Halstead ACE HE 24, Installation And Servicing Manual

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Page 2: ...Leads 30 9 3 Gas Control Valve 31 9 4 Fan 32 9 5 Burner 33 9 6 Combustion Chamber Front Insulation 33 9 7 Combustion Chamber Rear Insulation 33 9 8 Heat Exchanger 34 9 9 Pump Head Only 34 9 10 Diverte...

Page 3: ...ene and wash your hands before eating drinking or going to the lavatory If you do suffer irritation to the eyes or severe irritation to the skin seek medical attention Gas and Electricity Consumer Cou...

Page 4: ...x kW 19 7 25 4 50 30 C Btu h 67300 86700 Net kW 18 4 22 9 Central Heating Input Btu h 62800 78200 Max Rate Gross kW 20 4 24 8 Btu h 69700 84700 Net kW 5 6 6 9 Central Heating Input Btu h 19100 23600 M...

Page 5: ...y Ltr 1 8 2 1 Integral expansion vessel capacity Ltr 8 Maximum heating system water content using fitted expansion vessel 0 75 bar Ltr 84 Electrical supply 230V 50Hz Fuse at 3A Internal fuse T4H 4A 25...

Page 6: ...lat roof flashing plate Vertical flue kit Part no 956081 Flue system application Vertical flue kit Part no 956081 Split pipe vertical flue outlet kit Part no 956080 with flat roof flashing plate Raise...

Page 7: ...6081 2 5 2 KIT B VERTICAL CONCENTRIC FLUE 3b Standard concentric 100 60 vertical flue application Figures 3b 3c through roof attics with a maximum length of 12000mm The kit comprises of the roof termi...

Page 8: ...In replacement installations the chimney has to be cleared of debris and all flue parts Chimney plate Flexible corrugated plastic flue liner 80mm according to EN 14471 Max length 30m Min length 5m KIT...

Page 9: ...mm and 500 mm long each duct extends the flue length by up to 950 mm and 450 mm respectively 93 Extension Elbow Allows an additional bend in the flue and has an equivalent length of 1550 mm This elbow...

Page 10: ...ON PLUME DIVERTER TERMINAL INSTALLATION INSTRUCTIONS The diverter allows the terminal clearance to be reduced as follows see diagrams below Clearance H From a surface facing the terminal 600mm Clearan...

Page 11: ...2 9 APPLIANCE HYDRAULIC CIRCUITS 4 CH MODE DHW MODE 9...

Page 12: ...y a purpose designed K6 terminal guard optional extra Part No 951507 g The air inlet flue outlet MUST NOT be closer than 25 mm 1 in to combustible material h Condensing appliances have a tendency to f...

Page 13: ...ain is routed to outside it should be to a drain or soak away and any external pipe work should be in 32 mm Insulation to protect from freezing in cold weather conditions is also advisable 3 6 GAS SUP...

Page 14: ...rol panel This can be viewed by lowering the bottom front panel PRESSURE RELIEF VALVE A pressure relief valve set to 3 bar 43 5 psi is supplied with the appliance however it will start to open at appr...

Page 15: ...SIGN Note No automatic bypass required however it is recommended to leave one radiator open to ensure pump over run function It is also recommended to fit TRV s on all radiators except in the rooms wi...

Page 16: ...paper template in the required position ensuring that the necessary clearances are achieved Ensure square ness by hanging a plumb line b Mark the position of the largest wall fixing holes Refer to Fig...

Page 17: ...system pipes to the central heating flow and return valves using 22mm pipe work 12 VIEW OF CONNECTIONS ON REAR OF BOILER 4 5 GAS CONNECTION Refer to Figure 12 Connect the gas supply pipe to the gas s...

Page 18: ...no less than 15mm diameter copper pipe to the outlet The pipe outlet should be positioned so that the discharge of water or steam can be noticed but cannot create a hazard to the occupants of the prem...

Page 19: ...lue system extension ducts as necessary referring to the flue kit instructions and fit to the flue elbow e Fit the flue terminal to the flue system ensuring that the duct joints are not disturbed and...

Page 20: ...rectly and does not leak 5 Drain the entire system using the manual drain valve to flush out any debris and refill to 0 2 bar above the system design pressure between 0 5 and 1 0 bar by repeating the...

Page 21: ...e the DHW tap and ensure that the burner goes out the display reads o and the pump stops after an over run period of 5 minutes i Ensure that the room thermostat if fitted is calling for heat Turn the...

Page 22: ...return thermisters which monitor the appliance s operating temperature Abnormal temperatures will cause the appliance to go to lockout and the LED display will show code 1 Allow the appliance to cool...

Page 23: ...ive during frost conditions e Explain the function of the control knob and how to reset the appliance Emphasise that if cut outs persists the appliance should be turned off and the installer or servic...

Page 24: ...ce vertical flue adaptor If suitable equipment to analyse the flue gas is available remove the plastic cap and fit a 6 mm inside diameter sample tube When the appliance is operating at maximum output...

Page 25: ...nect the ignitor plug earth lead and detection plug from the ignitor and detection electrodes e Unscrew the screw holding the gas valve lead plug and disconnect the plug f Disconnect the electrical le...

Page 26: ...g a soft brush If either the electrode or the ceramic insulation shows signs of damage or wear replace the electrode s and their gasket b Check that the alignments of the ignition and detection electr...

Page 27: ...ection 6 1 e Check the operation of the appliance in both CH and DHW modes as applicable f Remove the manometer and tighten the inlet pressure test point sealing screw g Test for gas tightness 6 8 RE...

Page 28: ...26 INTERNAL WIRING DIAGRAM 7 7 1 FUNCTIONAL FLOW WIRING DIAGRAM 29...

Page 29: ...PLAY FASCIA PANEL Refer to Figure 31 The Digital Display shows error code 3 in a lockout condition To RESET the boiler turn the control knob fully anti clockwise to the 8 3 FAULT FINDING CODES In the...

Page 30: ...ated which prevents the appliance from firing in CH mode for 5 minutes Ensure that the control is not in this mode by removing power from the control and restoring it after a delay of 10 seconds RESET...

Page 31: ...tem failure Failure of internal self checking system Check PCB No flame E BCC error No flame Incorrect missing BCC Reseat or replace BCC if fitted Check CH flow and return Water flow failure Check pum...

Page 32: ...the electrical supply leads d Unscrew the two screws holding the ignitor unit remove ignitor unit e Fit the new ignitor unit g Re assemble in reverse order ensure that the ignitor unit is orientated a...

Page 33: ...rectly then check for gas soundness 36 34 35 If a new gas valve is fitted it must be adjusted to operate within the quoted CO2 values see Combustion set up table below A suitable calibrated flue gas a...

Page 34: ...ed from valve body 4 5mm 4 5mm to top of screw If the gas control valve is changed then when the appliance is running the flue gas CO2 should be measured refer to section 6 1 and compared to the value...

Page 35: ...ective mask is worn when changing or handling the insulation material Refer to Figure 42 a Ensure supply voltage is isolated and that the gas supply is isolated b Remove the gas control valve fan burn...

Page 36: ...Remove the saddle brackets and slide the heat exchanger forwards and out p Re assemble in reverse order check integrity of the flow and return pipe O rings and fibre washers and replace as necessary...

Page 37: ...g the hydroblock onto the mounting studs and remove the hydroblock j Align the replacement hydroblock against the mounting studs and secure using the three screws k Re assemble in reverse order ensure...

Page 38: ...necessary and check for water leaks Note the pressure relief valve should not be used to drain the system 9 13 PRESSURE RELIEF VALVE Refer to Figure 48 a Ensure supply voltage is isolated b Disconnec...

Page 39: ...he 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 necessa...

Page 40: ...ew the auto air vent and fit replacement e Re assemble in reverse order ensure that all joints and seals are correctly re fitted f Open the isolating cocks and vent air from the system using the manua...

Page 41: ...n the boiler using the manual drain tap on the CH flow water isolating cock figure 18 in conjunction with the manual bleed valve located on the top LHS of the heat exchanger refer to Figures 44 and 54...

Page 42: ...ion vessel 1 451020 13 Pressure Relief Valve 1 300734 14 Flow Return temperature thermister 2 500661 15 Flue thermister ACE HE 1 500662 16 Plate Heat Exchanger 1 451015 17 Plate Heat Exchanger Filter...

Page 43: ...55 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 41...

Page 44: ...Direct Line 01787 475557 Fax 01787 474588 Service Helpline 01926 834834 Training 01926 834838 Email sales halsteadboilers co uk or service halsteadboilers co uk or training halsteadboilers co uk Webs...