Table of Contents
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Table of Contents
Related Manuals for Halstead Ace HE 24
Summary of Contents for Halstead Ace HE 24
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Page 2: Table Of Contents
INTRODUCTION ....... 0 The Halstead Ace HE24 and Ace HE30 are high efficiency Important Information . -
Page 3: Important Information
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. CORGI REGISTERED INSTALLERS) IN ACCORDANCE ignition, which provides a modulated heat output to either central WITH THE GAS SAFETY (INSTALLATION AND USE) heating (CH) or domestic hot water (DHW) demands, and with REGULATIONS (CURRENT EDITION). -
Page 4: Technical Specifications
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 gas supply at 20 mbar (8 in.wg) inlet pressure). -
Page 5: General Specifications
Appliance Ace HE24 Ace HE30 Design Domestic Hot Water Ltr/min 12.3 (gpm) (2.2) (2.8) Performance raised 35°C DHW Specific Rate (D) EN 625 Ltr/min 10.9 14.7 Min Mains Water Inlet Pressure for Max Heat Output (psi) (14.5) Min Mains Water Inlet Pressure for Operation (psi) (4.4) Max Mains... -
Page 6: Overall Dimensions & Minimum Clearances
OVERALL DIMENSIONS AND MINIMUM CLEARANCES CONCENTRIC AIR / FLUE DUCT SPECIFICATIONS The Ace HE24 & HE30 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 DHW 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 Details below show efficiently with the minimum of maintenance necessary. Halstead the water system volume that is acceptable for this vessel. If the...
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Page 15: Domestic Hot Water System
Higher flow rates will not room thermostat, as described in section 4. For further information damage the appliance but may reduce the water temperature contact: Halstead Boilers Ltd, Service Helpline: 01926 834834. below an acceptable level. (Refer to Figure 28). TYPICAL SYSTEM DESIGN... -
Page 16: 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 17: Mounting The Appliance
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. Position the top of the appliance approximately 10mm above the top of the Fill the central heating system and domestic hot water system, as wall mounting plate and use the side wings on the plate to locate described in section 5.1, and then proceed to Section 4.5. -
Page 18: Condensate Connection
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 19: 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 the terminal is the correct way round and the external wall-sealing... -
Page 20: 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 21: 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: 01926 834834. -
Page 22: Dhw Flow Rate
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 regulator from the appliance as instructed in section 9. -
Page 23: Users Instructions
5.10 USERS INSTRUCTIONS APPLIANCE LOG BOOK Upon completion of commissioning and testing the system, the A logbook is supplied with this appliance to record installation installer must instruct the user in how to operate the appliance by and commissioning details and to make future servicing of the drawing the user’s attention to the following. -
Page 24: 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 25: 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 22, 23, 24, and 25 g) Remove the base panel (1 screw). -
Page 26: 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 27: Re-Assembly & Re-Commissioning
RE-ASSEMBLY & RE-COMMISSIONING FINAL CHECKS a) Re-assemble all components in reverse order. a) Ensure the fascia panel into the upright position and secure with the two screws. b) Check that all joints and seals are correctly fitted. Re-fit the front casing panel. Turn on the gas and electricity supply and light the appliance, as described in section 5.2. -
Page 28: Internal Wiring Diagram
INTERNAL WIRING DIAGRAM 7.1 : FUNCTIONAL FLOW WIRING DIAGRAM... -
Page 29: Fault Finding
Check that the DHW flow rate at the tap is greater than 2.5 in section 9 (Parts Replacement). litres/minute. For further information contact: Halstead Boilers Ltd. Service Help b) Check the operation of the DHW flow switch, Figure 28. line: 01926 834834 c) Check the wires to the DHW flow switch. -
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
Check PCB/X1B connector 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: 01926 834834... -
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 34, 35 & 36 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: Throttle Adjustment Tool
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... -
Page 35: Burner
BURNER COMBUSTION CHAMBER FRONT INSULATION Refer to Figures 34, 40 & 41 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. -
Page 37: Diverter Valve Motorised Head
f) Re-assemble in reverse order; ensure that all joints and seals are 9.11 HYDROBLOCK ASSEMBLY correctly re-fitted. g) Open the isolating cocks and vent air from the system using the Refer to Figure 47 manual air vent. Re-pressurise the system as necessary and check for Ensure supply voltage is isolated. -
Page 38: Pressure Relief Valve
Note: It is likely that there will still be some water spillage when the Hydroblock is removed. 8 47 9.13 PRESSURE RELIEF VALVE Refer to Figures 18 & 22 a) Ensure supply voltage is isolated. b) Drain down the appliance; refer to section 9.24. -
Page 39: Plate Heat Exchanger And Filter
i) Undo the nut connecting the plate heat exchanger to the DHW water isolating cock pipe. j) Lift up the plate heat exchanger and remove. k) Fit the replacement plate heat exchanger, using new case seals as necessary, ensuring the filter is fitted correctly. l) Re-assemble in reverse order;... -
Page 40: Pressure Gauge
9.20 CONTROL PCB 9.18 PRESSURE GAUGE Refer to Figures 21, 29 & 52 Refer to Figure 51 a) Ensure supply voltage is isolated. a) Ensure supply voltage is isolated. b) Drain down the appliance; refer to section 9.24. b) Remove the casing front panel, unscrew and lower the control fascia panel. -
Page 41: Time Clock
b) Remove the electrical lead to the DHW flow switch. 9.21 TIME CLOCK c) Close the DHW inlet isolating cock, open a DHW tap at the Refer to Figures 53 lowest point in the system and allow the pressure to dissipate. Close a) Ensure supply voltage is isolated. -
Page 42: Short Parts List
SHORT PARTS LIST Refer to Figure 55 G C Part No. Description No off Makers Pt No. Ignition electrode incl. gasket 988526 Detection electrode incl. gasket 988540 Spark generator unit incl. spark leads 500665 Gas control valve assembly – NG 988541 Fan assembly 601016... - Page 44 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. 10/05 751094...