HeatMaster
Installation, Operating and
Servicing Instructions
HM 60 N / 70 N / 100 N / 150 JUMBO
HM 60 N / 70 N / 100 N
With ACV BG 2000-S premix gas burner
HM 60 N / 70 N / 100 N
With ACV BM 101 oil burner
HM 150 JUMBO
With ACV BM 151 oil burner
excellence in hot water
66400501
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DESCRIPTION
OPERATING PRINCIPLE
CONSTRUCTION FEATURES
The HeatMaster is a high performance, direct fired hot water storage
heater, which has indirect heat transfer due to its Tank-in-Tank
construction.
Outer body
The outer body containing the primary fluid is made of thick STW 22
steel.
At the heart of the HeatMaster is a stainless steel cylinder through
which the flue tubes pass. This is surrounded by a mild steel shell
containing the primary water (neutral fluid). The outer shell extends
down to the combustion chamber and even around the flue tubes.
The area of the heat transfer surface is therefore much greater than
that of standard direct fired water heaters.
TANK-IN-TANK heat exchanger
The ring-shaped inner tank with its large heating surface for producing
domestic hot water is built of Chrome/Nickel 18/10 stainless steel. It
is corrugated over its full height by an exclusive production process
and entirely argon arc welded by the TIG (Tungsten Inert Gas)
method.
A circulating pump fitted to the primary circuit moves the water
around the tank, heating it faster and maintaining an even
temperature across the primary jacket.
Combustion gas circuit
The combustion gas circuit is paint-protected and comprises:
• Flue pipes
The burner, either gas or oil, fires onto the primary water which
indirectly heats the stainless steel cylinder containing the DHW. As
with all Tank-in-Tanks, this is corrugated over its full height and
suspended in the HeatMaster by its hot and cold water connections.
Depending on output, HeatMaster models contain several
steel flue pipes with an internal diameter of 64 mm. Each
pipe is fitted with a baffle of special steel designed to
improve heat exchange and reduce flue gas temperature.
The cylinder expands and contracts during use and this, together
with the fact that cold water does not come into contact with the
intense heat of the burner flame, means that limescale buildup is
prevented.
• Combustion chamber
The combustion chamber on HeatMaster models is
entirely water cooled.
Insulation
This scale resistant feature, along with the corrosion resistance of
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
CFCs.
The HeatMaster has one very major advantage over other direct
fired water heaters - because it heats the DHW with a primary
circuit, this primary water can be used to provide central heating as
well.
Casing
The boiler is covered by a steel jacket which has been scoured and
phosphated before being stove enamelled at 220 °C.
The jacket of the HM 150 Jumbo is delivered separately and must
be assembled on site following the instructions supplied with it.
By connecting two, three, four or more HeatMasters together in a
module, most hot water and heating demands can be met.
Burner
Indeed, when used in conjunction with HR and Jumbo hot water
storage tanks the Heatmaster can supply even the largest hot water
requirement.
All HeatMaster models can be fitted with pressure jet gas burners or
oil burners.The HeatMaster 60, 70 and 100 can also be fitted with the
low-NOx pre-mix BG 2000 gas burner.
Standard equipment
The HeatMaster 60 N / 70 N / 100 N and 150 Jumbo has the following
items as standard :
- On/off switch
- Summer/Winter switch
- Timeclock
- primary circulating shunt pump
- primary expansion vessels
- primary safety valve
- pressure and temperature gauge
- drain valve
- body completely insulated in rigid polyurethane foam
2
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DESCRIPTION
Features of HeatMaster 70 N / 100 N
Flue reduction collar
Top cover
Central heating
flow pipe
Automatic air vent
Domestic hot
water outlet
Domestic cold water inlet
Flue pipes and
turbulators
Heating circuit filling valve
with removable hose and
non-return valve
Tank-in-Tank
heat exchanger
Primary expansion vessel
Primary shunt pump
Insulation
Burner
Casing front panel
Heating return
Primary circuit
Combustion chamber
Burner chamber plate
Safety features of the HeatMaster 60 N
Control panel HeatMaster 60 N
Thermal reset high
limit thermostat
Combined temperature
and pressure gauge
Manual reset high
limit thermostat
Manual reset high
limit thermostat
Burner
lockout
indicator
Time clock
Low water
pressure switch
I
O
Primary safety valve
Primary circuit low
water pressure
indicator
ON / OFF
switch
Control
thermostat
Control thermostat
High limit cutoff
indicator
Summer / Winter switch
3
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DESCRIPTION
Safety features of the HeatMaster 70 N and 100 N
Control panel HeatMaster 70 N and HeatMaster 100 N
Thermal reset high
limit thermostat
Combined temperature
and pressure gauge
Manual reset high
limit thermostat
Manual reset high
limit thermostat
Burner
lockout
Summer / Winter switch
indicator
Time clock
Low water
pressure switch
I
O
Control thermostat
Primary circuit low
water pressure
indicator
ON / OFF
switch
Control
thermostat
High limit cutoff
indicator
Primary safety valve
Safety features of the HeatMaster 150 Jumbo
Control panel HeatMaster 150 Jumbo
Primary safety valve
Mains power
electrical connection
(multi-pin plug)
Thermal reset high
limit thermostat
Combined temperature
and pressure gauge
Primary circuit low
water pressure indicator
bar
Manual reset high
limit thermostat
Relay base
Time clock
I
Low water
O
9
GRASSLIN
8
pressure switch
ON / OFF switch
Fuse
Manual reset high
limit thermostat
Control thermostat
Thermal reset high
limit thermostat
Servicing socket
(230 V ˜ 50 Hz)
Control thermostat
4
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TECHNICAL SPECIFICATION
MAXIMUM OPERATING CONDITIONS
BURNER CHAMBER PLATE
Maximum service pressure (tank full of water)
- Primary circuit: 3 bar
- Secondary circuit: 10 bar
The burner chamber plate has 4 threads (M 10 x 20) for attaching
the burner. It is protected from heat by a blanket insulation.
Test pressure (tank full of water)
- Primary circuit: 4.5 bar
- Secondary circuit: 13 bar
Operating temperature
- Maximum temperature: 90 °C
Water quality
• Chlorures: < 150 mg/l (304)
< 2000 mg/l (Duplex)
• 6 ≤ ph ≥ 8
DOMESTIC HOT WATER PERFORMANCES
HM 60 N
BM 101
HM 60 N
HM 70 N
BM 101
HM 70 N
HM 100 N
BM 101
HM 100 N
HM 150
JUMBO
BG 2000-S/60
BG 2000-S/70
BG 2000-S/100
Peak delivery at 40 °C
Peak delivery at 45 °C
Peak delivery at 60 °C
Peak delivery at 70 °C
Peak delivery at 80 °C
L/10’
L/10’
L/10’
L/10’
L/10’
474
378
245
193
135
474
378
245
193
135
646
543
346
268
207
646
543
346
268
207
905
777
514
343
258
905
777
514
343
258
1504
1289
870
700
540
Peak delivery at 40 °C
Peak delivery at 45 °C
Peak delivery at 60 °C
Peak delivery at 70 °C
Peak delivery at 80 °C
L/60’
L/60’
L/60’
L/60’
L/60’
1942
1656
1106
681
1942
1656
1106
681
2133
1794
1219
971
2133
1794
1219
971
3172
2680
1813
1226
893
3172
2680
1813
1226
893
4828
4138
2864
2131
1362
499
499
636
636
Continuous delivery at 40 °C
Continuous delivery at 45 °C
Continuous delivery at 60 °C
Continuous delivery at 70 °C
Continuous delivery at 80 °C
L/h
L/h
L/h
L/h
L/h
1835
1573
1101
791
1835
1573
1101
791
1835
1573
1067
918
1835
1573
1067
918
2776
2379
1665
1104
804
2776
2379
1665
1104
804
3989
3419
2393
1718
987
455
455
580
580
Reheat time at 60 °C
min
9
9
16
16
13
13
17
GENERAL FEATURES
HM 60 N
HM 70 N
HM 100 N
HM 150
JUMBO
Maximum Input
kW
kW
%
69.9
62.5
0.57
162
82
69.9
63.0
0.60
239
108
11/2”
1”
107.0
96.8
0.65
330
130
11/2”
1”
154.0
139.1
0.52
645
Maximum Output
Maintenance loss at 60 °C as rated value
Total capacity
L
Primary circuit capacity
Heating connection
L
245
Ø
11/2”
3/4”
2.46
220
54
DN 50
2”
Hot water connection
Ø
Hot water tank heat exchange surface
Weight empty
m2
Kg
mbar
3.14
270
46
3.95
320
83
5.30
530
Pressure drop primary circuit
120
5
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TECHNICAL SPECIFICATION
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 weight (page 5) and dimensions given
below.
A mm
1698
1698
1743
1743
2093
2093
2124
B mm
1583
1583
1630
1630
2030
2030
2117
C mm
538
D mm
625
E mm
540
F mm
390
390
390
390
390
390
600
G Ø mm
150
H mm
1098
1098
1289
1289
1693
1693
1383
J mm
281
281
285
285
285
285
590
K mm
1665
1665
1720
1720
2120
2120
2250
HM 60 N
HM 60 N BG 2000-S 60
HM 70
538
801
540
150
678
797
680
150
HM 70 N BG 2000-S 70
HM 100 N
680
937
680
150
680
797
680
150
HM 100 N BG 2000-S 100
HM 150 Jumbo
680
937
680
150
1020
1440
1020
250
HeatMaster 60 N
Without burner
With ACV BG 2000-S
premix gas burner
F
G
A
A
B
H
K
C/2
J
C
D
C
D
E
6
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TECHNICAL SPECIFICATION
HeatMaster 70 N and HeatMaster 100 N
G
F
Without burner
With ACV BG 2000-S
premix gas burner
K
A
A
B
H
C/2
J
C
D
C
D
E
HeatMaster 150 Jumbo
F
562
H
A
K
C
D
G
E
J
7
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INSTALLATION
BOILER ROOM
CHIMNEY CONNECTIONS
Important
•
•
•
Keep vents free at all times.
IMPORTANT
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
the mains gas tap at the meter and inform the appropriate
services immediately.
Boilers must be installed by an approved heating
engineer, in accordance with the prevailing local
standards and regulations.
•
Access
Flue size should not be less then the outlet size of the
boiler.
The boiler room must be large enough to allow good access to the
boiler.The following minimum distances are required around the boiler:
- front
- side
- behind 150 mm
- above 700 mm
500 mm
100 mm
Chimney connection type: B23
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.
This must be easy to remove to give access to the flue pipes when
servicing the boiler.
Ventilation
The boiler room must be fitted with top and bottom vents sized
according to the table below or to current regulations.
A. Top vent
B. Bottom vent
C. Draught regulator
D. Inspection window
The table below gives an example conforming to the Belgian standards.
F
E. Height of lined chimney
F. Chimney diameter
Ventilation
60 N
70 N
100 N
150
Jumbo
Min. fresh air
requirement
Bottom
m3/h
dm2
dm2
126
2.11
2.0
126
2.11
2.0
194
3.20
2.0
278
4.8
2.0
Top
C
A
Other countries should refer to their own standards.
B
Base
D
The base on which the boiler rests must be made of non-combustible
materials.
Chimney
60 N
70 N
100 N
150
minimum flue diameter
Jumbo
E = 5 m Ø F min. mm
E = 10 m Ø F min. mm
E = 15 m Ø F min. mm
189
159
150
189
159
150
234
178
150
286
250
250
Note:
Regulations vary from country to country therefore
the table above is intended only as a guide.
Due to the high efficiency of our boilers, the flue gasses
exit at low temperature. Accordingly, there is risk that
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.
8
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INSTALLATION
Balanced flue boiler connection type: C
•
•
•
•
C13: concentric horizontal connection
C33: concentric vetical connection
C53: parallel chimney connection
C63: concentric vertical connection without terminal (only in
Germany and Luxembourg).
C33
120
C13
C53
Maximum length concentric : 6 metres
Maximum length parallel : 12 metres
Note: a 90 degree bend = 1 metre equivalent length
A condensation drain outlet must be fitted close to the boiler to prevent condensation products from
the chimney running into the boiler.
To avoid condensation water running out of the terminal, all horizontal flue runs must fall back
towards the boiler.
9
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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.
I
I
I
O
O
O
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 coun-
tries,
a
temperature and pressure relief valve must be
fitted - consult your ACV stockist for assistance.
Example of hot water connection with thermostatic mixer
1. Stop cock
2. Non-return valve
3. Pressure reducing valve
4. Expansion relief valve
Example of series connection
Preferable for high temperature applications with up to three units.
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)
6
2
8
I
I
I
O
O
O
3
1
2
7
10
4
11
5
Example of heating + storage connection
Recommended for applications requiring a high peak flow.
I
O
9
I
O
DANGER!
As a safety measure against scalding, we
strongly recommend installing a thermostatic
mixing valve.
10
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INSTALLATION
HEATING CONNECTION
OIL SUPPLY CONNECTIONS - ACV BM BURNERS
(If another make of buner is fitted please refer to that manufacturers technical
manual)
The HeatMaster has two connections at the rear that can be used to
connect a central heating circuit. Connecting a heating system may
reduce the domestic hot water performance.
Installation without return
Expansion
The HM 60 is fitted with an 8 litre expansion vessel. HM 70/100
models are fitted with two 10 litre expansion vessels, and the
HM 150 Jumbo is fitted with four 8 litre expansion vessels. These
expansion vessels are sized for hot water operation 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).
Example of a single circuit connection
1. 3-way valve
H
2. Heating pump
3. Non-return valve
4. Isolating valves
5. Safety valve set to 3 bar with pressure gauge
6. Expansion vessel
7. Drain cock
L1
8. Controller
L (m)
(L = H + L1)
8
H (m)
0.5
1
Ø int. 8 mm
Ø int. 10 mm
3
4
10
20
40
60
20
40
1
2
1.5
2
80
100
I
O
Installation with return
5
L1
6
4
H
7
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.
H
L1
L (m)
(L = H + L1)
H (m)
0
Ø int. 8 mm
Ø int. 10 mm
35
30
25
20
15
8
100
100
100
90
0.5
1
1.5
2
70
2
30
3.5
6
20
11
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INSTALLATION
ELECTRICAL CONNECTIONS
WIRING DIAGRAM
Power supply
HeatMaster wiring diagram legend
The boiler operates with a 230 V - 50 Hz single phase supply.
A double pole isolator with a 6 amp fuse or a 6 amp MCB 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.
60 N, 70 N, 100 N (page 13) and 150 Jumbo (page 14)
1.
230 V power connection plug
2.
On/off switch
3.
4.
5.
6.
Temperature high limit cutoff indicator (except HM 150 Jumbo)
Manual reset high limit thermostat
Primary circuit low water pressure indicator
Low water pressure switch
Conformity
Boiler installation must comply with the prevailing local standards
and legislation.
7.
Time clock
8.
9.
Summer/winter switch (except HM 150 Jumbo)
Hot water priority link (except HM 150 Jumbo)
Burner lockout indicator (except HM 150 Jumbo)
Room thermostat connection (option)
Central heating pump
Safety
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
The stainless steel tank must be earthed separately.
HeatMaster shunt pump
Burner plug connector
The power to the boiler must be switched off before
any work is carried out.
Water flow switch connection (option)
Thermal reset high limit thermostat 95 °C
Control thermostat
230 V servicing socket (only HM 150 Jumbo)
Relay (only HM 150 Jumbo)
Electrical connection HeatMaster 60 N, 70 N and 100 N
L1
L1
N
N
T1 T2 S3 B4
T1 T2 S3 B4
14
B.
Blue
Black
Brown
Grey
Bk.
Br.
G.
Gr.
Or.
Pk.
R.
Green
Orange
Pink
12
13
11
15
Red
Or
V.
W.
Y.
Violet
1
2
3
4
5
2
6
7
8
9 10 11 12 13 14 15 16 17 18 19 20
White
Yellow
Yellow / Green
Y/Gr
Y/Gr
G
G
Y/Gr.
B
B
B
10
1
9
C
Or
8
Or
Or
B
5
4
7
95 °C
3
1
2
16
C
B
Bk
6
2
1
1
C
5
103 °C
0 - 90 °C
G
4
3
2
1
2
17
P
C
B
W
B
B
I
2
O
Br
B
L1
L1
N
N
1
12
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INSTALLATION
Electrical connection HeatMaster 150 Jumbo
B.
Blue
Pk.
R.
V.
W.
Y.
Y/Gr.
Pink
Red
Violet
White
Yellow
Bk.
Br.
G.
Gr.
Or.
Black
Brown
Grey
Green
Orange
Yellow / Green
W
Bk
19
A2
A1
A1
6
1
11
5
4
9
A2
95 °C
16
B
W
B
C
1
10 - 100 °C
W
2
1
C
17
Br
1
3
5
5
7
4
103 °C
2
4
C
W
1
2
2
1
6
2
R
R
B
B
C
B
Bk
Y/Gr
18
Br
Y/Gr
Or
B
R
6,3 A
B
B
1
2
3
4
5
6
7
8
9 10 11 12 13 14 15 16 17 18 19 20
1
L1
N T1 T2 S3
W
R
Y/Gr
220/240V
~ 50 Hz
15
11
14
L1
N T1 T2 S3 B4
ph
n
230V signal connections
Boiler run
13
12
High temperature
Burner lock out
13
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COMMISSIONING
HeatMaster 70 N and 100 N
FILLING THE HOT WATER AND HEATING CIRCUITS
C
IMPORTANT
Hot water tank must be pressurised before the heating
circuit is filled.
B
1. Close the primary circuit filling valves (A)
2. Open the stop valve (B) and the drawoff tap (C).
When water flows out of the tap, the hot water tank is full and
the drawoff tap (C) should be closed.
3. Fill the primary (heating) circuit by opening the valves (A) and
pressurising to 1 bar.
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.
A
5. After venting the air from the system, bring the pressure up to
the static head plus 0.5 bar: 1.5 bar = 10m and 2 bar = 15 m.
6. Check that the electrical connection and boiler room ventilation
conform to the relevant standards.
7. Set the thermostat between 60 and 90 °C.
8. Switch the on/off switch to the ON position.
I
O
9. For gas burner, check the gas supply pressure on starting up.
10. For the oil burner, check the oil supply (and return). Proceed
with the necessary venting, measurements and settings.
11. Set the heating control to heat demand. When the burner
operates, check the flue gas discharge pipes for leaks.
12. After 5 minutes of operation, vent the primary circuit again
maintaining the water pressure at 1 bar.
13. Then restart the unit and check the combustion.
HeatMaster 60 N
HeatMaster 150 Jumbo
C
C
B
B
I
O
A
u
m
b
o
A
Kerkplein 39
1601 Sint-Pieters-Leeuw(Ruisbroek) Belgium
Num.
Code
T
y
p
.
Anno
Max.
T
e
m
p
.
Chauffage-CV-Heizung
E
a
u
s
a
n
i
t
a
i
r
.
w
a
t
e
r
-
B
r
a
u
c
h
w
a
s
s
e
r
Débit-Debiet-Abflussmenge
bar
Agréation-Keuring-Prüfnummer
.
I
O
GRASSLIN
14
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BURNER FEATURES
ACV BG 2000-S premix gas burners dimensions
ACV BG 2000-S PREMIX GAS BURNERS
Description
Type
A
B
C
The burner tube is coated with metal fibre (NIT) which, in addition to
its remarkable heat exchange capabilities, gives greater durability.
BG 2000-S / 60
BG 2000-S / 70
BG 2000-S / 100
375
375
375
228
248
248
248
342
342
The main components are a venturi and one (model 60 and 70) or
two (model 100) gas valves, technology specially developed by
Honeywell for low Nox premix air/gas burners with automatic ignition
and ionisation flame detection.
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.
A
B
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.
C
If there is a blockage in the chimney outlet, the air flow diminishes,
and the same reactions as those described above cause the
burner to shut down in safety mode.
The BG 2000-S burner fitted to the HeatMaster 60, 70 and 100
is controlled by a Honeywell module which controls burner
operating safety.
BG 2000-S burners are preset at the factory
for natural gas.
Conversion to propane:
Not applicable for Belgium.
Conversion kit included with burner comprising:
- Cap(s)
- Nameplate(s)
- Sticker with settings.
- Mounting instructions.
Air-gas mixture control system
Venturi
Fan
Air - gas
mixture
Air
Offset regulation
screw
Gas
Gas flow
regulating screw
15
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BURNER FEATURES
Burner electrical connection BG 2000-S/60 and BG 2000-S/70
Electrical connections
B.
Blue
Bk.
Br.
G.
Black
Brown
Grey
L1
T2 S3 B4
T1
Gr.
Y.
Y/Gr.
Green
Yellow
Yellow / Green
1 2 3 4 5 6 7 8 9 101112
L1 N
Burner electrical connection BG 2000-S/100
Electrical connections
B.
Blue
Bk.
Br.
G.
Black
Brown
Grey
L1
N
T1
Gr.
Y.
Y/Gr.
Green
Yellow
Yellow / Green
B
Br
1 2 3 4 5 6 7 8 9 101112
L1 N
16
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BURNER FEATURES
ACV premix gas burner BG 2000-S/60 and BG 2000-S/70
Ignition electrode
Burner tube
Burner chamber plate insulation
Gas valve
Fan
Venturi
Chamber plate
Relay
Ionisation probe
Potentiometer setting
Gas inlet
Burner plug connector
Fan power plug
ACV premix gas burner BG 2000-S/100
Ignition electrode
Burner chamber plate insulation
Burner tube
Gas valve
Fan
Venturi
Chamber plate
Relay
Potentiometer setting
Ionisation probe
Gas inlet
Burner plug connector
Fan power plug
17
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BURNER FEATURES
HeatMaster 60, 70 and 100 Gas burner features - BG 2000
HM 60 N
+ BG 2000-S/60
HM 70 N
+ BG 2000-S/70
HM 100 N
+ BG 2000-S/100
HM 100 N
+ gas pressure
jet burner
HM 150 Jumbo
+ gas pressure
jet burner
Input
Output
kW
kW
%
69.9
63.0
91.2
9.5
69.9
63.0
91.5
9.0
85.0
77.4
92.9
9.0
96.8
90.0
92.9
9.0
154
139.1
91.5
9.0
Combustion efficiency - natural gas
Natural gas CO2
%
Gas G20 - 20 mbar - I 2E(S)B - I 2 Er - I 2H
Flow
m3/h
m3/h
m3/h
7.40
8.60
2.86
7.40
8.60
2.86
8.99
10.46
3.47
10.24
11.91
3.95
16.30
18.95
6.29
Gas G25 - 20/25 mbar - I 2L - I 2ELL
Flow
Gas G31 - 37/50 mbar - I 3P
Flow
Pressure drop combustion chamber
Flue gas temperature (net)
mbar
°C
0.6
186
0.6
172
1.4
145
1.4
165
0.6
181
Mass rate of combustion
products (grammes per second)
32.1
32.1
39.1
44.5
70.8
Gas category
BE
FR
AT
DK
ES
UK
IT
PT
IE
SE
NL
LU
DE
I 2Er
I 2E(S)B
I 2H
I 3P
I 2L
I 2ELL
18
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BURNER FEATURES
Features
ACV BM 101 AND BM 151 OIL BURNERS
-
-
-
Easy to install – fitted with safety closure and new burner
suspension system.
Description
The burner air pressure adjusts to the pressure in the burner
chamber.
An automatic damper shuts off the air flow when the burner is
turned off, preventing the boiler from cooling.
Quiet and extremely reliable.
Adjustable to the depth of the boiler burner chamber thanks to
the adjustable bracket at the mouth of the burner chamber.
Three air adjustment points to ensure the best air/oil mixture.
• upstream air presetting
The use of new technology enables our medium output burners to
meet current performance and emissions quality requirements.
These burners are fitted with high quality components including a
two-stage oil pump that permits soft start.
-
-
Components:
- Landis & Gyr relay
- A.E.G. motor
- Suntec pump
- May & Christe transformer
- Landis & Gyr oil preheater
-
• primary setting
• combustion head setting
Oil burner specification and perfomances
HM 60 N
HM 70 N
HM 100 N
HM 150 JUMBO
Burner type
Input
BM 101
69.9
1.50
60°
BM 101
69.9
1.50
60°
BM 151
107.0
2.00
BM 151
154.0
3.00
kW
Nozzle flow
Nozzle angle
Oil flow
US Gal/h
60°
60°
Kg/h
bar
5.9
5.9
8.92
13.0
Pump pressure
10.5
10.5
13.5
12.5
Pressure drop combustion chamber mbar
0.6
175
12.5
0.6
170
12.5
1.4
170
12.5
0.6
181
12.5
Flue gas temperature (net)
CO2
°C
%
Mass rate combustion
products (grammes per second)
29.6
29.6
44.8
64.7
BM oil burners dimensions
A mm
260
B mm
C mm
250
D mm
310
E mm
F mm
M 8
G Ø
90
L Ø
95
LK Ø
Kg
14
20
BM 101
BM 151
300
340
60 - 150
60 - 190
125 - 180
156 - 200
280
280
350
M 8
115
120
3°
G
B
C
E
D
F
A
19
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MAINTENANCE
SERVICE INTERVALS
SERVICING THE BOILER
ACV recommends that boilers should be serviced at least once a year.
The burner must be serviced and tested by a competent engineer.
If a boiler is subject to heavy use, it may require servicing more than
once a year - consult ACV for advice.
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.
3. Remove the flue to gain access to the top of the boiler.
4. Remove the casing top panel and lift off the flue reduction collar
by undoing the fastening bolts.
5. Remove the turbulators from the flue pipes for cleaning.
6. Unscrew the burner chamber plate and remove the burner.
7. Brush the flue pipes .
8. Clean the burner chamber and the burner.
9. Re-assemble turbulators, flue reduction collar and flue, checking
that the gasket on the flue reduction collar is in good condition.
Replace gasket if necessary.
Chimney flue
Casing top panel
Flue reduction collar
Burner chamber plate
Flue pipe and turbulators
Burner chamber
20
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MAINTENANCE
Draining the hot water circuit
SERVICING THE SAFETY DEVICES
1. Turn OFF the on/off switch on the boiler control panel, isolate
external electrical supply, and turn off the gas or oil supply to the
boiler.
- Check that all thermostats and safety devices are working properly.
- Test the safety valves on the central heating and hot water circuits.
2. Release the pressure in the heating circuit until the pressure
gauge indicates zero bar.
3. Close stop cock (1) and turn off tap (8).
4. Open valve (9) then valve (10) (first 9 then 10).
5. Let the water empty into the drain.
SERVICING THE BURNER
Oil burner
-
-
Check and if necessary clean the main filter on the oil line.
Check the alignment of the nozzle: check, clean or change the
nozzle and its filter, check that the electrodes and flame holder
are clean and correctly adjusted.
6
2
8
-
Reassemble and check that the safety components are working
properly.
Set the combustion parameters.
Check the combustion (CO2, CO and burner pressure) and record
the values and any remarks in the Service Record on page 24.
3
1
2
7
10
-
-
4
11
5
Gas burner
-
Check that the insulation and gasket on the burner chamber plate
are in good condition - replace if necessary.
-
Check and clean the burner and electrodes. Replace electrodes if
necessary (under normal use once a year).
-
-
Check that the safety components are working properly.
Check the combustion (CO2, CO and gas pressure) and record
the values and any remarks in the Service Record on page 24.
DRAINING THE BOILER
I
O
Water flowing out of the drain cock may be
extremely hot and could cause severe scalding.
Keep people away from discharges of hot
water.
9
Draining the heating circuit
For the tank to be emptied, valve (9) must be situated
at ground level.
1. Turn OFF the on/off switch on the boiler control panel, isolate
external electrical supply, and turn off the gas or oil supply to the
boiler.
2. Close the isolating valves (4).
3. Connect a hose to the drain cock (7).
4. Open the drain cock to drain the primary circuit.
SPARE PARTS
Please refer to the specific document available from ACV or your
distributor.
8
3
4
1
2
I
O
5
6
4
7
21
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USER GUIDE
Control panel HeatMaster 60 N
USING THE BOILER
Combined temperature
and pressure gauge
Manual reset high
limit thermostat
Your system should be serviced at least once a year
by a qualified engineer.
Burner
If the boiler is subject to heavy use, it may require
servicing more than once a year - consult your service
engineer for advice.
lockout
indicator
Time clock
Starting the burner:
In normal operation, the burner starts automatically
whenever the boiler temperature falls below the set
temperature.
I
O
Primary circuit low
water pressure
indicator
ON / OFF
switch
Control
thermostat
Understanding the control panel
There are no user parts inside the control panel.
High limit cutoff
indicator
Summer / Winter switch
1. On/Off switch
This turns the HeatMaster on or off.
Control panel HeatMaster 70 N and HeatMaster 100 N
2. Control thermostat - 60 to 90 °C
Manual reset high
limit thermostat
Combined temperature
and pressure gauge
When using the HeatMaster as a hot water generator only, the
temperature can be set between 60 °C and 90 °C.
If the HeatMaster is used for both hot water and central heating, the
control thermostat would normally be set at 80 °C to achieve optimum
operating conditions.
Burner
lockout
indicator
Summer / Winter switch
Time clock
3. Summer/Winter switch
This turns the heating pump (if fitted) on or off.
I
O
4. Manual reset high limit thermostat
If the boiler temperature exceeds 103 °C this safety device will
activate and the high temperature indicator will light up. To reset -
first allow the boiler to cool to below 60 °C, unscrew the cap and
press the reset button using a pencil or similar pointed device,
replace the cap. If the fault persists, turn the boiler off and call an
engineer.
Primary circuit low
water pressure
indicator
ON / OFF
switch
Control
thermostat
High limit cutoff
indicator
5. Time clock
This allows the HeatMaster to be timed on and off and operates on
a 24 hour sequence. Around the outside of the clock there are a
number of white tabs, these allow 15 minute switching periods. To
set the time clock simply push outwards the number of tabs required
for ON period.
Control panel HeatMaster 150 Jumbo
Mains power
electrical connection
(multi-pin plug)
Remember:
TAB IN = HeatMaster OFF
TAB OUT = HeatMaster ON
Combined temperature
and pressure gauge
Primary circuit low
water pressure indicator
6. Temperature and pressure gauge
bar
This gauge indicates both the temperature of the HeatMaster and
the pressure within the primary circuit.
The temperature should not exceed 90 °C - if it does, switch the
boiler off and check the thermostat setting. If the fault persists, call
an engineer.
Relay base
Time clock
I
The pressure should not fall below 1bar, if it does the please see the
'Heating System Pressure' paragraph later in this section.
O
9
GRASSLIN
8
ON / OFF switch
Fuse
Manual reset high
limit thermostat
7. Low primary water pressure indicator
If this indicator lights up, the primary circuit of the HeatMaster requires
topping up with water. Please see the 'Heating System Pressure'
paragraph later in this section.
Control thermostat
Thermal reset high
limit thermostat
Servicing socket
(230 V ˜ 50 Hz)
22
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USER GUIDE
Heating system pressure
From time to time you may need to top up the heating
HeatMaster 70 N and 100 N
system pressure.This pressure is indicated by the combined
temperature and pressure gauge on the boiler control
panel.
A
The minimum pressure when the boiler is cold should be
1 bar.The precise operating pressure required depends on
the height of the building, and your installer will have
informed you of this value at the time of installation (see
Commissioning Section - Filling the hot water and heating circuits).
If the pressure falls below 1 bar, the boiler water pressure
switch will turn the boiler off until pressure is restored.
To re-pressurise, the system needs to be topped up with
water.
First, switch the boiler OFF on the on/off switch and isolate
the external electrical supply. Then remove the casing top
front panel by pulling it forward. The filling valves “A” and
“B” can now be seen. Open both valves and allow the
system to fill. When the combined temperature and
pressure gauge shows the required pressure, close both
valves. Replace the casing top front panel. Restore the
power supply and switch the boiler on.
B
Safety Valves
If water discharges from any of the safety valves, switch the boiler
off and call a service engineer.
HeatMaster 60 N
HeatMaster 150 Jumbo
A
A
B
B
23
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USER GUIDE
RESETTING THE PRESSURE JET OIL OR GAS
BURNER
•
•
HM 60 N and HM Jumbo 150
➠ the lockout indicator is situated on the burner.
HM 70 N and 100 N
➠ the lockout indicator is situated on the burner and on the
control panel.
The red warning light indicates an operating fault. Wait five minutes
before resetting the burner.To reset : press the button located on the
burner.
If the burner does not relight, call the service engineer after ensuring
that the fault is not due to a power cut or low oil in the tank.
RESETTING THE BG 2000-S PREMIX GAS BURNER
•
HM 60 N BG 2000-S/60
➠ the lockout indicator is situated on the burner.
•
HM 70 N BG 2000-S/70 and HM 100 N BG 2000-S/100
➠ the lockout indicator is situated on the burner and on the
control panel.
1. Remove the burner cover.
2. Press the red button to restart the burner.
3. If the burner lights, replace the cover.
4. If the fault persists, call a service engineer.
BURNER TROUBLESHOOTING
For all burners
-
please refer to the relevant servicing and
troubleshooting instructions in your burner's technical manual.
24
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SERVICE RECORD
INSTALLATION DETAILS
Date installed :
Flue gas T° :
Model :
% CO2 (min. load) :
Serial number :
Efficiency :
Heating system pressure setting :
% CO2 (max. load) :
Gas pressure :
Name and signature :
➠
➠
➠ Gas
Oil
LPG
SERVICE RECORD
Date serviced :
Flue gas T° :
Remarks :
% CO2 (min. load) :
Efficiency :
% CO2 (max. load) :
Gas pressure :
Name and signature :
➠
➠
➠ Gas
Oil
LPG
LPG
LPG
LPG
LPG
Date serviced :
Flue gas T° :
Remarks :
Remarks :
Remarks :
Remarks :
% CO2 (min. load) :
Efficiency :
% CO2 (max. load) :
Gas pressure :
Name and signature :
➠
➠
➠ Gas
Oil
Date serviced :
Flue gas T° :
% CO2 (min. load) :
Efficiency :
% CO2 (max. load) :
Gas pressure :
Name and signature :
➠
➠
➠ Gas
Oil
Date serviced :
Flue gas T° :
% CO2 (min. load) :
Efficiency :
% CO2 (max. load) :
Gas pressure :
Name and signature :
➠
➠
➠ Gas
Oil
Date serviced :
Flue gas T° :
% CO2 (min. load) :
Efficiency :
% CO2 (max. load) :
Gas pressure :
Name and signature :
➠
➠
➠ Gas
Oil
25
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SERVICE RECORD
Date serviced :
Flue gas T° :
Remarks :
Remarks :
Remarks :
Remarks :
Remarks :
Remarks :
% CO2 (min. load) :
Efficiency :
% CO2 (max. load) :
Gas pressure :
Name and signature :
➠
➠
➠ Gas
Oil
LPG
LPG
LPG
LPG
LPG
LPG
Date serviced :
Flue gas T° :
% CO2 (min. load) :
Efficiency :
% CO2 (max. load) :
Gas pressure :
Name and signature :
➠
➠
➠ Gas
Oil
Date serviced :
Flue gas T° :
% CO2 (min. load) :
Efficiency :
% CO2 (max. load) :
Gas pressure :
Name and signature :
➠
➠
➠ Gas
Oil
Date serviced :
Flue gas T° :
% CO2 (min. load) :
Efficiency :
% CO2 (max. load) :
Gas pressure :
Name and signature :
➠
➠
➠ Gas
Oil
Date serviced :
Flue gas T° :
% CO2 (min. load) :
Efficiency :
% CO2 (max. load) :
Gas pressure :
Name and signature :
➠
➠
➠ Gas
Oil
Date serviced :
Flue gas T° :
% CO2 (min. load) :
Efficiency :
% CO2 (max. load) :
Gas pressure :
Name and signature :
➠
➠
➠ Gas
Oil
26
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SERVICE RECORD
Date serviced :
Flue gas T° :
Remarks :
Remarks :
Remarks :
Remarks :
Remarks :
Remarks :
% CO2 (min. load) :
Efficiency :
% CO2 (max. load) :
Gas pressure :
Name and signature :
➠
➠
➠ Gas
Oil
LPG
LPG
LPG
LPG
LPG
LPG
Date serviced :
Flue gas T° :
% CO2 (min. load) :
Efficiency :
% CO2 (max. load) :
Gas pressure :
Name and signature :
➠
➠
➠ Gas
Oil
Date serviced :
Flue gas T° :
% CO2 (min. load) :
Efficiency :
% CO2 (max. load) :
Gas pressure :
Name and signature :
➠
➠
➠ Gas
Oil
Date serviced :
Flue gas T° :
% CO2 (min. load) :
Efficiency :
% CO2 (max. load) :
Gas pressure :
Name and signature :
➠
➠
➠ Gas
Oil
Date serviced :
Flue gas T° :
% CO2 (min. load) :
Efficiency :
% CO2 (max. load) :
Gas pressure :
Name and signature :
➠
➠
➠ Gas
Oil
Date serviced :
Flue gas T° :
% CO2 (min. load) :
Efficiency :
% CO2 (max. load) :
Gas pressure :
Name and signature :
➠
➠
➠ Gas
Oil
27
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SERVICE RECORD
Date serviced :
Flue gas T° :
Remarks :
Remarks :
Remarks :
Remarks :
Remarks :
Remarks :
% CO2 (min. load) :
Efficiency :
% CO2 (max. load) :
Gas pressure :
Name and signature :
➠
➠
➠ Gas
Oil
LPG
LPG
LPG
LPG
LPG
LPG
Date serviced :
Flue gas T° :
% CO2 (min. load) :
Efficiency :
% CO2 (max. load) :
Gas pressure :
Name and signature :
➠
➠
➠ Gas
Oil
Date serviced :
Flue gas T° :
% CO2 (min. load) :
Efficiency :
% CO2 (max. load) :
Gas pressure :
Name and signature :
➠
➠
➠ Gas
Oil
Date serviced :
Flue gas T° :
% CO2 (min. load) :
Efficiency :
% CO2 (max. load) :
Gas pressure :
Name and signature :
➠
➠
➠ Gas
Oil
Date serviced :
Flue gas T° :
% CO2 (min. load) :
Efficiency :
% CO2 (max. load) :
Gas pressure :
Name and signature :
➠
➠
➠ Gas
Oil
Date serviced :
Flue gas T° :
% CO2 (min. load) :
Efficiency :
% CO2 (max. load) :
Gas pressure :
Name and signature :
➠
➠
➠ Gas
Oil
28
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excellence in hot water
INTERNATIONAL
ACV international n.v
ESPAÑA
ACV ESPAÑA
PORTUGAL
BOILERNOX LDA
KERKPLEIN, 39
B-1601 RUISBROEK - BELGIUM
TEL.: +32 2 334 82 20
FAX: +32 2 378 16 49
E-MAIL: [email protected]
C/DE LA TEIXIDORA, 76
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FAX:+351 244 823 758
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FAX:+33 4 72 47 08 72
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ACV NEDERLAND bv
POSTBUS 350
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TEL.:+31 180 42 10 55
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13/05/2003
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