Halstead CLUB HE 18, Installation And Servicing Instructions

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CNTENTS
1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
1.1 Impor tant Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 TECHNICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . 2
2.1 Gas Categories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Per formance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.3 General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.4 Overall Dimensions & Minimum Clearances . . . . . . . . . . . . . . 4
2.5 Concentric Air / Flue Duct Specifications . . . . . . . . . . . . . . . . 4
2.6 Specification for Chimney Flue Liner Kit (T ype B23) . . . . . . . . . 6
2.7 Specification for T win Flued (Type C53) . . . . . . . . . . . . . . . . . 7
2.8 Additional Concentric Flue Kits and Plume Diver ter Kit . . . . . . . 7
2.9 Appliance Hydraulic Cir cuits . . . . . . . . . . . . . . . . . . . . . . . . . 9
3 INSTALLATION REQUIREMENTS . . . . . . . . . . . . . . . . . 10
3.1 Statutor y Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.2 Appliance Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.3 Flue T erminal Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.4 V entilation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.5 Condensate Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.6 Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.7 Central Heating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.8 Electricity Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.9 Exter nal Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4 APPLIANCE INSTALLATION . . . . . . . . . . . . . . . . . . . . 16
4.1 Unpacking The Appliance . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.2 Pr eparing The Wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.3 Mounting The Appliance . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.4 Central Heating Ser vice Connections . . . . . . . . . . . . . . . . . . .17
4.5 Gas Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.6 Condensate Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.7 Pr essure Relief Valve Connection . . . . . . . . . . . . . . . . . . . . . 18
4.8 Air / Flue Duct Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.9 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5 COMMISSIONING AND TESTING . . . . . . . . . . . . . . . 20
5.1 Filling the W ater System . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.2 Commissioning the Appliance . . . . . . . . . . . . . . . . . . . . . . . 21
5.3 Final Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.4 Lockout Indication and r eset the appliance . . . . . . . . . . . . . . 22
5.5 Fr ost Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.6 Over heat Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.7 Users Instr uctions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.8 Appliance Log Book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6 ROUTINE SERVICING . . . . . . . . . . . . . . . . . . . . . . . . 23
6.1 Combustion Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.2 Gas Contr ol Valve, Fan & Burner Assembly . . . . . . . . . . . . . . 24
6.3 Bur ner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.4 Ignition & Detection Electr odes . . . . . . . . . . . . . . . . . . . . . . . 25
6.5 Combustion Chamber & Heat Exchanger . . . . . . . . . . . . . . . 25
6.6 Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.7 Re-assembly & Re-commissioning . . . . . . . . . . . . . . . . . . . . . 25
6.8 Final Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7 INTERNAL WIRING DIAGRAM . . . . . . . . . . . . . . . . . 26
7.1 Functional Flow W iring Diagram . . . . . . . . . . . . . . . . . . . . . 26
8 FAULT FINDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8.2 Diagnostic Digital Display . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8.3 Faulting Finding Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8.4 Central Heating Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . 28
9 REPLACEMENT OF PARTS . . . . . . . . . . . . . . . . . . . . . 30
9.1 Ignition and Detection Electr odes . . . . . . . . . . . . . . . . . . . . . 30
9.2 Igniter Unit and Ignition Leads . . . . . . . . . . . . . . . . . . . . . . . 30
9.3 Gas Contr ol Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
9.4 Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
9.5 Bur ner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
9.6 Combustion Chamber Fr ont Insulation . . . . . . . . . . . . . . . . . . 33
9.7 Combustion Chamber Rear Insulation . . . . . . . . . . . . . . . . . . 33
9.8 Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
9.9 Pump (Head Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
9.10 Hydr oblock Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
9.11 Expansion V essel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
9.12 Pr essure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
9.13 W ater Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . 36
9.14 Flue Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
9.15 Condensate Drain System . . . . . . . . . . . . . . . . . . . . . . . . . . 36
9.16 Pr essure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
9.17 Auto Air V ent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
9.18 Contr ol PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
9.19 Draining The Appliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
10 SHORT PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Introduction
The Halstead Club HE 18 is a high ef ficiency condensing, fully
automatic, wall mounted gas appliances suitable for either room
sealed or opened flued applications, for use with natural gas
(G20) only. The Club HE 18 is a sealed system condensing boiler
and is suitable to be connected to a central heating system
operating a standard ‘Y’ or ‘S’ plan system.
The appliance features an attractive white stove enamelled
casing, with inset control panels. The flue systems are in white
stove enamel to give a clean attractive appearance to the
installation.
A standard horizontal concentric air/flue duct terminal is
available, (maximum duct length of 755 mm (29
3
⁄
4
in)), suitable
for room sealed applications. The duct assembly is connected to
the appliance via a turret, which can be orientated to provide
different horizontal duct directions. Extension ducts may be fitted
in accordance with and up to the maximum dimensions stated in
these instructions.
A vertical concentric outlet kit is also available for installations
where an outside wall is not accessible or where it is desired to fit
the duct ‘through the roof’. Installation using the horizontal duct is
described in the main text of these instructions and additional
information is provided in the vertical outlet kit for the vertical
installation option. (Note: If the vertical outlet kit is to be used,
access to the roof is necessary).
Other flue kits are available for open flued, B
23
, and twin flued,
C
53
, and special C
13
& C
33
, applications, contact Halstead Boiler
Ltd Service Help Line: 01926 834834, for further details,
ONL Y HALSTEAD APPROVED FLUE KITS OR
EXTENSIONS MAY BE USED WITH THESE APPLIANCES.
CONTENTS INTRODUCTION
1