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Installation and Service Instruction
G. C. APPLIANCE No:
Hero 30: 41-260-01
Hero 40: 41-260-02
Hero 50: 41-260-03
Hero
Lightweight Cast Iron boiler
30, 40, 50, 60, 75, 90
To be left with user adjacent to gas meter
Hero 60: 41-260-04
Hero 75: 41-260-05
Hero 90: 41-260-06
0 0 8 6
Hero 40 PROPANE: 41-260-07
Hero 60 PROPANE: 41-260-08
EC 0087/BN/41
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Summary of Contents for Halstead Hero 30
- Page 1 Installation and Service Instruction To be left with user adjacent to gas meter EC 0087/BN/41 G. C. APPLIANCE No: 0 0 8 6 Hero 30: 41-260-01 Hero 60: 41-260-04 Hero 40 PROPANE: 41-260-07 Hero 40: 41-260-02 Hero 75: 41-260-05 Hero 60 PROPANE: 41-260-08...
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Page 2: Table Of Contents
CONTENTS INTRODUCTION GENERAL DESCRIPTION The Halstead Hero range consists of six different outputs. The outputs are available from 30,000 to 90,000 BTU/h and spot rated (non TECHNICAL SPECIFICATIONS ....1 modulating). -
Page 3: Technical Specifications
The appliances were certified by the Notified Body 0087. (gross) BTU/h 37020 49372 49372 61757 74040 74040 92806 111231 Heat Any alterations to the appliance not approved by Halstead Boilers 9.78 13.03 13.33 16.3 19.6 19.99 24.51 29.37 input (nett) BTU/h... -
Page 4: Overall Dimensions And Minimum Clearances
(section 4.5). Additional instructions for flue systems incorporating applications. The kit comprises of vertical terminal, pitched roof vertical applications are given in the Halstead Flue Guide and flashing, reducer sockets and vertical turret. User Instructions as part of the flue kit. - Page 5 ‘b‘ measured from the centre line of the extension elbow to the underside of the air cowl. Maximum allowable flue length of ‘a‘ + ‘b‘ = Hero 30 - 75 2460mm, Hero 90 1666mm Note: For vertical flue application flue kit 955082 and 988378 is required.
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Page 6: Se-Duct Applications
SE-DUCT APPLICATIONS Important Note~ The HERO 30 IS NOT SUITABLE FOR SE-DUCT APPLICATIONS. FLUE SYSTEM APPLICATION SE-Ducts should conform to the requirements of BS 5440 part TERMINAL RAIN SHIELD 1:2000 clause11. The entry of the concentric air / flue duct should be as close to the centre of the entry face of the SE-DUCT as possible. -
Page 7: Installation Requirements
INSTALLATION REQUIREMENTS STATUTORY REQUIREMENTS FLUE TERMINAL POSITION • GAS SAFETY (INSTALLATION AND USE) REGULATIONS (CURRENT EDITION) The appliance is suitable only for installation in GB and IE and • should be installed in accordance with the rules in force. • •... -
Page 8: Flue Terminal Position
d) A gas meter can only be connected by the Gas Supplier or e) A compartment used to enclose the appliance MUST be designed by their contractor. and constructed specifically for this purpose. An existing cupboard, or compartment, may be used provided it is modified e) An existing meter and / or pipework should be of sufficient size accordingly. -
Page 9: Central Heating Water Systems
3 bar and temperature of The valve should be so positioned so that any discharge of steam 110°C. Halstead boilers recommend that any plastic pipe used or water cannot cause any harm to occupants or electrical should not terminate within 2 metres of the appliance. - Page 10 OPEN VENTED SYSTEM AUTOMATIC COLD INDIRECT OPEN AIR VENT CYLINDER DRAIN WATER VENT OPEN VENT OFF TAP STORAGE • FEED AND EXPANSION TANK • • MINIMUM 15mm • HEAD 1.2m COLD FEED • • • 22mm COPPER • • • 22mm ISOLATING COPPER...
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Page 11: Installing The Appliance
INSTALLING THE APPLIANCE UNPACKING THE APPLIANCE PREPARING THE WALL / APPLIANCE Before installing the appliance ensure that the chosen location is The appliance and standard flue kit is supplied in a single suitable (Section 3.2) and that the requirements for flue position cardboard carton. - Page 12 FITTING BOILER ONTO WALLBRACKET • • • TO REMOVE FRONT PANELS UNSCREW THE SIX SCREWS • • • FITTING THE ADAPTOR TUBE TO FAN FITTING THE FLUE RESTRICTOR RESTRICTOR FLUE ADAPTOR FLUE TERMINAL • • • • • • • •...
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Page 13: Top Outlet Flue
h) Remove both casing panels from the boiler, (6 screws). MARKING THE POSITION OF A i) Lift the boiler into position; the rear bottom edge of the boiler SIDE FLUE locates onto the bottom return edge of the wall plate. Push the top of the appliance back. -
Page 14: Preparing The Horizontal Duct
4.3. 1 PREPARING THE FIT STRAIGHT AND ELBOW ADAPTOR HORIZONTAL DUCT a) Measure the required horizontal flue length as shown in Fig 15. STRAIGHT ADAPTOR • b) Fit the external sealing ring (grey) to the terminal assembly and assemble the air/flue ducts as shown in Fig 17. c) Achieve the correct flue length using Fig 17 as a guide. -
Page 15: Installing The Horizontal Duct From Inside The Building
INSTALLING THE HORIZONTAL 4.3.2 4.3.3 INSTALLING THE HORIZONTAL DUCT FROM INSIDE THE BUILDING DUCT FROM OUTSIDE THE BUILDING (wall thickness up to 800mm (31 in) only – WALL LINER (Flue hole diameter 100mm – Wall liner not required) REQUIRED) a) Using Fig 19 as a step by step guide secure the turret elbow a) Using Fig 18 as a step-by-step guide, insert the terminal end to the boiler ensuring that the gasket and ‘O’-ring seal(s) are of the flue system with external sealing ring (grey) through the... -
Page 16: Preparing And Installing The Vertical Duct
PREPARING AND INSTALLING GAS CONNECTION 4.3.4 THE VERTICAL DUCT Connect the gas supply to the inch BSPF (located at the bottom, right hand side of the appliance) isolation valve using a a) The vertical flue terminal kit (Part No: 988378) contains full suitable jointing compound. -
Page 17: Wiring Instructions
WIRING INSTRUCTIONS ELECTRICAL CONNECTIONS This appliance must have a permanent mains supply and be earthed. Use standard colours for the supply: Brown = Live (L) Blue = Neutral (N) Green/Yellow = Earth (E) Note~ It is highly recommended that this appliance is connected to an external control (timer / programmer) as part of the Approved Code of Practice and guidance Safety and Good Practice Guide 302. - Page 18 FULLY PUMPED ‘Y’ PLAN The wiring plan shown is based on the use of 10-way junction box Blue Fully pumped 'Y' Plan (Honeywell Part No. 42002116-001). Green/yellow Junction Box terminal 8 is switched live and terminal 9 is pump live. V4073A position zone...
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Page 19: Commissioning And Testing
COMMISSIONING AND TESTING Checks to ensure electrical safety should be carried out by a CONTROL BEZEL competent person. The whole of the gas installation should be inspected, checked for soundness and purged in accordance with the recommendations of BS 6891. Before carrying out the following procedures ensure that the main inner seal casing panel is correctly fitted. -
Page 20: Sealed Water Systems
i) Turn off the appliance and remove the test pressure gauge. USERS INSTRUCTRIONS Tighten the burner pressure test screw and re-light the Upon completion of commissioning and testing the system, the appliance. Check for leaks around the screw using leak installer should draw the user's attention to the following. -
Page 21: Routine Servicing Instructions
ROUTINE SERVICING To ensure the continued efficient operation of the appliance, it is e) Remove the 4 screws securing the left hand side casing panel highly recommended that regular servicing is carried out. As a and slide forwards to disengage. general guide a service on an annual basis should be adequate. -
Page 22: Main Burner Assembly & Combustion Chamber Insulation
b) Inspect the heat exchanger from both above and below (use MAIN BURNER ASSEMBLY & of a mirror could be an advantage) and brush out any debris COMBUSTION CHAMBER between the fins using a suitable brush. INSULATION c) Check for any signs of water leakage at both ends of the heat exchanger. -
Page 23: Replacement Of Parts
REPLACEMENT OF PARTS AIR PRESSURE SWITCH Before commencing any replacement operation, ISOLATE the mains electrical supply. a) Disconnect the 3 electrical connections from the switch. Open the hinged front door panel to expose the two inner casing b) Disconnect the sensing tubes from the switch. panels. -
Page 24: Fan Assembly
g) Replace the burner and re-assemble appliance in reverse FAN ASSEMBLY order. Ensure that the burner cradle assembly is correctly a) See note after section 7.4. located on the top runners and the tie rods. (Refer to Fig 35 b) Disconnect the live and neutral wires from the fan motor. Showing burner location on the runners and tie rods ) Push c) Disconnect the air pressure switch sensing tubes from the fan firmly to the rear of the appliance and ensure correct... -
Page 25: Combustion Chamber Insulation
7.10 7.10.2 SIDE PANEL INSULATION COMBUSTION CHAMBER INSULATION a) Carry out procedures detailed in section 7.6 points a) to e) inclusive. The design of the appliance is such that the combustion chamber b) Replace the insulation panel (s) and re-assemble the appliance insulation should not require replacement unless mechanically in reverse order taking note of point g) of section 7.6. -
Page 26: Fault Finding
FAULT FINDING Before proceeding through this fault finding, ensure all connections c) Ensure there is 230V at the permanent live ‘L1’ on the to the electronic circuit board and the mains supply plug (Refer to installation terminal block. Section 4.6) are correctly fitted. d) Ensure there is 230V at the switched live ’L3’... -
Page 27: Short Parts List
BURNER 30/40 700580 E96-057 BURNER 50/60 700581 E96-058 BURNER 75/90 700582 E96-059 FAN - HERO 50/60 601009 E96-060 FAN - HERO 30/40 601010 E96-061 FAN - HERO 75/90 601011 E96-062 CLIP ON OVERHEAT STAT 550527 E96-063 INJECTOR HERO 30/40 700590 E96-064... - Page 28 SERVICE HELPLINE 01926 834834 TRAINING INFORMATION 01926 834838 Halstead Boilers are continuously improving their products and therefore reserve the right to change specifications without HB 0203-750953 prior notice and accept no liability for any error or omission in the information contained in this document.
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