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Halstead Best db 80 Installation & Servicing Instructions Manual

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INSTALLATION &
SERVICING INSTRUCTIONS
FOR THE
Best 80 G. C. No. 41 333 56
Supplied By www.heating spares.co Tel. 0161 620 6677
HALSTEAD
EC 0087/AT/5342
0 0 8 6
HALSTEAD
Best db 80
Best db 80
CAST IRON
WALL MOUNTED
FAN ASSISTED BOILER
TO BE LEFT WITH THE USER
FOR USE WITH NATURAL GAS ONLY (G20)
SUPPLY PRESSURE 20 mbar

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  • Page 1 HALSTEAD INSTALLATION & HALSTEAD SERVICING INSTRUCTIONS Best db 80 Best db 80 FOR THE CAST IRON WALL MOUNTED FAN ASSISTED BOILER TO BE LEFT WITH THE USER FOR USE WITH NATURAL GAS ONLY (G20) Best 80 G. C. No. 41 333 56...

  • Page 2: Table Of Contents

    CONTENTS INTRODUCTION The Halstead Best db 80 is a wall mounted, fan assisted Page INTRODUCTION ......1 balanced flue natural gas boiler incorporating a cast iron heat exchanger.

  • Page 3: Technical Specifications

    TECHNICAL SPECIFICATIONS PERFORMANCE DATA GENERAL SPECIFICATIONS BEST 80 Best Best Main Burner 23.44 Heat Max. Injector mm (in) Dia. 4.12(.162) Output Btu/hr 79.977 Min. 17.57 Minimum Water Flow Rate Btu/hr 59.950 l/min (galls/min) 30.5(6.7) 29.6 Heat Max. Total Water Capacity litres (galls) 4.5(1.0) Input Btu/hr...
  • Page 4 • EXAMPLES OF ALTERNATIVE FLUE SYSTEMS TERMINAL VERTICAL DUCT COWL 2(a) HORIZONTAL • 2(b) HORIZONTAL • EXTENSION STRAIGHT FLUE STRAIGHT FLUE DUCT SUPPLIED AS STANDARD STANDARD • TELESCOPIC • EXTENSION FLUE DUCT FLANGED ELBOW • STANDARD • EXTENSION DUCT • DUCT FLANGED ELBOW EXITS APPLIANCE...

  • Page 5: Air/Flue Duct Specifications

    AIR/FLUE DUCT SPECIFICATIONS The appliance is supplied complete with a standard telescopic flue Socket (for use with elevated horizontal flues and vertical cowls) kit. This comprises a standard duct and a terminal duct and can Vertical Cowl Kit. (For use where an external wall is not available) be used for flue lengths between 506mm and 820mm without These optional kits may be used with the standard flue kit to cutting the ducts.
  • Page 6 SPECIFICATION FOR FLUE SYSTEMS WITH AN EXTRA 90° ELBOW (Refer to section 2.5(b) for maximum allowable lengths) • • Fig 4a - Use of the flanged elbow, one extension kit, 90° elbow, and standard 4(a) flue assembly. • Equivalent Length Shown is 3045mm Where ‘Lb’...
  • Page 7 c) The standard terminal must always be fitted horizontally. The Refer to Figures 3 to 7 to determine which option kits are required vertical terminal must always be used if a vertical outlet is before commencing the installation. required. Installation instructions for installing the appliance with a standard d) The flue must only terminate in a horizontal or vertical posi- flue and straight extension ducts (Fig.

  • Page 8: Exploded Diagram

    EXPLOADED DIAGRAM 34 35 Drawing amended 7/05/99 Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 9: Installation Requirements

    INSTALLATION REQUIREMENTS STATUTORY REQUIREMENTS FLUE TERMINAL POSITION • SAFETY (INSTALLATION AND USE) REGULATIONS 1984 (AS AMENDED). It is the law that all gas appliances are installed by a registered • person, in accordance with the above regulations. Failure to install •...

  • Page 10: Flue Terminal Position

    b) It is important that the position of the terminal allows free e) The governor at the meter must give a constant outlet pressure of 20mbar (8 in.wg) when the appliance is running. passage of air across it at all times. c) It is ESSENTIAL TO ENSURE that products of combustion f) The gas supply line should be purged.
  • Page 11 PIPE LAYOUT USING BY-PASS AND CLOSE COUPLED FEED AND VENT (fully pumped) TO DRAIN COLD OPEN INDIRECT AUTOMATIC OFF TAPS WATER VENT CYLINDER AIR VENT OPEN VENT STORAGE FEED AND EXPANSION TANK MINIMUM 15mm HEAD 1.2m COLD FEED 22mm COPPER 22mm COPPER ISOLATING...
  • Page 12 22mm or 28mm connections. BS5449:1:1977, clause 25. The open vent may be connected to the un-used connection on Halstead Boilers manufacture a Sealed System Pod that the top manifold. (Refer to Fig. 10) fits directly below the appliance. This incorporates an...

  • Page 13: Installing The Appliance

    INSTALLING THE APPLIANCE PREPARING THE WALL UNPACKING THE APPLIANCE The appliance and standard flue kit is supplied in a single cardboard Before installing the appliance ensure that the chosen location is carton. In addition various optional flue kits are available as suitable (Section 3.2) and that the requirements for flue position, described in section 2.5.

  • Page 14: Preparing The Appliance

    i) Cut the hole in the wall for the flue/air duct. The diameter AIR FLUE DUCT INSTALLATION should not be less than 100mm (4in) and must be horizontal. If the hole is not accessible from the outside of the building, its If the wall thickness is less than 800mm (31in) the air/flue duct minimum diameter should be sufficient to allow the insertion may be fitted without access to the external wall providing that the...
  • Page 15 • • AIR/FLUE DUCT ASSEMBLY EXTERNAL SEALING RING • • STANDARD TERMINAL Fits Inside Duct • EXTENSION DUCT(S) Fits Over Duct STANDARD DUCT • Fits Outside Elbow • MAX. 319mm MIN. OVERLAP 50mm (2in) • ACHIEVING THE CORRECT • FLUE LENGTH •...
  • Page 16 4.5.2 4.5.3 INSTALLING THE AIR/FLUE DUCT INSTALLING THE AIR/FLUE DUCT FROM INSIDE THE ROOM FROM OUTSIDE THE BUILDING (Flue hole diameter 100mm - wall liner not necessary) Wall thickness up to 800mm (31in) only. a) Secure the flue elbow with seal to the appliance using 4 screws. a) Push the terminal through the wall liner taking care to ensure b) From outside the building, push the flue system through the wall that the terminal is the correct way round and the external...

  • Page 17: Gas Connection

    GAS CONNECTION PIPEWORK INSTALLATION Connect the gas supply to the gas service cock using a suitable jointing compound.This is located at the lower right hand corner of the appliance. See fig 29. 28mm DHW FLOW WATER CONNECTIONS 22mm HEATING FLOW See Section 3.7 for detailed information.
  • Page 18 SCHEMATIC WIRING DIAGRAMS 4.8.3 COMBINED PUMPED CH & GRAVITY DHW The wiring plan shown is based on the use of 10-way junction box (Honeywell Part No. 42002116-001). Junction Box terminal 10 is switched live and terminal 9 is pump live. V4043H V4043H 28mm...
  • Page 19 FULLY PUMPED ‘Y’ PLAN The wiring plan shown is based on the use of 10-way junction box (Honeywell Part No. 42002116-001). Junction Box terminal 8 is switched live and terminal 9 is pump live. V4073A POSITION CT200 ZONE VALVE ROOM THERMOSTAT 230V 50Hz T6360B...

  • Page 20: Commissioning & Testing

    COMMISSIONING & TESTING CHECKS TO ENSURE ELECTRICAL SAFETY SHOULD BE h) Allow the boiler to operate for 10 minutes CARRIED OUT BY A COMPETENT PERSON. DO NOT USE i) Check the burner pressure is in accordance with the data in THE BOILER WITHOUT THE SEALED INNER CASING BEING section 2.1.

  • Page 21: Routine Servicing

    ROUTINE SERVICING To ensure continued efficient operation of the appliance, it is FAN ASSEMBLY recommended that it is checked and serviced as necessary at regular intervals. The frequency of servicing will depend upon the g) Disconnect the electrical connections to the fan. particular installation conditions and usage but in general once a h) Remove the two screws securing the fan assembly and remove year should be adequate.

  • Page 22: Parts Replacement

    PARTS REPLACEMENT LOCATION OF SERVICEABLE Before commencing any replacement operation, ISOLATE the COMPONENTS mains electrical supply, remove the front painted panel by sliding up and then away from the boiler, remove the right hand portion of the inner case by first pulling off the control knob, then unscrewing the upper and lower right hand screws (Fig.

  • Page 23: Potentiometer

    h) Separate the valve and manifold by unscrewing the POTENTIOMETER 3 extended screws. a) Unclip the aquastat housing from its mounting plate on the top i) Re-assemble in reverse order, ensuring all seals are in good of the gas valve by slightly pressing the two sides of the housing condition (replace where necessary).

  • Page 24: Fan Assembly

    b) Replace the front insulation, sliding the new piece in from 7.12 FAN ASSEMBLY either side. a) Remove the combustion chamber front panel as described in c) Replace the side insulation, sliding the new pieces in from section 7.9a & b. the front.

  • Page 25: Fault Finding

    FAULT FINDING Before proceeding through this fault finding guide, ensure all c) Ensure there is 230V at the permanent live ‘L’ on the connections to the electronic circuit board and the 12 way installation terminal block. connector to the ignition device are correctly fitted. d) Ensure there is 230V at the switched live ‘1’...

  • Page 26: Short Parts List

    SHORT PARTS LIST G.C. Part No. Description No. off Maker’s Part No. Main Burner (Aeromatic) 700539 Ignition Electrode 500573 Flame Detection Electrode 500574 Gas Valve (Without Ignition Device) 500569 Ignition Device (For Gas Valve) 500570 Aquastat PCB 600513 Thermistor 500572 Overheat Cut Off Device 500578 Potentiometer / On-Off Switch...

  • Page 27: Supplementary Instructions For Flue Systems With

    necessary hole in the wall(s) for the air/flue duct as defined in SUPPLEMENT 1 section 4.2. c) Install the boiler as described in section 4 with the exception Supplementary instructions for flue systems with a vertical outlet. of the flue system (4.5) a) Read the installation requirements and flue specifications d) Using the information and dimensions in Figures 3 to 7 shown described in section 3.
  • Page 28 Tel: (01787) 475557 Fax: (01787) 474588 SERVICE HOTLINE (01203) 351424 Halstead Boilers are continuously improving their products and therefore reserve the right to change specifications without prior notice and accept no liability for any error or omission in the information contained in this document.

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