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Summary of Contents for Halstead CLUB HE 18
- Page 1 TO BE GIVEN TO THE USER 0087 Pin 87/BQ/44 G.C. Appliance No. 41-260-20 Club HE 18 S E A L E D S Y S T E M C O N D E N S I N G B O I L E R...
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Page 2: Table Of Contents
........2 (G20) only. The Club HE 18 is a sealed system condensing boiler Performance Data . -
Page 3: Important Information
IMPORTANT INFORMATION GENERAL DESCRIPTION IT IS A STATUTORY REQUIREMENT THAT ALL GAS This appliance incorporates a microprocessor based, fully APPLIANCES ARE INSTALLED BY COMPETENT PERSONS, modulating air/gas ratio control system with direct burner (i.e. CORGI REGISTERED INSTALLERS) IN ACCORDANCE ignition, which provides a modulated heat output to central WITH THE GAS SAFETY (INSTALLATION AND USE) heating (CH) demands, with internal frost protection provided as REGULATIONS (CURRENT EDITION). -
Page 4: Technical Specifications
C13, C33, Britain and Ireland) using gas category 2H (G20 with a governed C53, or B23 gas supply at 20 mbar (8 in.wg) inlet pressure). PERFORMANCE DATA Appliance Club HE 18 Mode Rate 18.0 (Btu/h) (61500) Central Heating Output (non-condensing) (80 - 60 °C) -
Page 5: General Specifications
GENERAL SPECIFICATIONS Appliance Club HE 18 Total weight (full) 44.1 Total weight (empty) 42.0 Max lift weight 41.0 Total water capacity Integral expansion vessel capacity Maximum heating system water content using fitted expansion vessel, @ 0.75 bar Electrical supply 230V 50Hz... -
Page 6: Overall Dimensions & Minimum Clearances
OVERALL DIMENSIONS AND MINIMUM CLEARANCES CONCENTRIC AIR / FLUE DUCT SPECIFICATIONS The Club HE 18 can be installed to a number of different parts to the appliance and end terminal. Flue extension ducts and concentric flue systems. The different flue applications as shown in extension elbows are available as accessories. - Page 7 Standard concentric (ø100/60) vertical flue application, Figures 2.5.1 KIT A HORIZONTAL WALL TERMINAL 3b, 3c, through roof attics with a maximum length of 12000mm. (C13) - PART NO.956083 The kit comprises of the roof terminal, flashing kit, vertical adaptor with sampling point and bracket. Standard horizontal flue kit - Part no.
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Page 8: Specification For Chimney Flue Liner Kit (Type B23)
flue will be routed vertically alongside the outside wall to above the roofline. Special seals are required to prevent rainwater penetrating the pipe joints. For installation details refer to the flue kit instructions. KIT E CHIMNEY FLUE LINER KIT (B23) – PART NO. 956082 This kit is suitable for open flue application in accordance with BS5440 where a room sealed flue installation is impractical. -
Page 9: Specification For Twin Flued (Type C53)
KIT F: TWIN FLUE SYSTEM (C53) – ADDITIONAL CONCENTRIC FLUE KITS PART NO. 956080 The following additional concentric kits are available as optional extras. This flue system kit is designed for installations where the air intake position is different than the flue duct exit point. The kit comprises of a twin adaptor Flue Extension Ducts - 1000 mm and 500 mm long, (each from which the air intake is taken from the adjacent outside wall (see duct extends the flue length by up to 950 mm and 450 mm... - Page 10 2.8.1 PLUME DIVERTER TERMINAL The resistance of the diverter is equivalent to 0.5 metre of flue length. Ensure this is used when INSTALLATION calculating the maximum allowable flue length. Plume Diverter Kit Part No: 956103 (maximum horizontal flue length restricted to 4.5 (For use with Standard horizontal flue kit - Part no 956083 - only) metres when using the plume diverter).
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Page 11: Appliance Hydraulic Circuits
APPLIANCE HYDRAULIC CIRCUITS CH MODE... -
Page 12: Installation Requirements
For further information contact: position selected for installation should be within the building, Halstead Boiler Ltd, Service Help Line: 01926 834834. unless otherwise protected by a suitable enclosure and MUST allow adequate space for installation, servicing and operation of the VENTILATION REQUIREMENTS appliance and for air circulation around it (Section 2.4 and 3.4). -
Page 13: Condensate Disposal
If the appliance is installed in a room or internal space with other FLUE TERMINAL POSITION opened flued appliances, then the size of the air vent necessary • should be calculated in accordance with BS 5440-2 Table 2. Where an open flued system is used, and the flue duct air inlet is •... - Page 14 EXPANSION VESSEL – The integral expansion vessel is pre- efficiently with the minimum of maintenance necessary. Halstead charged to a pressure of between 0.5 and 1.0 bar. This should Boilers fully support this professional approach and recommend be checked before the water system is filled. Details below show that the system is cleansed with an effective chemical cleanser the water system volume that is acceptable for this vessel.
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Page 15: Electricity Supply
The mains cable must be at least 0.75 mm2 (24/0.2 mm) PVC 01926 834834. insulated to BS 6500 table 16. ‘S’ PLAN INSTALLATION TIMED CH & DHW FOR FURTHER INFORMATION PLEASE CONTACT HALSTEAD BOILERS LTD SERVICE HELPLINE TEL: 01926 834834... - Page 16 ‘S’ PLAN INSTALLATION TIMED CH & DHW FURTHER INFORMATION PLEASE CONTACT HALSTEAD BOILERS LTD SERVICE HELPLINE TEL: 01926 834834 ‘Y’ PLAN INSTALLATION TIMED CH & DHW FOR FURTHER INFORMATION PLEASE CONTACT HALSTEAD BOILERS LTD SERVICE HELPLINE TEL: 01926 834834...
- Page 17 ‘Y’ PLAN INSTALLATION TIMED CH & DHW FURTHER INFORMATION PLEASE CONTACT HALSTEAD BOILERS LTD SERVICE HELPLINE TEL: 01926 834834...
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Page 18: Appliance Installation
APPLIANCE INSTALLATION Before installing the appliance, check that the chosen location is PREPARING THE WALL suitable (section 3.2) and that the requirements for flue position a) Fix the paper template in the required position (ensuring that the (section 3.3) and minimum clearances (Figure 1b) are satisfied. necessary clearances are achieved). -
Page 19: Mounting The Appliance
Fill the central heating system as described in section 5.1, and then MOUNTING THE APPLIANCE proceed to Section 4.5. Lift the appliance into position as shown in Figure 14. Position the top of the appliance approximately 20mm above the top of the wall mounting plate and use the side wings on the plate to locate VIEW OF CONNECTIONS the appliance in a horizontal direction. -
Page 20: Condensate Connection
CONDENSATE CONNECTION PRESSURE RELIEF VALVE CONNECTION Refer to Figure 16 The safety valve is located at the bottom RHS of the appliance. Connect 15mm copper pipe using the male flanged nut and olive Connect preferably a 22 mm plastic push fit or adhesive overflow pipe to provided, to the safety valve outlet, and then continue the discharge the condensate outlet. -
Page 21: Electrical Connections
4.8.1 INSTALLING THE AIR/FLUE DUCT 4.8.2 INSTALLING THE AIR/FLUE DUCT FROM INSIDE THE ROOM FROM OUTSIDE THE BUILDING Wall thickness up to 800 mm (31 in) only. (Flue hole diameter 100 mm – wall liner not necessary) a) Push the terminal through the wall liner taking care to ensure that Secure the flue elbow with seal to the appliance using 4 screws. -
Page 22: Commissioning And Testing
COMMISSIONING & TESTING 5) Drain the entire system using the manual drain valve to flush FILLING THE WATER SYSTEM out any debris, and refill to 0.2 bar above the system design pressure (between 0.5 and 1.0 bar) by repeating the above Before commissioning the appliance, the whole gas installation procedure. -
Page 23: Commissioning The Appliance
REQUIRED. HOWEVER IF THE APPLIANCE FAILS TO to air in the gas supply line. The boiler will automatically have five OPERATE CORRECTLY CONTACT THE HALSTEAD attempts at ignition. It may be necessary to turn the control knob fully BOILERS LTD SERVICE HELPLINE: 01926 834834. -
Page 24: Final Checks
Allow the appliance to cool and turn the control knob fully anti- FINAL CHECKS clockwise to reset. Turn the control knob to standby. On its central heating control thermostat, a slow cycle device b) Remove the manometer and tighten the appliance inlet operates. -
Page 25: Routine Servicing
If the measured combustion values are significantly carry out any service work. outside the figures stated in section 2.3 contact Service the appliance by following the full procedure detailed Halstead Boilers Ltd. Service Helpline: below: 01926 834834. COMBUSTION CHECK When the appliance is operating at maximum output check that the gas supply pressure is 20.0 mbar, using the inlet pressure test... -
Page 26: Gas Control Valve, Fan & Burner Assembly
Unscrew the screw holding the gas valve lead plug, and GAS CONTROL VALVE, FAN & disconnect the plug. BURNER ASSEMBLY f) Disconnect the electrical leads from the fan (2 plugs). Refer to Figures 25, 26, 27 and 28 g) Remove the base panel (1 screw). -
Page 27: Burner
j) Remove the 4 nuts holding the combustion chamber front COMBUSTION CHAMBER cover in place. & HEAT EXCHANGER k) Remove the gas control valve, fan & burner assembly, by Inspect the inside of the combustion chamber for debris. If carefully pulling forward the combustion chamber front and necessary, clean the inside of the tubes with a soft brush. -
Page 28: Internal Wiring Diagram
INTERNAL WIRING DIAGRAM 7.1 : FUNCTIONAL FLOW WIRING DIAGRAM... -
Page 29: Fault Finding
FAULT FINDING further information contact: Halstead Boilers Ltd. Service Help GENERAL line: 01926 834834. Before looking for a fault condition, check that: The mains electrical supply is turned on. DIAGNOSTIC DIGITAL DISPLAY room thermostat and clock (where fitted) are calling for heat. -
Page 30: Central Heating Fault Finding
Halstead CENTRAL HEATING FAULT FINDING Boilers Ltd Service Help Line: 01926 834834 Upon a demand for Central Heating, (closure of the time clock and room thermostat, where fitted), the controls should carry out Note: Whenever a CH demand is removed, a set of start up checks, followed by an ignition sequence. -
Page 31: Blocking Codes
NOTE: FAULT CODES 1 TO 4 CAN BE RESET BY FOLLOWING THE PROCEDURE ABOVE, HOWEVER IF ANY OTHER FAULT CODE IS SHOWING PLEASE CONTACT YOUR INSTALLER OR HALSTEAD BOILERS LTD. SERVICE HELP LINE: 01926 834834. Note: All Lock-out and Blocking codes will flash if displayed. -
Page 32: Replacement Of Parts
REPLACEMENT OF PARTS d) Fit the new electrode, and new gasket. Before commencing any service operation, ISOLATE the mains electrical supply and TURN OFF the gas supply at the main e) Check that electrode is aligned as detailed as appropriate in service cock. -
Page 33: Gas Control Valve
GAS CONTROL VALVE Refer to Figures 36, 37 and 38 9.3.1 GAS CONTROL VALVE REMOVAL, REPLACEMENT AND SET-UP Remove casing and control panels as described in section 6.2. Unscrew the gas valve electrical plug and disconnect from the gas valve. c) Ensuring the gas isolating cock is in the off position, undo the union nut holding the gas valve feed pipe to the gas isolating... -
Page 34: Fan
6.1, and compared to the values stated section 2.3. If the measured value does not correspond to the Performance Data, then contact: Halstead Boilers Ltd. Service Help line: 01926 834834. Always seal the gas valve adjustment screw with paint after adjustment Turn the control knob back to normal operation mode and within 3 seconds back to 'service mode'. -
Page 35: Burner
BURNER COMBUSTION CHAMBER FRONT INSULATION Refer to Figures 36, 42 and 43 The design of the appliance is such that the combustion chamber a) Ensure supply voltage is isolated, and that the gas supply is insulation should not require replacement unless mechanically isolated. -
Page 36: Heat Exchanger
g) Rotate the flow pipe anticlockwise and gently pull down to disengage the flow pipe from the heat exchanger. h) Remove the retaining clip from the heat exchanger return inlet, and undo the nut connecting the return pipe to the hydroblock adaptor fitting (See Figure 46). -
Page 37: Hydroblock Assembly
f) Re-assemble in reverse order; ensure that all joints and seals are Remove the clip holding the return pipe in place. correctly re-fitted. g) Undo the nut connecting the CH return pipe to the CH return g) Open the isolating cocks and vent air from the system using the isolating cock, and disengage the CH return pipe from the manual air vent. -
Page 38: Pressure Relief Valve
9.12 d) Fit the replacement flue sensor and reconnect the electrical lead PRESSURE RELIEF VALVE (blue plug). Refer to Figures 21 and 25 Note: the thermal fuse is not removable or a a) Ensure supply voltage is isolated. serviceable item, should the heat exchanger b) Drain down the appliance;... -
Page 39: Auto Air Vent
If the boiler requires resetting turn the control knob anti-clockwise to 9.17 AUTO AIR VENT 'STANDBY' position and then back to 'ON' within two seconds. Refer to section 5.4. Refer to Figure 48 a) Ensure supply voltage is isolated. b) Drain down the appliance; refer to section 9.19. -
Page 40: Draining The Appliance
d) Drain down the CH system from the external drain point, and 9.19 DRAINING THE APPLIANCE drain the boiler using the manual drain tap on the CH flow water isolating cock (figure 21), in conjunction with the manual air vent Refer to Figures 21, 46 and 53 located on the top LHS of the heat exchanger;... -
Page 41: Short Parts List
Flow/Return temperature thermister 500661 Flue thermister ACE HE 500662 Pressure gauge 450961 Auto Air Vent 500674 Control PCB and box assembly – Club HE 18 988542 User Control fascia assembly 988549 Air vent pipe and seal 988545 Manual bleed valve 300730 Heat Exchanger seals &... - Page 43 Service Helpline: 01926 834834. Training: 01926 834838. Email: sales@halsteadboilers.co.uk or service@halsteadboilers.co.uk or training@halsteadboilers.co.uk Website: www.halsteadboilers.co.uk Halstead Boilers is continuously improving its products and may therefore change specifications without prior notice. The statutory rights of the consumer are not affected. 01/06 751113...
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