ACV TER Manuale utente

66403100 06/2005

Inst allat ion, Operat ing and

Servicing Instructions

excellence in hot water

TER

66403100 06/2005 Page 2

1. PRODUCT DESCRIPTION

Medium-power, heating only boiler, for industrial and commercial applications

 Boiler body manufactured out of STW22 carbon steel plates

 Stylish metal casing, painted red

 Replaceable heating elements

 Rigid polyurethane foam insulation

 Control panel, complete with

- main switch

- 4 power stages status lights

- overheating warning lights

- boiler temperature thermometer

- boiler control thermostat adjustable between 30 and 90°C

- overheating safety thermostat, to be resetted manually

 Available in 5 models between 57 and 259 kw

2. CONSTRUCTION FEATURES

BOILER BODY

Manufactured out of ST37 high-thickness steel. The boiler body is submitted to a

hydraulic test pressure of 6 bars (the maximum allowable working pressure is 4 bars).

HEATING ELEMENTS

Replaceable elements, mounted on the front of the boiler body with a pressure gasket. The

heating elements are made out of Incoloy stainless steel, with a specific thermal

load of 12.9 W/cm².

ELECTRICAL CONNECTION PANEL

The panel is equipped with:

- Power terminal board for three-phase power supply (400 V + N)

- Control circuit terminal board for single-phase 230 V power supply

- Grounding terminal

- Four power contactor groups

- 4-power stage cascade programmer

- Fast cut-off relay

- Programmer resetting relay

INSULATION

CFC-free, 50 mm thick rigid polyurethane foam insulation.

CASING

The casing is entirely made out of steel plates and submitted to degreasing and phosphating before

epoxy-powder painting. After painting, the panels are baked at 220°C. This coating guarantees a

good resistance and a perfect finish.

PACKAGING

A special packaging has been designed for the vertical transport of the unit.

The boiler is wrapped in shrink wrap film to protect it against scratches and to make any

damage caused during transport immediately visible.

66403100 06/2005 Page 3

GENERAL LAYOUT

1. Boiler body

2. rigid polyurethane foam insulation

3. Enameled casing

4. Heating water supply

5. Heating water return

6. Heating elements

7. Cascade programmer

8. Electrical panel

9. Connection terminals

10. Control panel

66403100 06/2005 Page 4

3. DESCRIPTION OF THE CONTROL PANEL

1) Thermometer

2) Main switch

3) 1st stage operation light

4) 2nd stage operation light

5) 3th stage operation light

6) 4th stage operation light

7) Overheating lock-out indicating light

8) Boiler control thermostat (30-90°C)

9) Manually resettable safety thermostat, set at 103 °C

To access to the connection terminals, unscrew the two screws "A" and remove the front panel.

66403100 06/2005 Page 5

4. DIMENSIONS AND TECHNICAL SPECIFICATIONS

TYPE TER 57 TER 86 TER 115 TER 144 TER 201 TER 259

Partnumber 00080401 000080801 00081201 00081601 00079101 00079901

Power kW 57,6 86,4 115,2 144 201,6 259,2

Power voltage V 3x400 + N 3x400 + N 3x400 + N 3x400 + N 3x400 + N 3x400 + N

Control circuit voltage V 230 230 230 230 230 230

Heating elements nombre 12 x 2 18 x 2 24 x 2 30 x 2 42 x 2 54 x 2

Total capacity L 155 155 155 155 250 250

Working pressure (max) bar 4 4 4 4 4 4

Temperature (max) °C 90 90 90 90 90 90

Heating connection

(female)

ø 2” 2” 2” 2” DN 100* DN 100*

Dimensions A mm 80 80 80 80 80 80

B mm 124 124 124 124 190 190

C mm 1134 1134 1134 1134 1060 1060

D mm 130 130 130 130 197 197

E mm 610 610 610 610 752 752

F mm 1380 1380 1380 1380 1380 1380

G mm 610 610 610 610 752 752

Weigth (empty) Kg 102 102 102 102 195 195

(*) Above 144 kW, heating circuit connection with DN 100 flange.

66403100 06/2005 Page 6

5. SIZING OF SUPPLY WIRES

The supply wires are sized depending of the type and current of the MCB. This last is sized

depending of the nominal current of the boiler. The admissible current of the supply wires depends

of the ambient temperature, the section, the length and the insulation of the wires, the wires ducts,

the mounting and the environment.

The following values are given for information for an ambient temperature of 25°C and a maximal

length of 5 meters. In all the circumstances, the installation must be in accordance with the current

IEE wiring regulations.

For higher temperatures, the current rating should be reduced according to the next table:

6. POWER CHARACTERISTICS: V 400/3/50 + N

Power, per stage kW Amperes, per stage, at V 400/3/50

Type Total power 1° 2° 3° 4° 1° 2° 3° 4° Amperes

total

kW Stage Stage Stage Stage Stage Stage Stage Stage

TER 57 57,6 14,4 14,4 14,4 14,4 20,9 20,9 20,9 20,9 84

TER 86 86,4 21,6 21,6 21,6 21,6 31,3 31,3 31,3 31,3 125

TER 115 115,2 28,8 28,8 28,8 28,8 41,7

41,7

167

TER 144 144,0 36,0 36,0 36,0 36,0 52,2 52,2 52,2 52,2 209

TER 201 201,6 50,4 50,4 50,4 50,4 73 73 73 73 292

TER 259 259,2 64,8 64,8 64,8 64,8 94 94 94 94 376

Diametre mm20,8 1 1,5 2,5 4,6 10 16 25 35 50 70 95 120 150 185 240

current Amp 13 16 20 27 36 47 65 87 115 143 178 220 265 310 355 480

T ambient °C 25 30 35 40 45 50 55

Current derating % 100 92 85 75 65 53 38

66403100 06/2005 Page 7

D Safety power relay (not

supplied by ACV)

Terminal for external

safety power relay (not

supplied by ACV)

Terminals for remote

indicators of the power

stages (230 V)

Fast cutoff relay

Programmer resetting relay

Microswitches of the programm

Safety

thermostat

Control thermostat

30 – 90 °C

Programmer motor

7. WIRING DIAGRAM OF THE CONTROL CIRCUIT 230V / Single phase / 50Hz

66403100 06/2005 Page 8

8. WIRING DIAGRAM OF THE CASCADE PROGRAMMER

FEEDRATE OF THE PROGRAMMER : 5 SECONDS PER GRADE

66403100 06/2005 Page 9

9. HYDRAULIC AND ELECTRICAL CONNECTIONS

230 V Warning !!! In order to ensure the proper

functioning of the safety thermostat, it is

mandatory to connect the phase / neutral the

right way

1) Controller

2) Climatic sensor

3) Overheating safety thermostat, interrupting the power

relays and powering the reset relay

4) Supply thermo-sensor

NB: the listed devices are not supplied by ACV.

01 CONTROLLED BY CLIMATIC SENSOR

02 STABILIZED TEMPERATURE CONTROL

Electrical connection

TER 57 up to 144

b) Boiler protection fuses

d) Safety relay with positive safety release coil

e) Control circuit protection fuses

g) Power terminals

h) Control circuit terminals 230V 50Hz

i) 1st – 2nd – 3rd – 4th stage contactors

j) Main circuit

k) Heating elements 2 x 2400 W

l) Control circuit main cut-out relay

m) Programmer resetting relay

n) Programmer

CAUTION!! For electrical safety reasons, it is

recommended to always install differential

cut-out devices on the power supply circuits.

WARNING !!!

For protection against electrical hazard, it is always

recommended to install a differential cut-out device

(Ground Fault Isolator) on the power supply circuit,

upstream of the boiler.

N.B. The devices "b", "d" and "e" are not part of ACV delivery.

66403100 06/2005 Page 10

TER 201 and 259

a) et b) Boiler protection fuses

c) et d) Safety relay with positive safety release coil

e) On/off switch of the control circuit

f) Power terminals for 2d, 3th and 4th stages

g) Power terminals 1st stage

h) Control circuit terminals 230V 50Hz

i) 1st – 2nd – 3th – 4th stage contactors

j) Main circuit

k) Heating elements 2 x 2400 W

l) Control circuit main cut-out relay

m) Programmer resetting relay

n) Programmer

WARNING !!!

For protection against electrical hazard, it is always recommended to install a differential cut-out device (Ground

Fault Isolator) on the power supply circuit, upstream of the boiler

N.B. The devices “ a ” ,“ b ” ,“ c ” ,“ d ” et “ e ” are not part of ACV delivery

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