with the • Combustion chamber
intense heat of the burner flame, means that limescale buildup is The combustion chamber on HeatMaster® models is entirely
prevented. water cooled.
This scale resistant feature, along with the corrosion resistance of Insulation
stainless steel, eliminates the need for sacrifical anodes. The boiler body is fully insulated by rigid polyurethane foam with a
high thermal insulation coefficient, sprayed on without the use of
The HeatMaster® has one very major advantage over other direct CFCs.
fired water heaters - because it heats the DHW with a primary
circuit, this primary water can be used to provide central heating as Casing
well. The boiler is covered by a steel jacket which has been scoured and
phosphated before being stove enamelled at 220°C.
By connecting two, three, four or more HeatMaster® together in a
module, most hot water and heating demands can be met. Burner
Models in the 201 range are always delivered with an ACV
Indeed, when used in conjunction with HR and Jumbo hot water BG 2000-M 201 air-gas premix burner.
storage tanks the HeatMaster® can supply even the largest hot
water requirement.
Standard equipment
The HeatMaster® 201 includes the following parts as standard:
- On/off switch
- Summer/Winter switch
- MCBA controller, including
• an electronic controller
• a low-water-level safety device
• a burner modulator
- 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 4 separate packages.
• Package No. 1: Foam-insulated body, hydraulic accessories,

and control panel.
• Package No. 2: Chimney reducing pipe.
• Package No. 3: The jacket.
• Package No. 4: The burner and its cover, the door insulation
and the sealing cord.
4
DESCRIPTION
“Tank-in-Tank” type storage

exchanger Turbulators
Heating outlet
Flue ways
Stainless steel pocket
Primary circuit
Heating return
Combustion chamber
Boiler drain cock
NTC 3 sensor Hot water outlet
Chimney reducer
Cold water inlet
Steam trap
NTC1 and NTC2 sensor

T&P valve (optional)
Insulation
Thermostat-pressure gauge bulb
Low-water-level pressure switch
Flange of the burner chamber plate
5
TECHNICAL SPECIFICATION
F
EFFECTIVE DIMENSIONS
338
The appliances delivered are factory-tested. Upon receipt, remove the packing and check that there is no damage to the appliances. Refer to the
dimensions and weights listed below for transport purposes.
The jacket is fitted by the installer on site (see the assembly instructions in the wooden protective case).
302 250
G 506
F
338 C
250
D
302 250
190
506
C
H
250
E F
338
190
302
G 506
E
A
C
250
D
B
190
A mm B mm C mm D mm E mm F mm G mm H mm
HeatMaster® 201 2085 300 1020 1320 1020 600 1383 590
GENERAL CHARACTERISTICS
Type HM 201
Fuel Natural gas/propane
Heating Hot water
Maximum Input kW 60 - 220 60 - 240
Maximum Output kW 56.4 - 200.2 56.4 - 218.4
Maintenance loss at 60°C as rated value % 0.3
Total capacity L 641
Primary circuit capacity L 241
Heating connection Ø 2”
Hot water connection Ø 2”
Chimney connection Ø mm 250
Hot water tank heat exchange surface m2
5.30
Weight empty Kg 550
Pressure drop primary circuit mbar 240
6
TECHNICAL SPECIFICATION
MAXIMUM OPERATING CONDITIONS HEATMASTER® SETTING INSTRUCTIONS
Maximum service pressure (tank full of water) Description

- Primary circuit: 3 bar The HeatMaster® 201 range is equipped with an electronic
- Secondary circuit: 10 bar controller (MCBA) which controls the burner (start-up, safety, and
modulation) and allows the controller to be adapted to the selected
Test pressure (tank full of water) application.
- Primary circuit: 4.5 bar
- Secondary circuit: 13 bar The MCBA system includes a controller with 3 levels for setting the
parameters: manufacturer, installer, and user. It includes 3
Operating temperature temperature sensors located in the primary and secondary circuits.
- Maximum temperature: 90°C
Water quality There are two operating modes:

• Chlorures: < 150 mg/l (304)
< 2000 mg/l (Duplex) 1. Heating mode
The T° is set by the user in the range 60 to 90°C.
• 6 ≤ ph ≤ 8
• Differential “ON” starts the burner.

• Differential “OFF” stops the burner.
• PI controller (Proportional Integral) in “Heating” mode.
DOMESTIC HOT WATER PERFORMANCES • The controller compares the primary temperature with the
setting and the module.
HM 201
The room thermostat detects the demand for heat.
Peak delivery at 40°C L/10’ 1745
Peak delivery at 45°C L/10’ 1489 2. Hot water mode (with priority to the hot water)
The T° is set by the user in the range 60 to 90°C.
Peak delivery at 70°C L/10’ 763 The sensor located in the secondary tank detects the demand for
hot water.
Peak delivery at 80°C L/10’ 586 As soon as the draw-off is detected, the controller goes to “demand
for hot water” mode:
Peak delivery at 40°C L/60’ 6690 • Differential “ON” starts the burner.
• Differential “OFF” stops the burner.
• PI controller (Proportional Integral) in “Hot water” mode.
Peak delivery at 60°C L/60’ 3534 • The controller compares the primary temperature with the
setting and the module.
• The charging pump starts up.
Peak delivery at 80°C L/60’ 1723 • The heating circulator pump is no longer supplied.
• The burner starts and the controller controls the modulation
based on the primary pump.
Continuous delivery at 40°C L/h 6117
Continuous delivery at 45°C L/h 5039 Parameters accessible by the user
Continuous delivery at 60°C L/h 2914 1. “Hot water” temperature, which can be set to 20 - 90°C.
2. Hot water mode ON/OFF.
Continuous delivery at 70°C L/h 2128 3. Heating mode: ON/OFF.
Continuous delivery at 80°C L/h 1468 4. “Heating” temperature, which can be set to 60 - 90°C.
N.B.: Parameters accessible for “service”

The outputs above are given for a hot water temperature of 90°C and Main basic characteristics:
a cold water temperature of 10°C. - Hot water priority active.
- Demand for heat detected by the room thermostat.
- Only one heating circuit.
An access code is required to access “Service” parameters.
Please see pages 17 to 19 for further details.
7
INSTALLATION
BOILER ROOM
Note:
Important Regulations vary from country to country therefore
• Keep vents free at all times. the table above is intended only as a guide.
• Do not store inflammable products in the boiler room.
• Do not store corrosive products near the boiler, such as paints,
solvents, chlorine, salt, soap and other cleaning products.
• If you smell gas, do not switch on the light or light a flame. Turn off Due to the high efficiency of our boilers, the flue gasses
the mains gas tap at the meter and inform the appropriate exit at low temperature. Accordingly, there is risk that
services immediately. the flue gasses could condense, which could damage
the chimney. In order to avoid this risk, it is strongly
recommended that the chimney be lined.
Access
The boiler room must be large enough to allow good access to the
boiler. The following minimum distances are required around the Connecting the boiler to an air vent type: C
boiler: • C53: parallel connection
total loss of pressure (air intake + flue-gas discharge) may not exceed
- front 500 mm 250 Pa. See the table below showing the pressure drops for the various
- side 100 mm components.
- behind 150 mm
- above 350 mm
A condensation drain outlet must be fitted close to the

Ventilation boiler to prevent condensation products from the
The boiler room must have both low- and high-level ventilation, chimney running into the boiler.
in accordance with the local standards and provisions force.
The table below gives an example conforming to the Belgian standards. To avoid condensation water running out of the
terminal, all horizontal flue runs must fall back towards
Ventilation 201 the boiler.
Min. fresh air requirement m /h
3
436
Bottom dm 2
2.45
Top dm 2
7.30 A. Top vent
B. Bottom vent
C. Draught regulator
Other countries should refer to their own standards. D. Inspection window
E. Height of lined chimney
Base F. Chimney diameter
The base on which the boiler rests must be made of non-combustible F
materials.
CHIMNEY CONNECTIONS
C53 A
IMPORTANT
Boilers must be installed by an approved heating
engineer, in accordance with the prevailing local E
standards and regulations.
A
B23 A
C53
C
The duct size may not be smaller than the boiler outlet
duct.
Typical boiler connection: B23 D

B
The boiler is connected to the chimney by a metal pipe rising at an

angle from the boiler to the chimney.
A flue disconnection piece is required. Air Flue gas
This must be easy to remove to give access to the flue pipes when Ø 100 mm Ø 250 mm
servicing the boiler. Pipe, L. 1000mm 18.0 1.0
90° bend 70.0 3.0

Chimney / minimum flue diameter 201
45° bend 28.0 -
E=5m Ø F min. mm 350 Condensates trap - 5.0
E = 10 m Ø F min. mm 300 Terminal 50.0 3.0
E = 15 m Ø F min. mm 270
When connecting the flue gas outlet to an existing

chimney, do not take into account the pressure drop
on the “flue gas side”.
8
INSTALLATION
HOT WATER CONNECTIONS Example of parallel connection

Recommended for applications with a high continuous flow.
Pressure reducing valve
If the mains water pressure is greater than 6 bar, a pressure reducing
valve must be fitted.
Expansion relief valve

The tank expansion relief valve must be ACV approved and
calibrated to a maximum of 7 bar. The valve discharge must be
connected to the drain.
Hot water expansion vessel

A hot water expansion vessel must be installed.
Hot water circulation

If the tank is situated a long way from the point of use, then installing
a recirculation loop can provide a faster supply of hot water to the
outlets.
Temperature and pressure relief valve

If using the HeatMaster as an unvented hot water unit, in some
countries, a temperature and pressure relief valve must be fitted -
consult your ACV stockist for assistance.
Example of hot water connection Example of series connection

with thermostatic mixer Preferable for high temperature applications with up to three units.
1. Stop cock
2. Non-return valve
3. Pressure reducing valve
4. Expansion relief valve
5. Hot water expansion vessel
6. Hot water secondary pump (it fitted)
7. Thermostatic mixing valve
8. Drawoff tap
9. Drain cock
10. Stop cock for cleaning
11. Temperature relief valve (UK-only)
2 6
8
3
1 2 7
10
4
11
5
Example of heating + storage connection

Recommended for applications requiring a high peak flow.
DANGER!
As a safety measure, we strongly advise
installing a thermostatic mixer to prevent the
risk of burns.
9
INSTALLATION
HEATING CONNECTION ELECTRICAL CONNECTIONS

The HeatMaster® has two connections at the rear that can be used Electrical supply
to connect a central heating circuit. Connecting a heating system The boiler operates on a single-phase supply of 230V/50Hz. You
may reduce the domestic hot water performance. should install a control box with a double-pole switch and a 6 A fuse
or a 6A circuit breaker externally to the boiler to allow the boiler to
be isolated from the power supply for servicing and repairs.
WARNING
The power supply to the heating pump for the MCBA is
limited to 250W. In the event of a higher wattage,
Conformity
provide a relay between the pump and the MCBA.
Boiler installation must comply with the prevailing local standards and
legislation.
Expansion
The HeatMaster® 201 models are equipped with 4 8-litre expansion
Safety
vessels. These expansion vessels are sized for hot water operation
The stainless steel tank must be earthed separately.
only. If a heating system is connected to the primary circuit, calculate
the expansion capacity necessary for the total volume of the heating
system. (Refer to the technical instructions from a relevant manufacturer of
expansion vessels).
The power to the boiler must be switched off before
any work is carried out.
Example of a single circuit connection
1. 4-way valve
2. Heating pump
3. Non-return valve
4. Isolating valves HeatMaster® 201 wiring diagram key
5. Safety valve set to 3 bar with pressure gauge
6. Expansion vessel
01. Main switch
7. Drain cock
02. Module AM3-11
8. MCBA controller, module AM3-11
03. Module AM3-2
9. Surface-mounted sensor (optional)
04. MCBA
05. 24V transformer
06. Display
07. Room thermostat
08. Low-water-level safety device
09. NTC1 primary temperature sensor
10. NTC2 primary temperature sensor
11. NTC3 hot water temperature sensor
12. NTC4 outdoor sensor (optional)
13. Summer/Winter switch
14. NTC6 heating outlet sensor (optional)
8 15. Communication bus
16. Heating circulator pump (not supplied)
17. Heating circulator pump (not supplied) for use with 3-way power-
operated valve
18. Charging pump
5 19. Charging pump
20. 3-way power-operated valve
21. Alarm switch
22. Outside gas valve/burner operation switch
1 9 4 23. Hot water mode operating switch
6
24. Fan (BG 2000-M / 201)
7 25. Gas valve (BG 2000-M / 201)
26. Gas pressure switch (BG 2000-M / 201) (optional)
3 2 4 27. Charging circulator pump control relay
Note: The switches have zero voltage.
WARNING
The pimary safety valve is supplied with a plastic tube
connected to the discharge outlet - this is for test
purposes only and should be removed. The safety
valve should be connected to a drain using a metallic
pipe eg. copper.
WARNING
In the case of heating at low temperature, the use of
the kit (code: 10800099) is required.
10
X1 01 HeatMaster® 201 wiring
Br Bk
L 01
B B
N 02 B. Blue
03 Br. Brown
Bk
Pk X1.1 Bk. Black
X1.2
X7
X2 Bk Or. Orange
W X2.1
Bk X2.2 G. Grey
01 Bk 02
B R X3.1
R. Red
02 X3.2
AM3 - 11 W. White
03 Y. Yellow
16 Or
M1 M 04 V. Violet
B R
05 X1.1
W
X1.2
X7
06 Y
Pk X2.1
17 M G X2.2
14 x 0,25mm2
M2 07
B Pk 03
08 X3.1
Or
X3.2
09 27 AM3 - 2
G 2 1
18 M3 M 10
B 4 3 X3
11
Bk
X1.1 X7 01
12
Y 6 5
B V
19 X1.2 X2.8 02
M4 M 13
B G t 07
B 14 13 X1.3 X2.10 03
14
Or
X1.4 G 04
15 04
W G 08
X1.5 X2.9 05
A2 A1 W MCBA
X1.6
P
06
16
W R
X3.1 07 09
17
B Br
N X3.2 08
20 M5 M 18 X10 Or 10
R X3.3 09 11
19
B
X3.5 10
R W 11
20 X2.4 13
21 W V 12
21 X2.3
R 13
Y X2.2
Bk 12
22
Bk X3.4 14
22 G X2.1 Br
23
Br X4.3 15
X2.11 B 14
Pk B X4.2 16
24 X2.12 X7
23 Or W
X5.1 17 BUS A
25
V 15
Or X5.2 18 BUS B
X2.6
X4
3 x 0,75 Bk G 06
2 L1
3
2 1
1 B
3 N
24 W 14 x 0,25mm2
2 T1
1 V
2 1 T2
3 R
4 5 S3
5 Bk 2 x 2 fils
4 B4
4 x 0,75
X5
2 x 0,75 Br
B5
25 B
T6 05
G
T7
26 Or
T8
BG 2000-M/201
11
INSTALLATION
COMMISSIONING BURNER FEATURES
FILLING THE HOT WATER AND HEATING CIRCUITS ACV BG 2000-M MODULATING PREMIX GAS
BURNER
Description and operating method:

IMPORTANT
The BG 2000-M modulating burner's output is constantly adjusted to
Hot water tank must be pressurised before the heating
suit the fluctuating demand for heat, thus optimising operating
circuit is filled.
efficiency.
The gas tube is covered with a metal fibre (NIT), which, in addition to
its outstanding heat-exchange properties, increases its life.
1. Close the primary circuit filling valves (A and B)
2. Open the stop valve (1) and the draw-off tap (8). Fill the tank
The main parts are a venturi and a valve, a unit developed specially
with the water from the tap; close the draw-off tap (8).
by Honeywell for low NOx air/gas premix burners with automatic
3. Fill the primary (heating) circuit by opening the valves (A and B)
ignition and flame detection by ionisation.
and pressurising to 1 bar.
The pressure at the gas valve outlet is equal to the air pressure in
the neck of the venturi, less the offset. The fan sucks combustion air
through the venturi, into which the gas inlet emerges.
As it passes through, the air produces a pressure differential in the
constriction of the venturi and sucks the gas into the venturi outlet.
A perfect mix of air and gas then passes through the fan to the
burner tube.
This design ensures very quiet and safe operation:

• If there is an air blockage, the pressure differential in the venturi
falls, the gas flow diminshes, the flame goes out and the gas
valve closes: the burner is in safety shutdown mode.
A B
• If there is a blockage in the chimney outlet, the air flow diminishes,
and the same reactions as those described above cause the
2 6
burner to shut down in safety mode.
8
• The BG 2000-M burner on the HeatMaster® 201 is controlled by
3
1 2 7 an MCBA controller (Honeywell), which controls the safety of
10 operation of the burner and its modulation according to the
temperature.
4
11
5
The BG 2000-M burners are factory-set for

natural gas.
Air/gas mixture control system

Venturi Fan
Air Air/gas
mixture
Offset adjuster
screw
9
Gas
Gas flow adjuster

screw
4. Open the automatic air vent located on top of the boiler.

IMPORTANT - the screw cap must be left loose to allow future
automatic venting to take place.
5. After venting the air from the system, bring the pressure up to the
static head plus 0.5 bar: 1.5 bar = 10 m and 2 bar = 15 m.
6. Check that the electrical connection and boiler room ventilation
conform to the relevant standards.
7. Switch the on/off switch to the ON position.
8. Set the temperature values (see page 17).
9. Check the gas supply pressure (see page 13).
10. When the burner is on, check that the flue gas discharge pipes
are completely gas tight.
11. After operating for five minutes, turn off the boiler and drain the
heating circuit again, maintaining a pressure of 1 bar.
12. Turn the appliance back on and check the combustion (see
page 13).
12
BURNER FEATURES
201 gas burner characteristics

Type Heating Hot water
Input Kw 60 - 220 60 - 240
Nominal output Kw 56.4 - 200.2 56.4 - 218.4
Combustion efficiency - natural gas % 96.6 - 91.5 96.6 - 91.5
Natural gas CO2 % 9 9
Pressure loss of the flue-gas circuit mbar 2.4 2.9
Net T° of combusted gases °C 180 190
Mass flow rate of combustion products g/sec. 110.3 120.3
Gas G20 - 20 mbar - I 2E(R)B - I 2 Er - I 2H - I 2E - I 2ELL
Flow m3/h 6.35 - 23.28 6.35 - 25.40
Gas G25 - 20 mbar - I 2ELL / 25 mbar - I 2L
Flow m3/h 7.38 - 27.08 7.38 - 29.54
Gas G31 - 30/37/50 mbar - I 3P
Flow m3/h 2.45 - 9.00 2.45 - 9.81
CO2 % 11.0 - 11.2 11.0 - 11.2
Gas category
BE FR AT DK ES UK IT PT IE SE NL LU DE
I 2Er X
I 2E(R)B x
I 2H X X X X X X X X
I 3P X X X X X X
I 2L X
I 2ELL X
I 2E X
BG 2000-M/201
Burner adjustment
Tube (Prohibited in Belgium).
With the burner operating at full

Flame inspection window power, the CO2 must be in the
Ignition electrode range 8.8 to 9.2 % (natural gas)
or 10.5 to 10.6 % (propane).
If necessary, adjust the CO2 by Increase

Gas valve turning the screw clockwise to
reduce it and counter-clockwise
to increase it. (see photo
opposite).
Ø 5/4” gas supply

flange Fan
Reduce
Venturi
13
MAINTENANCE
SERVICE INTERVALS Draining the boiler’s primary circuit

1. Put the main switch on the control panel to OFF, cut the outside
ACV recommends that boilers should be serviced at least once a year. power supply and close the gas-supply valve to the boiler.
The burner must be serviced and tested by a competent engineer. 2. Close the isolating valves (4) or manually set the 4-way valve (1)
If a boiler is subject to heavy use, it may require servicing more than to “0”.
once a year - consult ACV for advice. 3. Connect a flexible tube to the drain cock (7). Make sure it is
properly connected.
4. Open the drain cock and allow the hot water to flow into the
SERVICING THE BOILER drain.
1. Turn OFF the on/off switch on the boiler control panel and isolate
external electrical supply.
2. Turn off the gas or oil supply to the boiler.
Vertical flue-gas outlet reducer

3. Take down and remove the flue lining to release the top of the
boiler.
4. Loosen the nuts and remove the chimney reducer.
5. Take out the turbulators from the flue ways to clean them. 8
6. Dismantle the chamber plate and remove the burner.
7. Brush the flue ways.
8. Clean the combustion chamber and the burner.
9. Replace the turbulators, the chimney reducer, and the flue lining; 5
check that the seal on the chimney reducer is in good condition.
Replace the seal if necessary.
1 9 4
Horizontal flue-gas outlet reducer 6
3. Loosen the nuts and remove the chimney reduction. 7
5. Take out the turbulators from the flue ways to clean them.
6. Dismantle the chamber plate and remove the burner. 3 2 4
7. Brush the flue ways.
8. Clean the combustion chamber and the burner.
9. Replace the turbulators, the chimney reducer, and the flue lining;
check that the seal between the chimney reducer and the
chimney is in good condition. Replace the seal if necessary. Drain the hot water circuit.
1. Put the main switch on the control panel to OFF, cut the outside
power supply and close the gas-supply valve to the boiler.
SERVICING THE SAFETY DEVICES 2. Release the pressure in the heating circuit until the pressure
gauge reads zero.
3. Close the cocks (1 and 8).
- Check that all thermostats and safety devices are working properly.
4. Open valve (9) and then (10).
- Test the safety valves on the central heating and hot water circuits.
5. Allow the hot water to flow into the drain.
2 6
SERVICING THE BURNER 8
- Check that the insulation and the seal on the chamber plate are in 3
good condition; replace them if necessary. 1 2 7
10
- Check and clean the burner and the electrodes. Replace the
electrodes if necessary (1 x per year in normal usage conditions) 4
- Check that the safety devices are in good working order. 11
5
- Check the combustion (CO2, CO, and gas pressure) and record the
values and any other comments on page 23 of the service record.
DRAINING THE BOILER
Water flowing out of the drain cock may be

extremely hot and could cause severe scalding.
Keep people away from discharges of hot
water.
The drain cock (9) must be at ground level for the

circuit to drain fully.
14
MCBA FOR SPECIALISTS:
INSTALLER, SERVICE ENGINEER
PILOT MODE Once the cause of the blockage has been resolved, the burner starts
automatically within 150 seconds at most.
Pilot mode
After you power down the appliance the screen displays Pilot mode, Status Boiler function
as shown in the figure above.
Internal check — three-way valve
This is the standard MCBA mode. The MCBA automatically returns
to this mode after 20 minutes if no keys have been pressed on the
screen. Any parameters that were modified are then enabled. Boiler burner in hot water ready function
The first character shows the current status of the boiler depending
on the condition of both the boiler and the burner. The last Test function: Central heating high power
2 characters indicate the start temperature.
Test function: Central heating low power
Status Boiler function

Test function: Boiler with fixed number of
revolutions
Pilot, no demand for heat
Fan first, fan after
Ignition
Operation of the boiler burner for the heating
Operation of the boiler burner for the domestic hot

water
Air pressure limit or obtaining the number of start

revolutions.
The burner goes out when the specified value is

reached. A demand for heat is present nonetheless.
Pump over-run time after the demand for domestic

hot water
Pump over-run time after the demand for central

heating
Burner blocked:
• :T1 > 95°C
• :T2 > 95°C
• : T2 - T1 > 10.20 or 40°C after a time of xx
• : dT1/dt > maximum gradient T1
• : water pressure switch not off
• : no fan signal
• : erroneous fan signal
• : T1 - T2 > max Delta
• : NTC3 short-circuit
• : NTC3 interrupt
• : wait for the fan to start
If the burner is blocked for one of the reasons mentioned above, the
screen display alternates between a 9 followed by the temperature
(two last digits) and b with the error code.
15
SAFETY STOP (ERROR MODE)

To unlock the system:
If a fault occurs while the appliance is running, the system locks and • Press RESET on the screen.
the screen starts to flash. The first character is an E and the next two • Contact your installer if the fault happens again.
characters give the code for this fault, as illustratedin the table below.
Table of error codes and how to resolve them
Codes Description of the fault Resolution of the fault
- Check the wiring (short-circuit in the 24V wiring)

Abnormal flame signal
- Check the electrode/ replace the MCBA (water damage).
- Check the ignition cable, the electrode and the

No flame signal after five attempts at firing the boiler position of the electrode.
- Check that there is gas at the burner.
Persistent lock - Press RESET
-If the problem persists after two RESET attempts,

EPROM error
replace the MCBA.
- Check the wiring and check the

Max input, thermostat open or 24V fuse gone.
24V fuse on the MCBA.
- If the problem persists after two RESET attempts,

To Internal error
replace the MCBA.
T1 > 110°C
- Check the NTC wiring and replace if necessary.
T2 > 110°C - Check the NTC wiring and replace if necessary.
- Check that the pump is turning. If there is

T1 gradient too high
no problem with the pump, drain the system.
- If the fan is working:

• Check the fan control connection and the fan wiring
• if the problem persists after 2 RESET attempts, replace the
fan
No fan signal present • if the problem persists, replace the MCBA.
- If the fan is not working:

• Check that the fan 230V connection. If the problem persists,
replace the fan.
- Check the connection and the NTC1 wiring

NTC 1 short-circuit
If the problem persists, replace the NTC1.

NTC 2 short-circuit

NTC 3 short-circuit

NTC 1 connection open


- If the problem persists after two RESET attempts,

Internal error
replace the MCBA.
Error while reading the parameters Press RESET. If the error persists, replace the MCBA.
Check the MCBA power supply voltage. If it is OK, replace

Problem with the power supply to the fan
the fan.
16
SETTING THE PARAMETERS
Parameter mode
To access Parameter mode when the system is in Pilot mode, press MODE once.
To scroll through the list of parameters, simply press “step”. To modify a parameter value, use the + or - keys.
Then press “Store” to save the value you just changed. The screen flashes once to confirm the data has been saved.
To activate the parameters you changed, press “Mode” once more (which brings you into Info mode). However, if you do not press a key, the
system returns to Pilot mode after 20 minutes and automatically enables the changes.
Key Display
MODE
Key Display Description of parameters Factory setting
Adjusting the hot water temperature 90
STEP
00 = Stop
Production 01 = Start
01
of hot water 02 = Stop + pump continuously on
STEP 03 = Start + pump continuously on
00 = Stop
Turn on/Turn off 01 = Start
01
the heating 02 = Stop + pump continuously on
STEP 03 = Start + pump continuously on
Maximum temperature in Central Heating mode 90
STEP
Parameters for the specialist: only accessible by using the Code
Key Screen Description of parameters Factory setting
Minimum central heating temperature when using an outdoor sensor 60
STEP
Minimum outdoor temperature

0
(adjust the heating curve)
STEP
Maximum outdoor temperature

20
(adjust the heating curve)
STEP
Frost protection temperature - 15
STEP
Correction based on the outdoor temperature 00
STEP
Blockage T 0 = Disabled 00
STEP
Booster 00 = Stop (minute) 00
STEP
17
Key Display Description of the parameters Factory setting
Night-time heating temperature reduction (°C) 10
STEP
Fan speed in heating mode (rpm x 100) 52

STEP
Max. fan speed in heating mode (rpm x 100) 00

STEP
Max fan speed in hot water mode (rpm x 100) 57

STEP
Max. fan speed in hot water mode (rpm x 100) 00

STEP
Min. fan speed (rpm x 100) 15

STEP
Min. fan speed (rpm x 100) 00

STEP
Fan speed at ignition (rpm x 100) 37

STEP
Heating pump time delay 0 = 10 sec (minute) 00
STEP
Hot water pump time delay 10.2 = 10 sec (minute) 16
STEP
Burner interlock hysteresis (heating) 00
STEP
Burner trigger hysteresis (heating) 01
STEP
Burner interlock hysteresis (hot water) 01
STEP
Burner trigger hysteresis (hot water) 03
STEP
Hot water mode interlock hysteresis 04
STEP
Hot water mode trigger hysteresis 01
STEP
18
Key Display Description of the parameters Factory setting
Heating lock time (sec x 10.2) 00
STEP
Hot water lock time (sec x 10.2) 00
STEP
Lock time to switch from hot water mode to heating mode (sec x
00
10.2)
STEP
Difference T1 - T2 for modulation 05
STEP
BUS address (-1 = disabled) - 01
STEP
Increase the primary temperature value to generate hot water

05
(relative to the hot water temperature)
STEP
1st digit: heating circuit (AM3-11 – 4-way valve)

0 = disabled 5 = enabled
00
STEP 2nd digit: the demand for heat comes from:
0 = room thermostat
1st digit: Hot water circulator pump (= 1)

12
STEP 2nd digit: tank with NTC3 sensor (= 2)
Manual fan speed (- 01 = modulation) - 01
STEP
1st digit: PWM pump operating speed

11
2nd digit: PWM pump speed during time-delay
STEP
Holding temperature 00
STEP
Maximum temperature for the heating circuit outlet

60
(AM3-11 – 4-way valve)
STEP
Minimum temperature for the heating circuit outlet

30
STEP
Hysteresis of the heating circuit outlet temperature

01
STEP
1st digit: Special pump (0 = disabled)

00
2nd digit: Minimum disable cycle (0 = disabled)
STEP
19
ENTERING THE CODE INFORMATION ON THE INSTALLATION
Code mode Info mode
You can access the following parameters by entering the service To switch from Pilot mode to Info mode, press “Mode” twice.
code:
• Parameters 5 - 42
• Communication mode
• Fan Speed mode Key Display
• ERROR mode
MODE
To access Code mode, press

MODE and STEP simultaneously
MODE
(only from Pilot mode!).
Press “STEP” until the system displays the information you need.
The point located behind the first position flashes to indicate that
the boiler is in “INFO” mode.
MODE STEP
Key Display Description of parameters
Press “STEP” once and the system displays “C” Start temperature T1 in °C
in position 1, followed by arbitrary STEP
characters in positions 3 and 4.
Return temperature T2 in °C
STEP
STEP
Hot water temperature T3 in °C
STEP
Press “+” or “-” to change the code.

Outdoor temperature T4 in °C
STEP
+ or - Not used
STEP
Start temperature calculated in °C

Press “STORE”, the screen flashes STEP
briefly to indicate that the code has been accepted.
Rate of increase in the start

temperature in °C/s
STEP
STORE
Rate of increase in the return

temperature in °C/s
STEP
Press “MODE” until Rate of increase in the hot water

the system displays the correct mode. temperature in °C/s
STEP
Heating circuit outlet temperature

Only ACX authorised installers know the access code. (AM3-11 – 4-way valve)
STEP
For further information, please contact our after-sales
department.
20
COMMUNICATION MODE (WITH CODE) ERROR MODE (WITH CODE)
When in this mode, the system displays the communication between “ERROR” mode indicates the most recent error, as well as the
the boiler and the control module, the optional interface kit or the status of the boiler and its readings at the time this error occurred.
optional programmable room thermostat.
Key Display
Key Display
MODE
MODE

Code mode
(See the table on page 16 for a full list)
No communication STEP
Status of the boiler at the time of the

error (See the table on page 16)
Communication between the boiler
module and the optional control STEP
modules only (RMCI)
STEP
Start temperature T1 at the time of
the error
Communication between all the MODE
devices connected
Return temperature T2 at the time of

the error
STEP
Hot water temperature T3 at the time

FAN MODE (WITH CODE) of the error
STEP
Outdoor temperature T4 at the time of
the error
Fan speed
STEP
MODE
The current fan speed is 5,500 rpm.
STEP Temperature sensor resistance tables
Temp. °C RΩ Temp. °C RΩ
-20 98200 40 6650

-15 75900 45 5520
-10 58800 50 4610
-5 45900 55 3860
0 36100 60 3250
5 28600 65 2750
10 22800 70 2340
15 18300 75 1940
20 14700 80 1710
25 12000 85 1470
30 9800 90 1260
35 8050 95 1100
100 950
21
SPARE PARTS
No. Jackets Codes HeatMaster® 201

A01 Right side 21471415
A02 Left side 21471415
A03 Right side rear corner 21478415
A04 Left side rear corner 21473415
A05 Rear panel 21474415
A06 Right side front corner 21472415
A07 Left front side 21479415
A08 Upper front panel 2147A415
A09 Lower front panel 2147B415
A10 Burner cover 21476415
A11 Rear top cover 21475415
A12 Front top cover 21475416
A13 Rear half-base 2147S415
A14 Unequipped control panel 21477416
A15 Body + accessories (package No. 1) 27300047
No. Accessories
B01 Low-water-level pressure switch 557D3011
B02 Wilo circulator pump 557A4007
B03 3 bar / Ø 3/4” - 1” safety valve 557A1048
B04 Burner chamber insulating cover 51700041
B05 8-l expansion vessel 55301200
B06 Steam trap, Ø 1/2” 557A3001
B07 Drain cock, Ø 3/4” 557A1000
B08 Fill set, Ø 1/2” 55426018
B09 Type A, high-level turbulators 507F2009
B10 Type B, low-level turbulators 507F2010
No. Setting and electrical accessories

C01 MCBA 537D8016
C02 Transformer 547D3021
C03 NTC Duplo (NTC1 - NTC2) 5476G002
C04 NTC Single (NTC3) 5476G003
C05 Module AM3-11 10800080
C06 Module AM3-2 10800060
C07 Full control panel 24614133
C08 Display 537D3020
C09 Display case 537D3023
C10 Pressure gauge-thermometer 54441008
C11 ON/OFF switch 54766016
C12 Summer/Winter switch 54766017
C13 Control panel self-adhesive 617G0105
No. Burner
D01 Full burner 237D0118
D02 Fan 537D3034
D03 Venturi 537D4042
D04 110 x 3.5mm O-ring 557A0045
D05 Plate fan seal 557A0040
D06 Burner chamber plate seal 557A0020
D07 Ø 98mm burner tube + NIT 537DZ019
D08 Chamber plate sealing cord 51700025
D09 Ignition electrode 537DZ020
D10 Ignition cable 25760046
D11 Burner chamber plate insulating stone 51700040
D12 Burner chamber plate 2147P416
D13 Gas valve 537D4041
D14 Valve flange 537D8021
22
SERVICE RECORD
INSTALLATION DETAILS
Service date: Flue gas T°: Model:
% CO2 (min. load): Efficiency: Serial number:
% CO2 (max. load): Gas pressure: Heating system pressure setting:
o Gas
o Propane Name and signature:
SERVICE NOTES
Service date: Flue gas T°: Comments:
% CO2 (min. load): Efficiency:
% CO2 (max. load): Gas pressure:
o Gas
o Gas
o Gas
o Gas
o Gas
23
SERVICE RECORD
o Gas
o Gas
o Gas
o Gas
o Gas
o Gas
24
excellence in hot water
INTERNATIONAL FRANCE SLOVAK REPUBLIC
ACV international n.v ACV FRANCE sa ACV SLOVAKIA s.r.o.
www.acv-world.com KERKPLEIN, 39
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TEL.: +32 2 334 82 20
FAX: +32 2 378 16 49
31, RUE AMPERE - Z.I MI - PLAINE
F-69680 CHASSIEU - FRANCE
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TEL.:+421 2 444 62 276
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E-MAIL: [email protected] E-MAIL: [email protected] E-MAIL: [email protected]
BELGIUM ITALIA SLOVENIA

ACV BELGIUM nv/sa ACV ITALIA ACV D.O.O. SLOVENIA
KERKPLEIN, 39 VIA PANA 92 OPEKARNA 22b
B-1601 RUISBROEK-BELGIUM I-48018 FAENZA (RA) - ITALIA 1420 TRBOVLJE - SLOVENIA
TEL.: +32 2 334 82 40 TEL.:+39 0546 64 61 44 TEL.:+386 356 32 830
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SAN PABLO 3800 POSTBUS 350 ST. DAVID’S BUSINESS PARK
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ACV CR SPOL. s.r.o ACV POLSKA sp. z.o.o. TRIANGLE TUBE PHASE III
NA KRECKU 365 UL.WITOSA 3 FREEWAY CENTER - 1 TRIANGLE LANE
CR-109 04 PRAHA 10 - CZECH REPUBLIC 87 - 800 WLOCLAWEK - POLAND BLACKWOOD NJ 08012 - USA
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HUNT HEATING PTY LTD TERMOX AS PROTHERM HEIZUNGSTECHNIK Gmbh
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HeatMaster®

Installation, Operating and

excellence in hot water

INTRODUCTION 1 TARGET GROUP

Using the boiler 2 SYMBOLS

TECHNICAL SPECIFICATION 6 Essential instruction for operating the system

Filling the hot water and heating circuits 12

ACV BG 2000-M modulating premix gas burner 12

MCBA FOR SPECIALISTS: INSTALLER,

GENERAL INFORMATION AND USING THE BOILER

General information Summer/Winter switch

This boiler is designed for central heating systems

The waste-gas pipe lines must reach

Only genuine factory parts may be used as replacement parts.

Note: ACV reserves the right to change the technical characteristics

SETTING THE PARAMETERS Setting the temperature of the hot water

Setting the temperature of the hot water: Store

(Temperature of the hot water)

Enabling and disabling central heating mode: 1X 1X

Reset the appliance:

OPERATING PRINCIPLE CONSTRUCTION FEATURES

The HeatMaster® is delivered in 4 separate packages.

• Package No. 1: Foam-insulated body, hydraulic accessories,

“Tank-in-Tank” type storage

Stainless steel pocket

Boiler drain cock

NTC 3 sensor Hot water outlet

Cold water inlet

NTC1 and NTC2 sensor

Thermostat-pressure gauge bulb

Low-water-level pressure switch

Flange of the burner chamber plate

MAXIMUM OPERATING CONDITIONS HEATMASTER® SETTING INSTRUCTIONS

Maximum service pressure (tank full of water) Description

Water quality There are two operating modes:

• Differential “ON” starts the burner.

N.B.: Parameters accessible for “service”

An access code is required to access “Service” parameters.

Please see pages 17 to 19 for further details.

A condensation drain outlet must be fitted close to the

Typical boiler connection: B23 D

The boiler is connected to the chimney by a metal pipe rising at an

90° bend 70.0 3.0

When connecting the flue gas outlet to an existing

HOT WATER CONNECTIONS Example of parallel connection

Expansion relief valve

Hot water expansion vessel

Hot water circulation

Temperature and pressure relief valve

Example of hot water connection Example of series connection

Example of heating + storage connection

HEATING CONNECTION ELECTRICAL CONNECTIONS

Note: The switches have zero voltage.

Description and operating method:

This design ensures very quiet and safe operation:

The BG 2000-M burners are factory-set for

Air/gas mixture control system

Gas flow adjuster

4. Open the automatic air vent located on top of the boiler.