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37

WATER HOUSING GROUP SET

9.11

THERMISTORS - DHW OR HEATING

The thermistors are immersed in the waterways hence slight water

loss is likely during this operation. Provision should be made to

collect a small amount of water underneath the appliance.

a)

Remove the casing front panel and lower the controls fascia

panel as described in section 9.6 step (a). 

b)

Isolate the appliance from the system as follows:
If replacing DHW thermistor turn off the inlet water valve (see

section 5) and open all DHW taps to empty the DHW circuit). 
If replacing CH thermistor, turn off the boiler flow and return

from the system using the isolation valves as shown in section 5.

c)

Unclip and remove the electrical connector plug from the

thermistor. Unscrew the thermistor from the waterway.

d)

Replace the thermistor and re-assemble in reverse order. Ensure

the copper washers are correctly fitted to provide a sealed

joint. Re-commission the system as described in section 5.

PLATE HEAT
EXCHANGER

SOCKET HEAD
CAPSCREWS (2)
(Secure plate 
heat exchanger)

DHW
FLOWSWITCH
(Pink Wires)

LARGE BRASS NUT
(Water flow 
regulator behind)

DHW PRESSURE 
SENSING PIPES

PRESSURE RELIEF
VALVE

BYPASS
(Underneath)

FLOW SWITCH

SECURING 
SCREWS (2) 

PRIMARY/FLOWSWITCH
(Violet Wires)

LARGE 
HEXAGON
NUT

‘O’ RING SEAL

FILTER

WATER FLOW REGULATOR
(Small diameter towards small
hexagonal nut)

SMALL 
HEXAGONAL 
NUT

PUMP

DHW

THERMISTOR

(Black 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 release it from
the housing.

d)

Transfer the electrical connections to the new micro switch, fit the
new micro switch and re-assemble in reverse order.

9.9.1

a)

On completion of replacing the PCB the CH maximum heat
input will require setting. 

b)

Connect a suitable manometer to the gas inlet and burner
pressure test points (see Fig. 35). 

c)

Set the clock to the ON position (I) and ensure any external
controls are calling for heat.

d)

Set the Main Switch to the Heating & Water position and turn
the temperature control knobs to high.

e)

Wait until appliance has lit (in CH mode only) and turn
potentiometer P3 (max CH set point) to the required burner
pressure between 9.7 and 1.3 mbar (originally factory set at
6.3mb)

PCB CH HEAT INPUT SETTING
PROCEDURE

29

36

OVERHEAT THERMOSTAT

PHIAL

PIPE CLIP

ELECTRICAL
CONNECTIONS

SECURING NUT &
OVERHEAT RESET BUTTON

c)

Remove carefully the control knob clips holding the control
knob in position and pull out the three control knobs from the
front of the fascia panel (Fig. 30).

d)

Unclip the electrical connector plugs from the PCB (refer to
section 7).

e)

Remove the six self taping screws securing the PCB

f)

Remove the PCB. Re-assembly is in reverse order

Содержание Ace High

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

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

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

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

Страница 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 ...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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...

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

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