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Halstead ACE HE 35 User Instructions

Combination condensing boiler
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751094 ACE HE INST MANUAL:751094 ACE HE
28/9/10
09:44
Page 1
ACE HE Type
24, 30 & 35
USER INSTRUCTIONS
TO BE GIVEN TO THE USER
0086
PIN 87/BQ/44
G.C. Appliance No. 47-333-19 (Ace HE 24)
G.C. Appliance No. 47-333-20 (Ace HE 30)
G.C. Appliance No. 47-333-13 (Ace HE 35)
C O M B I N AT I O N C O N D E N S I N G B O I L E R
Supplied By www.heating spares.co Tel. 0161 620 6677

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  • Page 1 G.C. Appliance No. 47-333-20 (Ace HE 30) G.C. Appliance No. 47-333-13 (Ace HE 35) C O M B I N AT I O N C O N D E N S I N G B O I L E R...

  • Page 2: Table Of Contents

    INTRODUCTION ....... 0 The Halstead Ace HE24, Ace HE30 and Ace HE35 are high Important Information .

  • Page 3: Important Information

    751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:44 Page 3 IMPORTANT INFORMATION GENERAL DESCRIPTION IT IS A STATUTORY REQUIREMENT THAT ALL GAS The appliances incorporate a microprocessor based, fully APPLIANCES ARE INSTALLED BY COMPETENT PERSONS, modulating air/gas ratio control system with direct burner (i.e.

  • Page 4: Technical Specifications

    751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:44 Page 4 TECHNICAL SPECIFICATIONS GAS CATEGORIES These appliances are certified to comply with the requirements of The appliance classification (as defined in EN 483) may be any EN 483, EN 677, and EN 625 for use in GB and IE (Great of the following depending on the chosen flue option: C13, C33, Britain and Ireland) using gas category 2H (G20 with a governed C53, or B23...

  • Page 5: General Specifications

    751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:44 Page 5 Appliance Ace HE24 Ace HE30 Ace HE35 Design Domestic Hot Water Ltr/min 12.3 14.3 (gpm) (2.2) (2.8) (3.1) Performance raised 35°C DHW Specific Rate (D) EN 625 Ltr/min 10.9 14.7 16.7 Min Mains Water Inlet Pressure for Max Heat Output...

  • Page 6: Overall Dimensions & Minimum Clearances

    751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:44 Page 6 OVERALL DIMENSIONS AND MINIMUM CLEARANCES Ø100mm 327mm 136mm 97mm 200mm 173mm SEE NOTE 758mm NOTE: 5mm for normal 907mm operation. 450mm for installation and servicing 446mm 200mm CONCENTRIC AIR / FLUE DUCT SPECIFICATIONS The Ace HE24, HE30 and HE35 can be installed to a number of connecting parts to the appliance and end terminal.
  • Page 7 751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:44 Page 7 2.5.1 KIT A + TELESCOPIC HORIZONTAL WALL Standard concentric (ø100/60) vertical flue application, Figures 3b, 3c, through roof attics with a maximum length of 12000mm. TERMINAL (C13) - PART NO.956120 The kit comprises of the roof terminal, flashing kit, vertical adaptor with sampling point and bracket.

  • Page 8: Specification For Chimney Flue Liner Kit (Type B23)

    751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:44 Page 8 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) –...

  • Page 9: Specification For Twin Flued (Type C53)

    751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:44 Page 9 FLUE LENGTHS Length supplied in standard kit - horizontal 815mm Max horizontal length (from boiler to chimney - 60/100mm) 2000mm Min horizontal length (from boiler to chimney - 60/100mm) 100mm Max vertical length (from boiler to chimney - 60/100mm) 2000mm...
  • Page 10 751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:45 Page 10 Horizontal flue terminal (all orientations) maximum 5000 mm (197 in) Horizontal flue terminal (rear exit) minimum 250 mm (10 in) Vertical flue terminal maximum 12000 mm (472 in) Vertical flue terminal minimum 600 mm (23 The 'equivalent' flue length must not exceed the maximum values stated.
  • Page 11 751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:45 Page 11 Note. The diverter allows the terminal clearance to be reduced as The Plume Diverter terminal must not under follows (see diagrams below): any circumstances deflect flue products Clearance H – From a surface facing the terminal - 600mm. downwards.

  • Page 12: Appliance Hydraulic Circuits

    751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:45 Page 12 APPLIANCE HYDRAULIC CIRCUITS FLUE PRODUCTS CH MODE MANUAL BLEED VALVE PRIMARY HEAT EXCHANGER BURNER & BURNER EXPANSION FLANGE VESSEL PRIMARY FLOW CH RETURN CONDENSATE THERMISTOR TRAP AUTOMATIC AIR VENT PUMP &...

  • Page 13: Installation Requirements

    For further information contact: a) The appliance is not suitable for external installations. The Halstead Boiler Ltd, Service Help Line: 08450 710780. position selected for installation should be within the building, unless otherwise protected by a suitable enclosure and MUST allow...

  • Page 14: Condensate Disposal

    751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:45 Page 14 d) 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.
  • Page 15 0.5 and 1.0 bar. This should efficiently with the minimum of maintenance necessary. Halstead be checked before the water system is filled. Details below show Boilers fully support this professional approach and recommend the water system volume that is acceptable for this vessel.

  • Page 16: Domestic Hot Water System

    Higher flow rates will not damage the appliance but may reduce the water temperature room thermostat, as described in section 4. For further information contact: Halstead Boilers Ltd, Service Helpline: 08450 710780. below an acceptable level. (Refer to Figure 28). TYPICAL SYSTEM DESIGN...

  • Page 17: Appliance Installation

    751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:45 Page 17 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.

  • Page 18: Mounting The Appliance

    751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:45 Page 18 REAR FLUE SIDE FLUE 2.5º b) Connect the mains water supply to the DHW inlet isolating valve. MOUNTING THE APPLIANCE c) Connect the DHW supply pipe to the DHW outlet connection. Lift the appliance into position as shown in Figure 11.

  • Page 19: Condensate Connection

    751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:45 Page 19 CONDENSATE CONNECTION PRESSURE RELIEF VALVE CONNECTION Refer to Figure 13 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 20: Electrical Connections

    751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:45 Page 20 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 a) Secure the flue elbow with seal to the appliance using 4 the terminal is the correct way round and the external wall-sealing...

  • Page 21: Commissioning And Testing

    751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:45 Page 21 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 22: Commissioning The Appliance

    REQUIRED. HOWEVER IF THE APPLIANCE FAILS TO attempts at ignition. It may be necessary to turn the control knob fully OPERATE CORRECTLY CONTACT THE HALSTEAD anti-clockwise to the reset/Standby position and repeat (d). (See BOILERS LTD SERVICE HELPLINE: 08450 710780.

  • Page 23: Dhw Flow Rate

    751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:45 Page 23 DHW FLOW RATE FROST PROTECTION A flow regulator is supplied factory fitted to the appliance to The appliance is fitted with a frost protection device. In the event ensure that no adjustment is necessary. Should the mains flow rate of very cold conditions, the pump may operate and the appliance be below the minimum required, it is possible to remove the flow light for a few minutes to protect the appliance and system from...

  • Page 24: Users Instructions

    751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:45 Page 24 USERS INSTRUCTIONS 5.10 APPLIANCE LOG BOOK Upon completion of commissioning and testing the system, the A logbook is supplied in the back of this manual to record installer must instruct the user in how to operate the appliance by installation and commissioning details and to make future drawing the user’s attention to the following.

  • 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: 08450 710780. 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

    751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:45 Page 26 COMBUSTION CHAMBER FRONT COVER BURNER INSULATION GAS VALVE FEED PIPE GAS VALVE e) 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).

  • Page 27: Gas Control Valve, Fan & Burner Assembly

    751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:45 Page 27 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.

  • Page 28: Re-Assembly & Re-Commissioning

    751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:45 Page 28 MAINS COLD INLET CONICAL FILTER SEALING WASHER FLOW REGULATOR FLOW SWITCH RE-ASSEMBLY & RE-COMMISSIONING FINAL CHECKS a) Re-assemble all components in reverse order. a) Ensure the fascia panel is placed into the upright position and secure with the two screws.

  • Page 29: Internal Wiring Diagram

    751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:45 Page 29 INTERNAL WIRING DIAGRAM 7.1 : FUNCTIONAL FLOW WIRING DIAGRAM Supplied By www.heating spares.co Tel. 0161 620 6677...

  • Page 30: Fault Finding

    9 (Parts Replacement). b) Check the operation of the DHW flow switch, Figure 28. For further information contact: Halstead Boilers Ltd. Service Help c) Check the wires to the DHW flow switch. line: 08450 710780. d) Check connector X8 is correctly connected to the PCB.

  • Page 31: Central Heating Fault Finding

    IN SERVICE POSITION OPTIMUM CH POSITION STANDBY/RESET POSITION (DISPLAY FLASHING) everything should be working correctly, if not contact Halstead CENTRAL HEATING FAULT FINDING Boilers Ltd Service Help Line: 08450 710780. Upon a demand for Central Heating, (closure of the time clock...

  • Page 32: Blocking Codes

    Check PCB fuse 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: 08450 710780. Note: All Lock-out and Blocking codes will flash if displayed.

  • Page 33: Replacement Of Parts

    751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:46 Page 33 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 34: Gas Control Valve

    751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:46 Page 34 GAS CONTROL VALVE 3 TORX SCREWS Refer to Figures 34, 35 & 36 9.3.1 GAS CONTROL VALVE REMOVAL, REPLACEMENT AND SET-UP a) Remove casing and control panels as described in section 6.2. b) Unscrew the gas valve electrical plug and disconnect from the gas valve.

  • Page 35: Fan

    2.3. If the measured value does isolated. not correspond to the Performance Data, then contact: Halstead Boilers Ltd. Service Help line: 08450 710780. b) Remove the gas control valve, fan & burner assembly; refer to section 6.2.

  • Page 36: Combustion Chamber Front Insulation

    751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:46 Page 36 COMBUSTION CHAMBER FRONT INSULATION The design of the appliance is such that the combustion chamber insulation should not require replacement unless mechanically damaged. It is recommended that to prevent dust, the insulation is dampened prior to removal, and that a protective mask is worn SCREW when changing or handling the insulation material.

  • Page 37: Pump (Head Only)

    751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:46 Page 37 p) Re-assemble in reverse order; check integrity of the flow and q) Open the isolating cocks and vent air from the system using the return pipe ‘O’ rings and fibre washers and replace as necessary. manual air vent.

  • Page 38: Hydroblock Assembly

    751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:46 Page 38 9.11 9.12 HYDROBLOCK ASSEMBLY EXPANSION VESSEL a) Ensure supply voltage is isolated. Refer to Figure 45 b) Drain down the appliance; refer to section 9.23. a) a) Ensure supply voltage is isolated. c) Undo the nut holding the manual air vent to the expansion vessel b) Disconnect the electrical leads to the pump head and diverter and disengage the link pipe from the heat exchanger by removing the...

  • Page 39: Pressure Relief Valve

    751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:46 Page 39 Note: the thermal fuse is not removable or 9.13 PRESSURE RELIEF VALVE a serviceable item, should the heat exchanger overheat then the thermal fuse Refer to Figures 18 & 22 will blow (blocking code ‘5’) and the entire a) Ensure supply voltage is isolated.

  • Page 40: Condensate Drain System

    751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:46 Page 40 8 48 PRIMARY FLOW PIPE FIBRE WASHER FILTER PLATE HEAT EXCHANGER 9.17 CONDENSATE DRAIN SYSTEM 9.18 PRESSURE GAUGE Refer to Figure 27 Refer to Figure 49 a) Ensure supply voltage is isolated. a) Ensure supply voltage is isolated.

  • Page 41: Auto Air Vent

    751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:46 Page 41 9.19 9.21 TIME CLOCK AUTO AIR VENT Refer to Figures 51 Refer to Figure 45 a) Ensure supply voltage is isolated. a) Ensure supply voltage is isolated. b) Remove the decorative front panel, unscrew and lower the b) Drain down the appliance;...

  • Page 42: Draining The Appliance

    751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:46 Page 42 24HR TIME CLOCK 230Vac CLOCK MOTOR N/O CONTACTS 2 BROWN CABLES RED CABLE 2 BLUE CABLES RED CABLE 9.23 DRAINING THE APPLIANCE Refer to Figures 18, 42 & 52 a) Before draining, give the appliance a brief CH demand, to ensure the diverter valve is in the CH position.

  • Page 43: Short Parts List

    H38-221 Control PCB c/w Box Assembly (Ace HE 24) 988542 H38-222 Control PCB c/w Box Assembly (Ace HE 30) 988543 Control PCB c/w Box Assembly (Ace HE 35) 988562 H38-223 User Control Fascia Assermbly 988544 E23-671 Time Clock - Grasslin FM1STUH...
  • Page 44 751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:46 Page 44 Supplied By www.heating spares.co Tel. 0161 620 6677...
  • Page 45 751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:46 Page 45 BENCHMARK No. GAS BOILER COMMISSIONING CHECKLIST BOILER SERIAL No. NOTIFICATION No. CONTROLS To comply with the Building Regulations, each section must have a tick in one or other of the boxes TIME &...

  • Page 46: Service Interval Record

    751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:46 Page 46 SERVICE INTERVAL RECORD It is recommended that your heating system is serviced regularly and that you complete the appropriate Service Interval Record below. SERVICE PROVIDER Before completing the appropriate Service Interval Record below, please ensure you have carried out the service as described in the boiler manufacturer’s instructions.
  • Page 47 751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:46 Page 48 Glen Dimplex Boilers, Stoney Lane, Prescot Merseyside L35 2XW. For telephone enquiries call: 0844 371 1111. Website: www.glendimplexboilers.co.uk Part of the Glen Dimplex Group Glen Dimplex Boilers is continuously improving its products and may therefore change specifications without prior notice. The statutory rights of the consumer are not affected.

This manual is also suitable for:

Ace he 24Ace he 30Ace he35

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