ACV Delta Classic Betriebsanleitung

INSTALLATION, OPERATING

AND SERVICING INSTRUCTIONS

DELTA Classic

Combination boiler

with atmospheric burner

ACV reserves the right to modality the technical specifications and components of its products without prior notice. 664Y0100

05/11/2002

1.1 INTENDED USERS OF THESE INSTRUCTIONS

These instructions are intended for:

- the specifying engineer

- the installation engineer

- the user

- servicing technicians

1.2 SYMBOLS

The following symbols are used in these instructions:

Essential instruction for operating the system

correctly.

Essential instruction for personal safety and

environmental protection.

Danger of electrocution.

Risk of burns.

1.3 APPLICABLE STANDARDS

The products have received the “EC” certificate in accordance with the

standards prevailing in different countries (European Directives

90/42/EEC, “efficiency”, 90/396/EEC “gas appliances”). These products

have also received the Belgian “HR+” mark.

1 INTRODUCTION 2

1.1 Intended users of these instructions 2

1.2 Symbols 2

1.3 Applicable standards 2

1.4 Warnings 2

2 INSTALLATION 3

2.1 Boiler room 3

2.2 Connections 3

2.4 Electrical connection 5

3 START-UP 6

3.1 Filling the heating and hot water circuits 6

3.2 Atmospheric burner troubleshooting 6

4 SERVICING 6

4.1 Recommendation 6

4.2 Servicing the gas boiler 6

4.3 Servicing the safety devices 6

4.4 Servicing the burner 7

4.5 Emptying the boiler 7

4.6 Spare parts 7

5 DESCRIPTION 8

5.1 Overview 8

5.2 Description of operation 8

5.3 Design features 9

6 TECHNICAL SPECIFICATION 10

6.1 Effective dimensions 10

6.2 Maximum operating conditions 10

6.3 Domestic hot water performance 10

6.4 Boiler performances 10

6.5 Atmospheric burner 11

7 USER GUIDE 12

7.1 Using the boiler 12

7.2 Boiler room 13

1.4 WARNINGS

These instructions are an integral part of the equipment to which they

refer and must be supplied to the user.

The product must be installed and serviced by qualified engineers, in

compliance with the prevailing standards.

ACV accepts no liability for any damage resulting from incorrect

installation or from the use of components or fittings not specified by

ACV.

Failure to observe instructions regarding tests and test

procedures can result in personal injury or pollution

risks.

Note:

ACV reserves the right to modify the technical specifications and

components of its products without prior notice.

INDEX 1 INTRODUCTION

2.1 BOILER ROOM

2.1.1 ACCESS

The boiler room must be large enough to allow good access to the

boiler. The following minimum distances (mm) are required around the

boiler:

- front 500 - sides 100

- rear 150 - above 700

2.1.2 VENTILATION

The boiler room must be fitted with top and bottom vents according to

the table below.

2.1.3 BASE

The base on which the boiler rests must be made of non-combustible

materials.

2.2 CONNECTION

2.2.1 CHIMNEY CONNECTION

The boiler can be connected to a standard flue that complies with the

regulations in force or is connected to a chimney. It must be easy to

remove to give access to the flue pipes when servicing the boiler.

IMPORTANT

Boilers must be installed by a qualified engineer, in

accordance with the prevailing local standards and

regulations.

2.2.2 CENTRAL HEATING CONNECTION

2.2.2.1 Examples of basic circuit configurations

The drain valve and safety valve must be connected to the sewer

drain.

1. 3-way manual motorisable mixer valve

2. Safety valve pre-set to 3 bar with pressure gauge

3. Circulator

4. Non-return valve

5. System filling valve

6. Expansion tank

7. Room thermostat

8. ACV 13 controller (see controller kit page 5)

9. Central heating isolating valve

10. Drain valve

Fig. 2: Configuration with circulator controlled

by a room thermostat

2 INSTALLATION

Fig. 3: Configuration with motor driven mixer valve

Fig. 1: Boiler room ventilation and chimney connection

A. Top vent

B. Bottom vent

C. Chimney height

D. Chimney diameter

G20 G25 G30-P30

Ventilation

Min. fresh air requirement m3/h 96,6 119,3 140,4

Top vent (A) dm21,5 1,5 1,5

Bottom vent (B) dm21,6 2 2,3

Chimney

C = 5 m Ø min. F mm 153 157 170

C = 10 m Ø min. F mm 153 153 153

C = 15 m Ø min. F mm 153 153 153

2.2.2.2 ACV circulation kit

ACV offers an optional pre-assembled circulation kit comprising:

- a circulator.

- a 3-way manual motorisable valve.

- connecting pipes including a second optional circuit.

- two isolating valves.

- adapters for mounting safety valve and filling valve to right or

left of expansion tank.

2.2.2.3 Discharge

The drain cock and safety valve must be connected to the waste

water system in accordance with current regulations.

2.2.3 DOMESTIC HOT WATER CONNECTION

2.2.3.1 Pressure reducer

If the water mains pressure is greater than 6 bar, a pressure

reducer calibrated to 4.5

bar must be fitted.

2.2.3.2 Safety unit

The tank safety unit must be ACV approved and calibrated to 7

bar.

The valve discharge must be connected to the sewer drain.

2.2.3.3 Hot water expansion tank

Installing a hot water expansion tank avoids any risk of pressure

surges due to water-hammer.

2.2.3.4 Hot water circulation

If the tank is situated a long way from the point of use, then

installing a closed return circuit can provide a faster supply of

hot water always available.

2.2.3.5 Description

1. Safety unit

2. Pressure reducer

3. Thermostatic mixing valve

4. Hot water circulator

5. Non-return valve

6. Hot water expansion tank

7. Inlet valve

8. Draw-off valve

9. Emptying valve

IMPORTANT

As a safety measure against burns, we strongly advise

installing a thermostatic mixing valve (recommended

temperature: 60° C).

Optional fittings available

2 INSTALLATION

Fig. 5a: Configuration without thermostatic mixing valve

Fig. 5b: Configuration with thermostatic mixing valve

Fig. 4: ACV circulation kit assembly

Safety unit Ø 3/4”

Pressure reducer Ø 3/4”

Thermostatic mixer Ø 3/4”

Hot water expansion tank 5 litres

Wiring diagram of ACV controller kits (fig. 7)

2 INSTALLATION

2.3 ELECTRICAL CONNECTION

2.3.1 POWER SUPPLY

The boiler operates with a 230 V - 50 Hz single phase supply. An

on-off switch box with 6 A fuses must be fitted outside the boiler to

allow power to be shut off during servicing and before any repairs are

carried out on the boiler.

2.3.2 COMPLIANCE

Boiler installation must comply with the prevailing local standards and

legislation.

2.3.3 SAFETY

The stainless steel tank must be earthed separately.

2.3.4 BURNER ELECTRICAL CONNECTION

The burner is supplied with power by a 3-core cable.

1. Boiler thermostat (60/90° C)

2. On/off switch

3. Summer/winter selector

4. Thermometer

5. Controller (optional)

6. TTB

7. Cut-off thermostat (95° C max.)

8. Safety thermostat (103° C max.)

9. Plug (power and control)

10. Room thermostat

11. Heating pump connection

12. To gas valve

Fig. 8: Control panel

The power to the boiler must be switched off before any

work is carried out. Fig. 9: Boiler wiring

M. Brown

O. Orange

N. Black

B. Blue

R. Red

T. Green-yellow

NT1 T2

230V-50 Hz

1O 11

241 3 5

20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1

bl n/z br

SQK 349

QAAD50

(QAAD70) QAC32 QAD22

P1 B5 B9 B3 B2

P1Y1Y2NB5B9B3B2

B2. Water temperature detector

B9. Outside temperature detector

B5. Analogue/digital room thermostat

P1. Central heating pump

Y1/Y2/N. Mixer valve (SQK349)

bl. Blue N

n/z. Black Y2

br. Brown Y1

230V / 50 Hz

ALIMENTATION

230V

Fig. 6a: kit 1

Fig. 6b: kit 2

2.2.4 CONTROLLER KITS

KIT 1: ACV 13.00 / Basic

Basic kit for regulating flow temperature according to

weather conditions.

It comprises: temperature regulator with analogue timer,

water temperature detector (-30/130° C), outside temperature

detector (-30/50° C), 230V - 3 spindle servomotor SQY 31

and intermediate socket.

KIT 1: ACV 13.00 / Standard

Basic kit for regulating flow temperature according to

weather conditions.

It comprises: temperature regulator with analogue timer,

water temperature detector (-30/130° C), outside temperature

detector (-30°/50'C), 230V - 3 spindle servomotor SQY

349 and intermediate socket.

3.1 FILLING THE HEATING AND HOT

WATER CIRCUITS

1. Fill the domestic hot water circuit and bring it up to pressure.

IMPORTANT

The hot water tank must be pressurised before the

heating circuit is filled.

2. Fill the heating circuit taking care not to exceed the 2 bar pressure

limit.

3. Vent the air from the top of the boiler.

4. After venting the air from the system, bring the pressure up to the

static head plus 0.5 bar: 1.5 bar = 10 m – 2 bar = 15 m.

5. Check the power connection, the boiler room ventilation, and ensu-

re that there are no leaks in the flue gas discharge pipes.

6. Set the thermostat (1) to between 60 and 90° C.

3 START-UP 4 SERVICING

Fig. 10: Control panel

7. Set the Summer/Winter selector (3) to the desired position.

8. Switch the on/off switch (2) to the ON position.

9. Check the gas supply pressure on starting up.

3.2 BURNER TROUBLESHOOTING

Refer to the servicing and troubleshooting instructions for the burner.

Before servicing or repairs, switch off the power at the

mains switch fitted in the boiler room by the electrician.

21 3

4.1 RECOMMENDATION

ACV advises that boilers should be serviced at least once a year.

The burner must be serviced and tested by a competent engineer.

4.2 SERVICING THE GAS BOILER

1 - Switch off the power at the mains switch outside the boiler and

close the gas tap.

2 - Set the on/off switch on the control panel to the OFF position.

3 - Release and remove the chimney flue (1) to free the top of the

boiler.

4 - Remove the jacket top (2) and lift off the flue reducer (3).

5 - Remove the baffles (4) from the flue pipes (5) for cleaning. Replace

them if in poor condition.

6 - Unscrew the burner chamber plate (6).

7 - Brush the flue pipes (5).

8 - Clean the burner chamber (7) and the burner (8).

9 - Check that the insulation on the burner chamber plate (6) is in

good condition.

1. Chimney flue

2. Jacket top

3. Chimney flue reducer

4. Baffles

5. Flue pipes

6. Burner chamber plate

7. Burner chamber

8. Burner

Fig. 11: Main components.

4.3 SERVICING THE SAFETY DEVICES

- Check that all thermostats and safety devices are working properly:

boiler thermostat, cut-off thermostat and manually reset safety

thermostat.

- Test the safety valves on the central heating and hot water circuits

4.4 SERVICING THE BURNER

- Check and clean the burner and ignition electrode.

- Check that the safety components are working properly.

4.5 EMPTYING THE BOILER

4.5.1 EMPTYING THE PRIMARY CIRCUIT (central heating):

1. Switch off the power to the boiler at the mains switch installed by

the electrician.

2. Close the isolating valves (1) of the boiler system.

3. Connect a hose to the drain valve (2).

Ensure that it is attached properly.

4. Open the drain valve and let the hot water drain out.

5. When the boiler is empty, return the isolating and safety valves to

their initial positions.

4.5.2 EMPTYING THE HOT WATER TANK:

1. Switch off the mains power to the boiler at the external switch

installed by the electrician.

2. Relieve the pressure in the primary circuit.

3. Close valves (A) and (B).

4. Open valves (C) and (D) (first C then D).

5. Let the water drain away.

6. After emptying, return the valves to their initial positions.

For the tank to be emptied, valve (C) must be situated at

ground level.

4.6 SPARE PARTS

Refer to the specific document available from ACV or your distributor.

4 SERVICING

Fig. 12a: Emptying the primary circuit

Fig. 12b: Emptying the hot water circuit

5.1 OVERVIEW

• Combination boiler (central heating and domestic hot water).

• Designed for venting through a chimney.

• TANK-IN-TANK indirect storage type domestic hot water production.

• Fittings necessary for connecting the circulation kit for feeding the

heating circuit (available as an option).

• Control panel with on/off switch, adjustable thermostat, thermometer,

“Summer/Winter” selector and knockout for fitting ACV integrated

control system (optional).

• Flue gas anti-backdraught safety device.

• Delivered complete with atmospheric type burner.

• DELTA Classic models G20, G25 and G30, for natural gas, with

rated outputs of 23.2, 28.7 and 34 kW.

• DELTA Classic model P30, for propane, with a rated output of

34.4 kW.

5.2 DESCRIPTION OF OPERATION

5.2.1 THE TANK-IN-TANK CONCEPT

The DELTA Performance series differs from traditional hot water

producers because of its ring-shaped tank immersed in the primary

fluid contained in the outer body. When there is a demand for hot water

from the central heating system or the domestic hot water system, the

thermostat starts the burner.The combustion gases quickly heat up the

primary fluid, creating a natural circulation around the tank.

5.2.2 DOMESTIC HOT WATER HEATED INDIRECTLY

This circulation facilitates heat exchange between the primary fluid and

the domestic water, which takes place all over the tank surface. The

corrugations on the inner and outer shells of the ring-shaped tank

further boost the area of heat exchange and speed up the heating

process of the domestic water.

5.2.3 EASY SETTING AND SAFETY ASSURED

With a single command, the water temperature of both the primary

circuit and the hot water circuit is set by the adjustable thermostat

situated on the tank in the primary circuit. A cut-off thermostat, placed

on top of the boiler, automatically cuts out the burner when the water

temperature in the primary circuit reaches 95° C. A manually reset

safety thermostat shuts off the burner if the temperature reaches

103° C.

5 DESCRIPTION

1. Primary fluid

2. Domestic hot water

3. Combustion chamber

4. Control thermostat

5. Burner

Fig. 13: Stainless steel domestic hot water tank

Fig. 14: Overview of boiler

5.3 DESIGN FEATURES

5.3.1 OUTER BODY

The outer body containing the primary fluid is made of STW 22 steel.

5.3.2 TANK-IN-TANK TYPE EXCHANGER ACCUMULATOR

The ring-shaped inner tank with its large heating surface for producing

domestic hot water is built of Chrome/Nickel 18/10 stainless steel. It is

corrugated over its full height by an exclusive production process and

entirely argon arc welded by the TIG (Tungsten Inert Gas) method.

5.3.3 COMBUSTION GAS CIRCUIT

The combustion gas circuit is protected by cold galvanisation. The

combustion gas circuit comprises:

5.3.3.1 Flue pipes

Depending on output, DELTA Classic models contain 4 or 8 steel

flue pipes with an internal diameter of 64 mm. Each pipe is fitted

with a baffle of special steel designed to improve heat exchange

and reduce flue gas temperature.

5.3.3.2 Combustion chamber

The combustion chamber on DELTA Classic models is water

cooled.

5.3.4 INSULATION

The boiler body is fully insulated by rigid polyurethane foam with a high

thermal insulation coefficient, sprayed on without the use of CFCs.

5.3.5 JACKET

The boiler is covered by a steel jacket which has been scoured and

phosphated before being stove enamelled at 220° C.

5.3.6 BURNER

DELTA Classic boilers are fitted with an atmospheric burner with elec-

tric ignition.

IMPORTANT

When starting the burner for the first time and when

servicing it, refer to the technical instructions supplied

with it.

5.3.7 CONTROL PANEL (Fig. 15)

1 - Thermostat adjustable between 60 and 90° C

2 - On/off switch

3 - Summer/winter selector

4 - Thermometer

5 - Knockout for (optional) controller.

5 DESCRIPTION

Fig. 15: Boiler structure

Fig. 16: Control panel

241 3 5

1. Inner ring-shaped domestic hot water tank

2. External body containing central heating circuit

3. Insulation

4. Jacket

5. Flue pipes

6. Baffles

7. Control thermostat 60/90° C

8. Lower heating return

9. Combustion chamber

10. Burner chamber plate

11. Boiler drain

12. Upper heating flow and return

13. Chimney connection

14. Control panel

15. Domestic hot water outlet

16. Domestic cold water inlet

17. Cut-off thermostat 95° C / Thermometer

18. Manually reset safety thermostat 103° C

19. Gas burner

20. Burner chamber disk.

6.1 EFFECTIVE DIMENSIONS

The units are delivered fully assembled, tested and packed on a

timber base with shockproof edges and protected by heat-shrunk

plastic film. On reception and after unpacking, check the equipment for

damage. For transport purposes, refer to the weights and dimensions

given below.

6.2 MAXIMUM OPERATING CONDITIONS

Maximum service pressure (tank full of water)

- Primary circuit: 3 bar

- Secondary circuit: 10 bar

Test pressure (tank full of water)

- Primary circuit: 4.5 bar

- Secondary circuit: 13 bar

Operating temperature

- Maximum temperature: 90° C

6 TECHNICAL SPECIFICATION

200

570 C

E542

160

118 158

Fig. 17: Effective dimensions

6.3 DOMESTIC HOT WATER PERFORMANCE

6.4 BOILER PERFORMANCES

Dimensions

G20 G25 G30/P30

1697 1697 1697

1460 1460 1460

154 154 154

360 390 390

712 712 712

Domestic hot water performances G20 G25 G30 P30

Operating at 80° c

Peak delivery at 40° C (6T = 30° C) litres/10’ 266 339 339 339

Peak delivery at 40° C (6T = 30° C) litres/60’ 820 1025 1151 1161

Continuous delivery 40° C (6T = 30° C) litres/h 665 823 975 986

Operating at 80° c

Initial heating time minutes 40 29 24 24

After draw-off of 140 l à 45° C minutes 16 12 10 10

Specific delivery litres/minutes 11 14 14,5 14,5

Results obtained without a thermostatic mixing valve and with water supply at 10° C

G20 G25 G30 P30

Input kW 26,1 33,1 39,0 40,0

Output kW 23,2 28,7 34 34,4

Combustion efficiency %89 89 89 89,5

Maintenance loss at 60° C as % of rated value %1,3 1 0,8 0,87

Mass rate of combustion products g/sec. 20 25 30 30

Average CO2%99910

Total capacity litres 178,5 167,5 167,5 167,5

Primary circuit capacity litres 114,5 87,5 87,5 87,5

Heating connection Ø1” 1” 1” 1”

Hot water connection Ø3/4” 3/4” 3/4” 3/4”

Hot water tank heat exchange surface m21,59 2,46 2,46 2,46

Weight empty Kg 154 186 186 186

Chimney connection B11 BS B11 BS B11 BS B11 BS

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