Halstead ACE HE 35 User Instructions Download Page 45

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Supplied By www.heating spares.co Tel. 0161 620 6677

GAS BOILER COMMISSIONING CHECKLIST

BENCHMARK No.

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

FOR ALL BOILERS CONFIRM THE FOLLOWING

TIME & TEMPERATURE CONTROL TO HEATING

ROOM T/STAT & PROGRAMMER/TIMER

PROGRAMMABLE ROOMSTAT

TIME & TEMPERATURE CONTROL TO HOT WATER CYLINDER T/STAT & PROGRAMMER/TIMER

COMBI BOILER

HEATING ZONE VALVES

FITTED

NOT REQUIRED

HOT WATER ZONE VALVES

FITTED

NOT REQUIRED

THERMOSTATIC RADIATOR VALVES

FITTED

AUTOMATIC BYPASS TO SYSTEM

FITTED

NOT REQUIRED

THE SYSTEM HAS BEEN FLUSHED IN ACCORDANCE WITH THE BOILER MANUFACTURER’S INSTRUCTIONS
THE SYSTEM CLEANER USED
THE INHIBITOR USED

FOR THE CENTRAL HEATING MODE, MEASURE & RECORD

GAS RATE

m3/hr

ft3/hr

BURNER OPERATING PRESSURE (IF APPLICABLE)

N/A

mBar

CENTRAL HEATING FLOW TEMPERATURE

ºC

CENTRAL HEATING RETURN TEMPERATURE

ºC

FOR COMBINATION BOILERS ONLY

HAS A WATER SCALE REDUCER BEEN FITTED?

YES

WHAT TYPE OF SCALE REDUCER HAS BEEN FITTED?

FOR CONDENSING BOILERS ONLY CONFIRM THE FOLLOWING

THE CONDENSATE DRAIN HAS BEEN INSTALLED IN ACCORDANCE WITH

THE MANUFACTURERS INSTRUCTIONS

YES

FOR ALL INSTALLATIONS CONFIRM THE FOLLOWING

THE HEATING AND HOT WATER SYSTEM COMPLIES

WITH CURRENT BUILDING REGULATIONS
THE APPLIANCE AND ASSOCIATED EQUIPMENT HAS BEEN INSTALLED AND COMMISSIONED

IN ACCORDANCE WITH THE MANUFACTURER’S INSTRUCTIONS
IF REQUIRED BY THE MANUFACTURER, HAVE YOU RECORDED A CO/CO

RATIO READING N/A

YES

CO/CO

RATIO

THE OPERATION OF THE APPLIANCE AND SYSTEM

CONTROLS HAVE BEEN DEMONSTRATED TO THE CUSTOMER
THE MANUFACTURER’S LITERATURE HAS BEEN LEFT WITH THE CUSTOMER

FOR THE DOMESTIC HOT WATER MODE, MEASURE & RECORD

GAS RATE

m3/hr

ft3/hr

MAXIMUM BURNER OPERATING PRESSURE (IF APPLICABLE)

N/A

mBar

COLD WATER INLET TEMPERATURE

ºC

HOT WATER OUTLET TEMPERATURE

ºC

WATER FLOW RATE

lts/min

COMMISSIONING

ENG’S NAME

CORGI ID No.

SIGN

DATE

751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:46 Page 45

Summary of Contents for ACE HE 35

Page 1: ...GIVEN TO THE USER 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 0086 PIN 87 BQ 44 ACE HE Type 24 30 35 CO M B I N AT I O N CO N D E N S I N G B O I LE R 751094 ACE HE INST MANUAL 751094 ACE HE 28 9 10 09 44 Page 1 ...

Page 2: ...1 9 3 Gas Control Valve 32 9 4 Fan 33 9 5 Burner 33 9 6 Combustion Chamber Front Insulation 34 9 7 Combustion Chamber Rear Insulation 34 9 8 Heat Exchanger 34 9 9 Pump Head Only 35 9 10 Diverter Valve Motorised Head 35 9 11 Hydroblock Assembly 36 9 12 Expansion Vessel 36 9 13 Pressure Relief Valve 37 9 14 Water Temperature Sensors 37 9 15 Flue Sensor 37 9 16 Plate Heat Exchanger and Filter 37 9 17...

Page 3: ...normal good hygiene 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 Council Energywatch Energywatch is an independent organisation which protects the interests of gas users If you need advice concerning energy issues they may be contacted on their consume...

Page 4: ...3 9 24 5 Central Heating Input Btu h 62800 81600 83600 Max Rate Gross kW 20 4 24 8 27 2 Btu h 69700 84700 92800 Net kW 5 6 6 9 8 5 Central Heating Input Btu h 19100 23600 29000 Min Rate Gross kW 6 2 7 5 9 4 Btu h 21200 25600 32100 Domestic Hot Water Output Max kW 24 0 30 0 35 0 Btu h 82000 102400 119400 Min kW 6 0 7 2 8 3 Btu h 20500 24600 28300 Net kW 24 6 31 3 35 7 Domestic Hot Water Input Btu h...

Page 5: ...ssion Pressure relief valve outlet 15 mm compression Condensate Drain 21 5 22 mm plastic overflow pipe 2 3 GENERAL SPECIFICATIONS NOTE THE STATED HEAT INPUT AND CO2 VALUES ARE NOMINAL AND MAY VARY BY 5 10 WHEN THE APPLIANCE IS RUN WITH LINE GAS DUE TO FLUCTUATIONS IN GAS QUALITY Appliance Ace HE24 Ace HE30 Ace HE35 Total weight full kg 45 1 51 7 51 7 Total weight empty kg 43 0 49 0 49 0 Max lift w...

Page 6: ...lly comprising the 2 5 CONCENTRIC AIR FLUE DUCT SPECIFICATIONS 8 FLUE OPTIONS connecting parts to the appliance and end terminal Flue extension ducts and extension elbows are available as accessories 1 The following flue systems are available for the ACE HE range 2 327mm 136mm Ø100mm 97mm 200mm 5mm 5mm 200mm SEE NOTE NOTE 5mm for normal operation 450mm for installation and servicing 907mm 446mm 75...

Page 7: ...rside of the air cowl For installation details refer to the flue kit instructions Fig 3 c Offset vertical flue a measured from boiler flue outlet centre line to the centre line of the extension elbow b measured from the top of the boiler to the underside of the air cowl Maximum allowable length of a b 8900mm 3c If the standard horizontal terminal is likely to cause nuisance to a neighbour or build...

Page 8: ...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 This kit is suitable for open flue application in accordance with BS5440 where a room sealed flue installation is impractical The kit comprises of a flue adaptor from the appliance to the chimne...

Page 9: ...lls of the building 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 Min vertical length from boiler to chimney 60 100mm 200mm Length supplied in standard kit vertical available in 10m 20m and 30m length N A...

Page 10: ...al flue terminal maximum 12000 mm 472 in Vertical flue terminal minimum 600 mm 231 2 in 2 8 ADDITIONAL CONCENTRIC FLUE KITS Refer to Figures 2 and 3 to determine which option kits are required before commencing the installation Instructions for installing the appliance with a horizontal flue and straight extension ducts are included in the main text of these instructions section 4 8 b The standard...

Page 11: ...learance F From internal or external clearances 300mm b Choose the direction required to deflect the flue products left or right only c Push the diverter elbow onto the angled outlet of the flue terminal in the desired rotational position and ensure the diverter is pushed up to the shoulder to fully engage the rubber seal d Fix the diverter to the flue terminal with the self drilling screw provide...

Page 12: ...TE HEAT EXCHANGER DHW FLOW THERMISTOR CH FLOW THERMISTOR PUMP HYDROBLOCK AUTOMATIC AIR VENT CH RETURN THERMISTOR FLUE PRODUCTS MANUAL BLEED VALVE PRIMARY FLOW PRIMARY RETURN CONDENSATE OUTLET CH FLOW DHW COLD INLET DHW HOT OUTLET CH RETURN PRIMARY HEAT EXCHANGER CONDENSATE TRAP BURNER BURNER FLANGE EXPANSION VESSEL PRESSURE GAUGE 3 BAR PRESSURE RELIEF VALVE FLOW SWITCH PLATE HEAT EXCHANGER DHW FLO...

Page 13: ...se 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 form a plume of water vapour at the terminal under certain operating conditions This is normal but positions where this would cause damage or a nuisance should be avoided Consideration should be given to the di...

Page 14: ...purged WARNING Before purging open all doors and windows also extinguish any cigarettes pipes and any other naked lights g The complete installation must be tested for gas tightness 3 7 CENTRAL HEATING SYSTEM a The appliances incorporate all the components necessary to allow them to be connected to a sealed central heating system Refer to Figure 8 for a typical system design which incorporates rad...

Page 15: ...ge is situated on the appliance control 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 approximately 2 7 bar It should not be used to flush the system FILLING LOOP This boiler is not fitted with a filling loop Any filling loop being fitted should comply with the current water supply water fittings regulation...

Page 16: ...ll radiators except in the rooms with a room thermostat FOR FURTHER INFORMATION PLEASE CONTACT HALSTEAD BOILERS LTD SERVICE HELPLINE TEL 08450 710780 a Wiring external to the appliance must be in accordance with the current I E E Wiring regulations BS 7671 for electrical installation and any local regulations which apply b The mains cable must be at least 0 75 mm2 24 0 2 mm PVC insulated to BS 650...

Page 17: ...the wall liner 130 mm 5 in The wall liner is available as an optional extra and must be sealed in position with mortar or equivalent e Drill the two largest fixing holes using a 10mm drill and insert the blue wall plugs provided Further holes can then be drilled should additional support be required for the boiler Screws and wall plugs are not supplied for this f Hang the wall mounting plate using...

Page 18: ...F BOILER 4 5 GAS CONNECTION Refer to Figures 8 12 Connect the gas supply pipe to the gas service cock using 15mm copper pipe and the 15mm nut and olive supplied Within 1000mm of the gas service cock it is recommended that the pipe diameter is stepped up to a minimum of 22mm diameter copper pipe For full rate operate appliance in DHW mode b Connect the mains water supply to the DHW inlet isolating ...

Page 19: ...t should be positioned so that the discharge of water or steam can be noticed but cannot create a hazard to the occupants of the premises or damage electrical components or wiring 4 8 AIR FLUE DUCT INSTALLATION For correct flue installation please refer to the installation instructions that are provided with the individual flue kit as described in sections 2 5 2 7 a Measure the required flue lengt...

Page 20: ...erminal to the flue system ensuring that the duct joints are not disturbed and that the external sealing ring is seated against the outside wall f Finally use the internal sealing ring to make good the internal hole Check that the external wall sealing ring and the terminal is correctly located on the outside wall from outside the building 15 2 ALIGN ASSEMBLED FLUE SYSTEM ELBOW TO APPLIANCE AND SE...

Page 21: ...ve 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 above procedure Follow the commissioning procedure described below and then repeat this instruction with the system hot It is recommended that the system is cleaned with a recognised system cleaner such as Fernox or Sentinel 6 Open the DHW inlet valve and open and close each h...

Page 22: ...nsure that the room thermostat if fitted is calling for heat Turn the clock override switch to the I position The ignition sequence will commence and when flame is detected the display will show C j Set the clock to the desired times by setting the tabs k Slide the clock override switch to the timed position and check the operation of the clock and room thermostat if fitted 5 2 COMMISSIONING THE A...

Page 23: ...rs 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 and turn the CH Temperature Control knob fully anti clockwise to the reset position to clear 5 8 OTHER FEATURES The following additional features are included in the appliance specification When the appliance cycles ...

Page 24: ... 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 service engineer consulted f Stress the importance of an annual service by a registered heating engineer g The electrical mains supply to the appliance must remain ON for the frost protection circuit to operate 5 10 ...

Page 25: ...re test point is located on the gas supply cock Before commencing any service operation ISOLATE the mains electrical supply and TURN OFF the gas supply at the main service cock If the measured combustion values are significantly outside the figures stated in section 2 3 contact Halstead Boilers Ltd Service Helpline 08450 710780 Operate in DHW mode at full rate After ten minutes operation check the...

Page 26: ...lug from the ignitor and detection electrodes e Unscrew the screw holding the gas valve lead plug and disconnect the plug f Disconnect the electrical leads from the fan 2 plugs g Remove the base panel 1 screw h Undo the nut holding the gas valve feed pipe to the gas isolating cock and disconnect i Disengage the gas valve feed pipe grommet from the casing by pushing it up 23 24 INSULATION BURNER FA...

Page 27: ...sulation shows signs of damage or wear replace the electrode s and their gasket b Check that the alignments of the ignition and detection electrodes are correct Refer to Figure 26 Adjust by carefully bending the tip of the electrode rod whilst supporting the base of the rod Do not put any pressure on the ceramic insulation HEAT EXCHANGER 6 5 COMBUSTION CHAMBER The condensate Drain has a removable ...

Page 28: ...nce 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 ASSEMBLY RE COMMISSIONING a Ensure the fascia panel is placed into the upright position and secure with the two screws b Re fit the front casing panel c Return all appliance and external controls if fitted to their original settings 6 9 FINAL CHE...

Page 29: ...Supplied By www heating spares co Tel 0161 620 6677 INTERNAL WIRING DIAGRAM 7 7 1 FUNCTIONAL FLOW WIRING DIAGRAM 29 27 751094 ACE HE INST MANUAL 751094 ACE HE 28 9 10 09 45 Page 29 ...

Page 30: ...the boiler turn the control knob fully anti clockwise to the 8 3 FAULT FINDING CODES In the event of the appliance failing to light refer to the Diagnostics Chart 30 When the hot water tap is turned on the control should perform a series of checks followed by an ignition sequence Refer to section 5 2 If the control has powered up correctly but does not respond to a DHW demand check the following a...

Page 31: ...ol is not in this mode by removing power from the control and restoring it after a delay of 10 seconds RESET LOCK OUT CODES LED CODE FAULT EFFECT REASON ACTION Check no air is in heat exchanger CH system 1 Overheated appliance Water temperature greater than 105 C Check plate heat exchanger is not blocked Check diverter valve operation Check flow return thermistor Differential check Check flow retu...

Page 32: ...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 is in heat exchanger CH system only incorrect Check pipe connections Check wires to flow and return sensors are not crossed P Power supply error Low mains voltage Check mains voltage into boiler No flame Check PCB connectors Check DHW flow switch l...

Page 33: ...wo 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 as shown in Figure 33 and that the brown electric supply lead is fitted to position 1 on the ignitor unit 9 2 IGNITOR UNIT AND IGNITION LEADS d Fit the new electrode and new gasket e Check that electrode is aligned as detailed as appropriate in...

Page 34: ...valve feed pipe seal are in good order and fitted correctly then check for gas soundness 36 34 35 If a new gas valve is fitted it must be adjusted as per the instructions that are supplied with the new gas valve A suitable calibrated flue gas analyser is required to measure the CO2 REPLACEMENT AND SET UP 9 3 1 GAS CONTROL VALVE REMOVAL 9 3 2 COMBUSTION CHECK SET UP When installing commissioning or...

Page 35: ...our screws holding the fan to the burner manifold and remove fan refer to Figure 39 f Attach and secure the replacement fan replace the gasket g Re assemble in reverse order ensure that all joints and seals are correctly re fitted 37 9 5 BURNER Refer to Figures 34 38 39 a Ensure supply voltage is isolated and that the gas supply is isolated b Remove the gas control valve fan burner assembly refer ...

Page 36: ...upply voltage is isolated and that the gas supply is isolated b Remove the gas control valve fan burner assembly refer to section 6 2 c Disconnect the electrical leads to the flue sensor flow sensor return sensor and thermal fuse d Drain down the appliance refer to section 9 23 e Disconnect the flue system from the appliance 4 screws and lift up to disengage the flue from the flue adaptor refer to...

Page 37: ...t air from the system using the manual air vent Re pressurise the system as necessary and check for water leaks 43 Note It is likely that there will still be some water spillage when the head is removed Refer to Figure 44 a Ensure supply voltage is isolated b Disconnect the electrical lead to the diverter valve motorised head c Unscrew the locating screw refer to Figure 44 d Unclip the diverter va...

Page 38: ...se the system as necessary and check for water leaks a Ensure supply voltage is isolated b Drain down the appliance refer to section 9 23 c Undo the nut holding the manual air vent to the expansion vessel and disengage the link pipe from the heat exchanger by removing the clip and pulling upwards through the grommet at the top or by rotating out of the way d Remove the upper expansion vessel retai...

Page 39: ...d blue plug 9 15 FLUE SENSOR Note the thermal fuse is not removable or a serviceable item should the heat exchanger overheat then the thermal fuse will blow blocking code 5 and the entire heat exchanger will need replacing 47 Refer to Figure 48 a Ensure supply voltage is isolated b Drain down the appliance refer to section 9 23 c Close the DHW inlet isolating cock open a DHW tap at the lowest poin...

Page 40: ...d 9 18 PRESSURE GAUGE Refer to Figure 49 a Ensure supply voltage is isolated b Drain down the appliance refer to section 9 23 c Disconnect the pressure gauge capillary gland nut from the pressure relief valve d Having removed the decorative front and lowered the control fascia disengage the pressure gauge from the fascia panel and remove the gauge e Fit the new pressure gauge and re assemble in re...

Page 41: ... section 5 4 50 PCB HOUSING BCC Electrical Connectors Securing Screws 9 21 TIME CLOCK Refer to Figures 51 a Ensure supply voltage is isolated b Remove the decorative front panel unscrew and lower the control fascia panel c Unplug the electrical leads from the PCB Refer to section 7 d Unplug the four electrical leads from the back of the clock e Remove the four retaining screws and withdraw the clo...

Page 42: ...ystem from the external drain point and drain 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 f Where the DHW circuit is to be worked on close the DHW inlet isolating cock open a DHW tap at the lowest point in the system and allow the pressure to di...

Page 43: ...erature 2 500661 15 H38 219 Thermistor Flue 1 500662 16 H29 190 Heat Exchanger 16 Plate 1 451015 17 H29 192 CH Filter Plate Heat Exchange 1 500498 18 H38 220 Thermistor Outlet DHW 1 500663 19 E23 541 Pressure Gauge 4bar Altecnic IC96467238 1 450961 20 H29 204 Air Vent Auto 1 500674 21a H38 221 Control PCB c w Box Assembly Ace HE 24 1 988542 21b H38 222 Control PCB c w Box Assembly Ace HE 30 1 9885...

Page 44: ...Supplied By www heating spares co Tel 0161 620 6677 53 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 42 751094 ACE HE INST MANUAL 751094 ACE HE 28 9 10 09 46 Page 44 ...

Page 45: ...TING RETURN TEMPERATURE ºC FOR COMBINATION BOILERS ONLY HAS A WATER SCALE REDUCER BEEN FITTED YES NO WHAT TYPE OF SCALE REDUCER HAS BEEN FITTED FOR CONDENSING BOILERS ONLY CONFIRM THE FOLLOWING THE CONDENSATE DRAIN HAS BEEN INSTALLED IN ACCORDANCE WITH THE MANUFACTURERS INSTRUCTIONS YES FOR ALL INSTALLATIONS CONFIRM THE FOLLOWING THE HEATING AND HOT WATER SYSTEM COMPLIES WITH CURRENT BUILDING REGU...

Page 46: ...AME TEL No CORGI ID SERIAL No COMMENTS SIGNATURE SERVICE 3 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID SERIAL No COMMENTS SIGNATURE SERVICE 4 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID SERIAL No COMMENTS SIGNATURE SERVICE 5 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID SERIAL No COMMENTS SIGNATURE SERVICE 6 DATE ENGINEER NAME COMPANY NAME TEL No CORGI ID SERIAL No COMMENTS SIGNATURE SER...

Page 47: ...r 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 03 10 751094 Issue 3 751094 ACE HE INST MANUAL 751094 ACE HE 28 9 10 09 46 Page 48 ...

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