Halstead Ace High Installation And Servicing Instructions Download Page 2

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CONTENTS

INTRODUCTION

The

Halstead Ace

and

Ace High

are fully automatic wall-mounted,

fan-assisted, balanced flue, gas combination appliances for use with

natural gas (G20). They incorporate a microprocessor based, fully

modulating, gas control system with direct burner ignition. The Ace High

has a higher domestic hot water heat output and provides a higher flow

rate.
Both the Halstead Ace and Ace High feature an attractive white stove

enamelled casing with an inset control panel. The flue elbow and air

ducts are also white stove enamelled to give a clean, attractive

appearance to the installation.
The Ace High provides both central heating and instantaneous domestic

hot water at outputs between 11 kW (37,500 BTU/h) and 30 kW

(102,000 BTU/h). The Ace provides both central heating and

instantaneous domestic hot water at outputs between 8.8 kW (30,000

Btu/h) and 24 kW (82,000 Btu/h).
Heat output is controlled according to demand (in both domestic hot

water and central heating mode) by the modulating gas control valve.

The appliance always gives priority to domestic hot water supply.
The appliance is supplied with a standard telescopic concentric air and

flue duct system suitable for flue lengths of up to 820mm (32in). The duct

assembly is connected to the boiler via a turret which can exit the boiler

in any horizontal direction. Horizontal extension ducts may be fitted in

accordance with and up to the maximum dimensions stated in these

instructions.
A vertical outlet kit is also available for installations where an outside

wall is not accessible and it is desired to fit the duct ‘through the roof’.
Installation using the standard flue kit is described in the main text of

these instructions and supplementary instructions at the rear of this

booklet describe installation involving the vertical outlet kit.

NO OTHER

FLUE KITS OR EXTENSIONS MAY BE USED WITH THIS

APPLIANCE.

The appliance can be installed from inside the room without access to

the external wall providing that a wall liner is fitted and that the wall

thickness is less than 0.5m (19in).The wall liner is available as an

optional extra. See section 4 for further details. (Note: If the vertical

outlet kit is to be used, access to the roof is necessary).
The appliance is designed for use with sealed primary water systems

and incorporates a circulation pump, diverter valve assembly, pressure

gauge, flow switch, safety valve and system expansion vessel. A

separate DHW expansion vessel is not required. Isolation valves are

fitted to the service connections, and an automatic heating bypass is

fitted to maintain an adequate flow rate through the boiler.
If thermostatic radiator valves are installed we recommend that one

radiator is fitted with lockshield valves (normally in the bathroom) to

allow pump overrun circulation.
Internal frost protection is fitted as standard equipment. The boiler may

be used with any certified mains voltage room thermostat.
An electro-mechanical 24hr time clock is fitted as standard.

NOTE: British Standard BS7593: 1992 stresses the
importance of cleansing and flushing of the system to

ensure it continues to run efficiently with the minimum of

maintenance necessary. Halstead Boilers fully support this

professional approach and recommend that the system is

cleansed with an effective chemical cleanser and protected

long term with a suitable inhibitor. Such products are

available from Fernox and Sentinel.
Gas Consumer Council

The Gas Consumer Council (GCC) is an independent organisation which

protects the interest of gas users. If you need advice, you will find the

telephone number in your local directory under ‘Gas’.

GENERAL DESCRIPTION

TECHNICAL SPECIFICATIONS . . . . . . . . . . . . . . .1

2.1

Gas Categories . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

2.2

Performance data, Halstead Ace & Ace High . . . . . . . . . .1

2.3

Minimum clearances, Halstead Ace & Ace High . . . . . . .1

2.4

General specifications, Halstead Ace & Ace High . . . . . .1

2.5

Overall appliance dimensions . . . . . . . . . . . . . . . . . . . .1

2.6

Concentric air/flue duct specifications . . . . . . . . . . . . . .3

2.8

Exploded diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

2.9

Hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

INSTALLATION REQUIREMENTS . . . . . . . . . . . . . .8

3.1

Statutory requirements . . . . . . . . . . . . . . . . . . . . . . . . .8

3.2

Boiler location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

3.3

Flue terminal position . . . . . . . . . . . . . . . . . . . . . . . . . .9

3.4

Ventilation requirements . . . . . . . . . . . . . . . . . . . . . . . .9

3.5

Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

3.6

Central heating system . . . . . . . . . . . . . . . . . . . . . . . . .9

3.7

Domestic hot water systems . . . . . . . . . . . . . . . . . . . . .10

3.8

Electricity supply . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

3.9

External controls . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

4.0

INSTALLING THE APPLIANCE . . . . . . . . . . . . . . .12

4.1

Unpacking the appliance . . . . . . . . . . . . . . . . . . . . . .12

4.2

Preparing the wall . . . . . . . . . . . . . . . . . . . . . . . . . . .12

4.3

Mounting the boiler . . . . . . . . . . . . . . . . . . . . . . . . . .13

4.4

Service connections . . . . . . . . . . . . . . . . . . . . . . . . . .13

4.5

Gas connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

4.6

Pressure relief valve connection . . . . . . . . . . . . . . . . . .13

4.7

Air/flue duct installation . . . . . . . . . . . . . . . . . . . . . . .14

4.8

Wiring instructions . . . . . . . . . . . . . . . . . . . . . . . . . . .17

COMMISSIONING AND TESTING . . . . . . . . . . . .18

5.1

Filling the water system . . . . . . . . . . . . . . . . . . . . . . . .18

5.2

Commissioning the appliance . . . . . . . . . . . . . . . . . . .19

5.3

DHW flow rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

5.4

Final checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

5.5

Ignition lockout . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

5.6

Overheat thermostat . . . . . . . . . . . . . . . . . . . . . . . . . .20

5.7

Frost protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

5.8

Other features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

5.9

User’s instructions . . . . . . . . . . . . . . . . . . . . . . . . . . .20

5.10

Boiler logbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

ROUTINE SERVICING INSTRUCTIONS . . . . . . . . .21

INTERNAL WIRING DIAGRAMS . . . . . . . . . . . . .23

7.1

Functional flow diagram . . . . . . . . . . . . . . . . . . . . . . .23

7.2

Illustrated wiring diagram . . . . . . . . . . . . . . . . . . . . . .24

FAULT FINDING . . . . . . . . . . . . . . . . . . . . . . . .25

8.1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

8.2

Diagnostic indicator LED’s . . . . . . . . . . . . . . . . . . . . . .25

8.3

Ignition faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

8.4

DHW fault finding . . . . . . . . . . . . . . . . . . . . . . . . . . .25

8.5

Central heating fault finding . . . . . . . . . . . . . . . . . . . .25

REPLACEMENT OF PARTS . . . . . . . . . . . . . . . . .27

9.1

Heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

9.2

Combustion chamber insulation . . . . . . . . . . . . . . . . . .27

9.3

Fan assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

9.4

Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

9.5

Ignition and detection electrodes . . . . . . . . . . . . . . . . .27

9.6

Multifunctional gas control . . . . . . . . . . . . . . . . . . . . .27

9.6.1

Gas control replacement . . . . . . . . . . . . . . . . . . . . . . .27

9.6.2

Gas control and PCB burner pressure setting procedure . .27

9.7

Air Pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . .28

9.8

Overheat thermostat . . . . . . . . . . . . . . . . . . . . . . . . . .28

9.9

PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

9.10

CH/DHW Microswitches . . . . . . . . . . . . . . . . . . . . . .29

9.11

Thermistors D.H.W. or Heating . . . . . . . . . . . . . . . . . .29

9.12

Water flow regulator . . . . . . . . . . . . . . . . . . . . . . . . .30

9.13

DHW heat exchanger . . . . . . . . . . . . . . . . . . . . . . . .30

9.14

DHW flow switch body . . . . . . . . . . . . . . . . . . . . . . .30

9.15

Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

9.16

Pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . .30

9.17

Pressure gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

9.18

Auto air vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

9.19

System expansion vessel . . . . . . . . . . . . . . . . . . . . . . .31

9.20

Time clock. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

SHORT PARTS LIST . . . . . . . . . . . . . . . . . . . . . .31

Supplementary instructions for flue systems

with a vertical outlet. . . . . . . . . . . . . . . . . . . . . . . . . .32

Summary of Contents for Ace High

Page 1: ...CE No 41 333 77 Ace G C APPLIANCE No 41 333 78 Ace High 0 0 8 6 Ace and Ace High Wall Mounted Gas Combination Boiler Installation and Servicing Instructions To be left with user adjacent to gas meter EC 0087 BM 37 ...

Page 2: ...on is fitted as standard equipment The boiler may be used with any certified mains voltage room thermostat An electro mechanical 24hr time clock is fitted as standard NOTE British Standard BS7593 1992 stresses the importance of cleansing and flushing of the system to ensure it continues to run efficiently with the minimum of maintenance necessary Halstead Boilers fully support this professional ap...

Page 3: ...ng return 22mm compression Domestic water inlet 15mm compression Domestic water outlet 15mm compression Pressure relief valve outlet 15mm tail CONNECTION SIZES 2 4 GENERAL SPECIFICATIONS 1 b NOTE 10mm for normal operation 450mm for installation and servicing 2 5 OVERALL DIMENTIONS AND MINIMUM CLEARANCES The Seasonal Efficiency SEDBUK is 78 1 and conforms with Band D The efficiency value is used in...

Page 4: ... STANDARD DUCT 90 EXTENSION ELBOW EXTENSION DUCT 2 d FLUE WITH 90 BEND TERMINAL DUCT STANDARD DUCT FLANGED ELBOW 90 EXTENSION ELBOW EXTENSION DUCTS 2 e HORIZONTAL FLUE WITH 90 BEND 2 f VERTICAL STRAIGHT FLUE VERTICAL COWL EXTENSION DUCT EXTENSION DUCT EXTENSION DUCT STANDARD DUCT VERTICAL TURRET SOCKET 2 g OFFSET VERTICAL FLUE EXTENSION DUCTS 90 EXTENSION ELBOW FLANGED ELBOW STANDARD DUCT EXITS AP...

Page 5: ... Refer to section 2 6 a for maximum allowable lengths L S L R 3 a L L 3 b Fig 3a Standard flue assembly using either side or rear outlet Flue length L measured from the boiler outlet centre line to the outside wall face max 820 R distance from boiler outlet centre to rear of boiler 188mm S distance fron boiler centre to side of boiler 225mm Allow for minimum clearance of 5mm at side of boiler Fig ...

Page 6: ...et socket 90 extension elbow standard flue assy extension s a measured from the top of the boiler casing to the centre line of the extension elbow b measured from the centre line of the extension elbow to the outside wall face Maximum allowable flue length of a b Ace 4000mm Ace High 2000mm Fig 6 As fig 5 but with additional 90 extension elbow a measured from the top of the boiler casing to the cen...

Page 7: ...osition However 90 flue elbows may be used to drop the height of the flue system by 500mm d The flue system must use either a flanged elbow or a vertical flue turret socket at the entry exit to the appliance e All joints must be correctly made and secured in accordance with the installation instructions 7 a L 7 b b a Fig 7 a Vertical flue assembly with Vertical turret socket standard duct vertical...

Page 8: ...8 EXPLODED DIAGRAM for key no references see spare parts catalogue Drawing amended 8 6 00 6 ...

Page 9: ...ate Heat Exchanger Overheat Stat DHW out Heating Flow By Pass 3 bar Pressure Relief Valve DOMESTIC HOT WATER MODE AUTOMATIC AIR VENT EXPANSION VESSEL Heating Return PRESSURE GAUGE PUMP Cold Water IN Overheat Stat DHW out Heating Flow By Pass 3 bar Pressure Relief Valve CENTRAL HEATING MODE Plate Heat Exchanger ...

Page 10: ... is the law that all gas appliances are installed by a registered person in accordance with the rules in force Failure to install appliances correctly could lead to prosecution It is in your own interest and that of safety to ensure that the law is complied with In addition to the above regulations this appliance must be installed in accordance with the current IEE Wiring Regulations for electrica...

Page 11: ... from outside the building the necessary areas quoted above may be halved If the cupboard or compartment is full room height 2 3 m min then NO purpose made ventilation is required 3 5 GAS SUPPLY a The Gas Supplier should be consulted at the installation planning stage in order to establish the availability of an adequate supply of gas b An existing service pipe MUST NOT be used without prior consu...

Page 12: ... DOMESTIC HOT COLD WATER SUPPLY TAPS AND MIXING TAPS All equipment designed for use at mains water pressure is suitable SHOWERS BIDETS Any mains pressure shower or bidet complying with the Local Water Undertaking bylaws is suitable h Consider IRN 116 and Byelaw 90 91 Ensure that necessary action have been carried out to account for thermal expansion of water If thermal expansion is not provided th...

Page 13: ... fitted at least one radiator preferable in the bathroom must be permanently open i e fitted with two lockshield valves APPLIANCE CH FLOW DOMESTIC HOT WATER OUT GAS SUPPLY MAINS IN CH RETURN RADIATOR WITH 2 LOCKSHIELD VALVES IN OPEN POSITION PRESSURE RELIEF VALVE OUTLET TO DRAIN DOMESTIC HOT WATER DOMESTIC COLD WATER PRESSURE REDUCING VALVE IF REQUIRED BS STOP VALVE FIXED SPINDLE MAINS WATER DRAIN...

Page 14: ...utlet if required and the water and gas connections Remove the paper template and proceed as follows b Cut the hole in the wall for the air flue duct The diameter must not be less than 100mm and the hole must be horizontal If the hole is not accessible from outside it s minimum diameter must be sufficient to allow insertion of the wall liner 130mm 51 4 in The wall liner is available as an optional...

Page 15: ...central heating system to the boiler flow and return using the connections shown in Fig 19 d Connect the mains water supply and outlet to the appropriate connections as shown in Fig 19 4 4 SERVICE CONNECTIONS 4 3 MOUNTING THE BOILER 4 5 GAS CONNECTION PRESSURE RELIEF 45mm SERVICE CONNECTIONS rear view a Connect a suitable discharge pipe to the pressure relief valve tube The pipe should be a minimu...

Page 16: ...is always slid into the end of the standard or extension duct where appropriate c Achieve the correct flue length using Figure 22 as a guide Note that the flue length is measured to the inside of the external wall sealing ring In most cases it will be possible to achieve the required flue length without cutting the ducts however where necessary the plain ends of the extension ducts may be cut Neve...

Page 17: ...RMINAL L 2 STANDARD DUCT Push ducts fully over elbow and drill two 3 3mm dia holes Secure with self tapping screws 3 EXTENSION Push extension duct if required over standard duct engage fully Drill two 3 3mm dia holes and secure with self tapping screws 6 Drill and screw telescopic overlap 5 STANDARD TERMINAL Slide telescopic section to achieve length L 4 Check terminal is correctly aligned see Fig...

Page 18: ...will adversely affect performance and TOP 4 7 3 INSTALLING THE AIR FLUE DUCT FROM INSIDE THE ROOM Wall thickness up to 800 mm 31in only a Push the terminal through the wall liner taking care to ensure that the terminal is the correct way round and the external wall sealing ring does not become dislodged b Pull the flue system towards the boiler to seat the external sealing ring against the outside...

Page 19: ...H AGAINST THE WALL TO FORM A GOOD SEAL 2 INSERT FLUE LENGTHS FROM OUTSIDE THE ROOM ENSURE EXTERNAL WALL SEALING RING FORMS A GOOD SEAL EXTERNAL WALL SEALING RING TOP 100mm Dia HOLE INTERNAL WALL SEALING RING FIBRE SEAL FITTED Flue hole diameter 100mm wall liner not necessary a Secure the flue elbow with seals and flue adaptor where necessary to the appliance using the 4 screws provided b Fit exter...

Page 20: ... with a recognised system cleaner such as Fernox or Sentinel 6 Open the DHW inlet valve and open and close each hot water tap in turn to clear all the air from the pipes and the boiler 7 Remove the pump end cap and rotate the rotor replace the cap 8 If filling loop is used disconnect filling loop 9 Prior to firing up the boiler to check the gas rates the Central Heating and Boiler system should be...

Page 21: ...low and re check burner pressure If it is necessary to adjust the DHW burner pressure the method is described in section 9 6 Gas valve replacement e Close the DHW tap and ensure that the Burner On LED Fig 30 goes off the burner goes out and the pump stops after an overrun period f Ensure that the room thermostat if fitted is calling for heat Turn the Main Switch to Heating Water and turn the heati...

Page 22: ...n the appliance is left either in the Hot Water or Heating Water mode The clock can be switched to the off setting The following additional features are included in the appliance specification ANTI CYCLE DEVICE When the appliance cycles on it s central heating control setting a slow cycle device operates The timer set to 3 mins is activated after the end of burn cycle to prevent rapid cycling of t...

Page 23: ...ove the 4 screws securing the burner on the gas manifold e Unscrew and remove the two screws securing the control panel in the upright position and pivot the panel forwards f Remove the two spark and one detection electrode leads from the electrodes Check that the injectors fitted in the gas manifold are free from dirt and debris If necessary clean the injector orifice carefully using a soft brush...

Page 24: ...ce in both central heating and DHW modes and ensure that the DHW maximum and minimum burner pressures after ten minutes running are as stated on the data badge c Remove the pressure gauge and tighten the sealing screw Re light the appliance and test for gas soundness a Carefully disconnect the tab connectors on the fan wiring from the fan b Disconnect the air pressure switch sensing pipes from the...

Page 25: ...INTERNAL WIRING DIAGRAMS 7 7 1 FUNCTIONAL FLOW WIRING DIAGRAM 23 ...

Page 26: ...7 2 ILLUSTRATED WIRING DIAGRAM 24 ...

Page 27: ...tat left hand underside of casing NOTE There may be a fault condition preventing ongoing operation of the appliance Follow fault finding procedure In the event of the boiler failing to light investigate the problem by following the flow chart When the hot water tap is turned on the controls should carry out a set of start up checks flow chart 1 followed by an ignition sequence flow chart 2 If the ...

Page 28: ...replace If fuse OK replace board Check pump rotation Is 230V present across pins 1 and 3 on X3 Replace PCB Replace fan YES Start YES YES YES YES YES YES NO NO NO NO NO NO NO YES YES YES Is green LED Power ON illuminating primary flow switch contacts closed Replace flow switch Turn Mains Switch to Heating and Water mode PCB should carry out APS pump flow switch and overheat checks Is red LED Safety...

Page 29: ... ignition and or detection electrode s and check that both electrodes are aligned as detailed in figure 34 Re assemble in reverse order Ensure that all joints and seals are correctly re fitted a Remove the casing front panel as described in section 9 1 step a and lower the controls fascia panel after removing the two retaining screws b Carefully pull off the electrical connector plug from the mult...

Page 30: ...t between the minimum and maximum gas control setting originally factory set at 6 3 mbar This can be adjusted with the potentiometer P3 l Isolate the appliance and remove the link between pins 1 and 2 on terminal X4A Switch the appliance back on at the mains isolation switch m Check that the pressures are correctly set by turning on and off the DHW tap several times and on each occasion allowing t...

Page 31: ...k Wires CH THERMISTOR Grey Wires 9 10 CH DHW MICROSWITCH a Remove the casing front panel and lower the controls fascia panel as described in section 9 6 step a b Release the appropriate micro switch assembly from the spindle by sliding out the retaining spring clip Refer to figure 37 c Unscrew the three screws fixing the plastic housing halves together and slide the micro switch forwards to releas...

Page 32: ...ete controls fascia panel and base plate as described in section 9 13 c Isolate the cold water inlet valve and drain the DHW circuit by opening all DHW taps d Refer to Figure 38 Unscrew the two screws securing the switch body to the main brass block Note the position of the alignment pin e Remove the two spring clips which secure the pressure sensing pipes into the switch body and pull out the pip...

Page 33: ...e to the CH return To replace the expansion vessel it is necessary to isolate the central heating and DHW systems from the appliance drain the appliance and remove the appliance from the wall The vessel can then be unscrewed and replaced 9 20 TIME CLOCK a Remove the casing front panel and lower the controls fascia panel as described in section 9 6 step a b Unplug the four electrical connectors fro...

Page 34: ...d in section 4 up to section 4 7 but making the necessary hole s in the ceiling roof instead of the wall Use the following instructions in place of section 4 7 c Measure the vertical distance from the top of the boiler case to the roof line Fig 39 Use this length to calculate the number of extension ducts required d Starting at the boiler fit the vertical socket standard duct and extensions requir...

Page 35: ... 01926 834834 e mail sales halsteadboilers co uk or service halsteadboilers co uk Website www halsteadboilers co uk SERVICE HELPLINE 01926 834834 Halstead Boilers are continuously improving their products and therefore reserve the right to change specifications without prior notice and accept no liability for any error or omission in the information contained in this document ...

Page 36: ...ED FLUE COMBINATION BOILER FOR USE WITH NATURAL GAS B R I T I S H M A D E B O I L E R S G C APPLIANCE No 47 333 10 Ace EC 0063 AS 5304 TO BE LEFT WITH THE USER ADJACENT TO THE GAS METER 0 0 8 6 USER INSTRUCTIONS FOR THE HALSTEAD Ace Ace ...

Page 37: ...set to an ON period see diagram or set the clock over ride switch to the ON position Turn up the room thermostat if fitted The boiler will run through a series of tests then the burner will light and the three green LEDs Power On Heating and Burner On will be illuminated 3 Hot water will be supplied as soon as any Domestic Hot Water tap is turned on and the green Hot Water LED will be illuminated ...

Page 38: ...low the appliance to cool then press the overheat reset button once It is located underneath the appliance at the left hand side the ignition 7 3 FROST PROTECTION This appliance is fitted with a frost protection device In the event of very cold conditions the pump may operate and the boiler may light for a few minutes to protect the appliance and system from potential frost damage This can only fu...

Page 39: ...he appliance it MUST NOT be used until the fault has been rectified by a competent person 9 CLEANING Use only a damp cloth and mild detergent to clean the appliance outer casing DO NOT use abrasive cleaners 8 3 C H WATER FLOW SWITCH This device prevents the burner from igniting if there is inadequate water flow through the main heat exchanger If the Power On LED flashes this indicates failure of t...

Page 40: ...Ace Ace High Wickes Combi 82 102 05 04 ACE ACE HIGH WICKES COMBI 82 102 ...

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