Halstead CLUB HE 18, Installation And Servicing Instructions

Page 1: ...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 0087 Pin 87 BQ 44 G C Appliance No 41 260 20 Club HE 18 INSTALLATION AND SERVICING INSTRUCTIONS TO BE GIVEN TO THE USER...

Page 2: ...alve 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 Hydroblock Assembly 35 9 11 Expan...

Page 3: ...you may be susceptible to irritation High dust levels are usual only if the material is broken Normal handling should not cause discomfort but follow normal good hygiene and wash your hands before ea...

Page 4: ...e Central Heating Output non condensing 80 60 C Max kW 18 0 Btu h 61500 Min kW 6 0 Btu h 20500 Central Heating Output condensing 50 30 C Max kW 19 7 Btu h 67300 Net kW 18 4 Central Heating Input Max R...

Page 5: ...Nat Gas 50 30 C 53 CO2 value max rate Nat Gas G20 9 2 0 3 case on 9 0 0 2 case off CO2 value min rate Nat Gas ref only G20 8 6 0 3 CO CO2 Ratio max rate Nat Gas G20 0 0011 0 0014 Flue products mass f...

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: ...additional concentric kits are available as optional extras Flue Extension Ducts 1000 mm and 500 mm long each duct extends the flue length by up to 950 mm and 450 mm respectively 93 Extension Elbow Al...

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 9...

Page 12: ...UST be protected by 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 ha...

Page 13: ...intaining a continuous 2 5 fall away from the appliance If the drain 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...

Page 14: ...s to obtain the total minimum expansion vessel capacity required in litres PRESSURE GAUGE A pressure gauge is situated on the appliance control panel PRESSURE RELIEF VALVE A pressure relief valve set...

Page 15: ...nsulated to BS 6500 table 16 3 8 ELECTRICITY SUPPLY 8 S PLAN INSTALLATION TIMED CH DHW FOR FURTHER INFORMATION PLEASE CONTACT HALSTEAD BOILERS LTD SERVICE HELPLINE TEL 01926 834834 The Club HE 18 appl...

Page 16: ...CONTACT HALSTEAD BOILERS LTD SERVICE HELPLINE TEL 01926 834834 FOR FURTHER INFORMATION PLEASE CONTACT HALSTEAD BOILERS LTD SERVICE HELPLINE TEL 01926 834834 14 9 S PLAN INSTALLATION TIMED CH DHW Y PLA...

Page 17: ...15 FOR FURTHER INFORMATION PLEASE CONTACT HALSTEAD BOILERS LTD SERVICE HELPLINE TEL 01926 834834 Y PLAN INSTALLATION TIMED CH DHW 11...

Page 18: ...nsure squareness by hanging a plumb line b Mark the position of the primary wall fixing holes Refer to Figures 12 and 13 c Mark the position of the flue outlet For side flue installation extend the fl...

Page 19: ...3 SERVICE CONNECTIONS 4 4 CENTRAL HEATING Refer to Figure 15 a Connect the central heating system pipes to the central heating flow and return valves using 22mm pipe work 4 5 GAS CONNECTION Refer to F...

Page 20: ...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 21: ...ing 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 that the external sealing ring is seated again...

Page 22: ...ebris and refill to 0 2 bar above the system design pressure between 0 5 and 1 0 bar by repeating the above procedure Follow the commissioning procedure described below and then repeat this instructio...

Page 23: ...e test point is 20 1 mbar for natural gas h Check the operation of the programmer or room thermostat if fitted i Turn off the demand from the programmer room thermostat or turn the control knob to the...

Page 24: ...of very cold conditions the pump may operate and the appliance light for a few minutes to protect the appliance and system from potential frost damage This can only function if the gas and electricity...

Page 25: ...vertical flue adaptor If suitable equipment to analyse the flue gas is available remove the sampling cap and fit a 6 mm inside diameter sample tube When the appliance is operating at maximum output ch...

Page 26: ...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 27: ...ket b Check that the alignments of the ignition and detection electrodes are correct Refer to Figure 29 Adjust by carefully bending the tip of the electrode rod whilst supporting the base of the rod D...

Page 28: ...26 INTERNAL WIRING DIAGRAM 7 7 1 FUNCTIONAL FLOW WIRING DIAGRAM 31...

Page 29: ...lt finding operation involving making or breaking electrical connections always check for EARTH CONTINUITY POLARITY and RESISTANCE TO EARTH Detailed procedures for replacing faulty components are desc...

Page 30: ...ed which prevents the appliance from firing 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 LOCK OUT COD...

Page 31: ...BCC error No flame Incorrect missing BCC Reseat or replace BCC if fitted Check CH flow and return Water flow failure Check pump O Flame for a short period Sensor temperature differential Check no air...

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: ...d correctly then check for gas soundness 38 36 37 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...

Page 34: ...input Case off 8 9 9 1 X measured from valve body 4 3mm to top of screw nominal If the gas control valve is changed then when the appliance is running the flue gas CO2 should be measured refer to sec...

Page 35: ...otective mask is worn when changing or handling the insulation material Refer to Figure 44 a Ensure supply voltage is isolated and that the gas supply is isolated b Remove the gas control valve fan bu...

Page 36: ...refer to Figure 46 o 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...

Page 37: ...is likely that there will still be some water spillage when the Hydroblock is removed a Ensure supply voltage is isolated b Drain down the appliance refer to section 9 19 c Undo the nut holding the m...

Page 38: ...e sensor to release the bayonet connection and remove from the heat exchanger 9 14 FLUE SENSOR 50 9 15 CONDENSATE DRAIN SYSTEM Refer to Figure 30 a Ensure supply voltage is isolated b Open the drain s...

Page 39: ...ONTROL PCB Refer to Figures 24 31 and 52 a Ensure supply voltage is isolated b Remove the casing front panel unscrew and lower the control fascia panel c Unplug the electrical leads from the PCB Refer...

Page 40: ...ot draining the entire CH system close the CH flow and CH return water isolating cocks d Drain down the CH system from the external drain point and drain the boiler using the manual drain tap on the C...

Page 41: ...Exchanger HE 24 1 451101 9 Pump Head 6 metre 1 500672 10 Hydroblock assembly 1 500651 11 Expansion vessel 1 451020 12 Pressure Relief Valve 1 300734 13 Flow Return temperature thermister 2 500661 14 F...

Page 42: ...55 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 40...

Page 43: ...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...