halstead Ace He Type 24 User guide

751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:44 Page 1

24, 30 & 35

ACE HE Type

USER INSTRUCTIONS

TO BE GIVEN TO THE USER

0086

PIN 87/BQ/44

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)

COMBINATION CONDENSING BOILER

751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:44 Page 2

CNTENTS

CONTENTS INTRODUCTION

1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0

1.1 Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

1.2 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 TECHNICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . 2

2.1 Gas Categories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

2.2 Performance 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 (Type B23) . . . . . . . . . . . 6

2.7 Specification for Twin Flued (Type C53) . . . . . . . . . . . . . . . . . . . . 7

2.8 Additional Concentric Flue Kits and Plume Diverter Kit . . . . . . . . . 7

2.9 Appliance Hydraulic Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

3 INSTALLATION REQUIREMENTS . . . . . . . . . . . . . . . . . . . 11

3.1 Statutory Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.2 Appliance Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.3 Flue Terminal Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.4 Ventilation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3.5 Condensate Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3.6 Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3.7 Central Heating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

3.8 Domestic Hot Water System . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3.9 Electricity Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

3.10 External Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

4 APPLIANCE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 15

4.1 Unpacking The Appliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4.2 Preparing The Wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

4.3 Mounting The Appliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4.4 Central Heating & Domestic Hot Water Service Connections . . . . .16

4.5 Gas Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4.6 Condensate Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4.7 Pressure Relief Valve Connection . . . . . . . . . . . . . . . . . . . . . . . . 17

4.8 Air / Flue Duct Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

4.9 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

5 COMMISSIONING AND TESTING . . . . . . . . . . . . . . . . . . 19

5.1 Filling the Water System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

5.2 Commissioning the Appliance . . . . . . . . . . . . . . . . . . . . . . . . . . 20

5.3 DHW Flow Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

5.4 Final Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

5.5 Lockout Indication and reset the appliance . . . . . . . . . . . . . . . . . 21

5.6 Frost Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

5.7 Overheat Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

5.8 Other Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

5.9 Users Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

5.10 Appliance Log Book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

6 ROUTINE SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . 23

6.1 Combustion Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

6.2 Gas Control Valve, Fan & Burner Assembly . . . . . . . . . . . . . . . . 25

6.3 Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

6.4 Ignition & Detection Electrodes . . . . . . . . . . . . . . . . . . . . . . . . . 25

6.5 Combustion Chamber & Heat Exchanger . . . . . . . . . . . . . . . . . . 25

6.6 Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

6.7 Domestic Cold Water Inlet Filter . . . . . . . . . . . . . . . . . . . . . . . . 25

Re-assembly & Re-commissioning . . . . . . . . . . . . . . . . . . . . . . . . 26

6.8

6.9 Final Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

7 INTERNAL WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . 27

7.1 Functional Flow Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . 27

8 FAULT FINDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

8.2 Diagnostic Digital Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

8.3 Faulting Finding Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

8.4 Domestic Hot Water Fault Finding . . . . . . . . . . . . . . . . . . . . . . . 28

8.5 Central Heating Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . . . 29

9 REPLACEMENT OF PARTS . . . . . . . . . . . . . . . . . . . . . . . 31

9.1 Ignition and Detection Electrodes . . . . . . . . . . . . . . . . . . . . . . . . 31

9.2 Igniter Unit and Ignition Leads . . . . . . . . . . . . . . . . . . . . . . . . . . 31

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 Condensate Drain System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

9.18 Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

9.19 Auto Air Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

9.20 Control PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

9.21 Time Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

9.22 DHW Flow Switch, DHW Flow Regulator and DHW Filter . . . . . . 39

9.23 Draining The Appliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

10 SHORT PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Introduction

1

The Halstead Ace HE24, Ace HE30 and Ace HE35 are high
efficiency condensing, fully automatic, wall mounted gas
appliances suitable for either room sealed or opened flued
applications, for use with natural gas (G20) only. These
combination appliances provide the user with both central heating
(CH) and domestic hot water (DHW) on demand.

The appliances feature 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
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

, and special C13& C33, applications, contact Halstead Boiler

C

53

Ltd Service Help Line: 08450 710780, for further details,

ONLY HALSTEAD APPROVED FLUE KITS OR
EXTENSIONS MAY BE USED WITH THESE APPLIANCES.

3

⁄4 in)), suitable

, and twin flued,

23

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1.1

IT IS A STATUTORY REQUIREMENT THAT ALL GAS
APPLIANCES ARE INSTALLED BY COMPETENT PERSONS,
(i.e. CORGI REGISTERED INSTALLERS) IN ACCORDANCE
WITH THE GAS SAFETY (INSTALLATION AND USE)
REGULATIONS (CURRENT EDITION). FAILURE TO
COMPLY WITH THESE REGULATIONS MAY LEAD TO
PROSECUTION.

These appliances have been tested and certified in order to
satisfy the necessary European Directives and comply with the
latest Building Regulations, including the efficiency requirements
of the SEDBUK scheme.

Gas Appliance Directive 90/396/EEC
Efficiency of Hot Water Boilers Directive 92/42/EEC
Low Voltage Directive 93/68/EEC
Electromagnetic Compatibility Directive 92/31/EEC
No modifications to these appliances should be made unless they

are fully approved by the manufacturer.
Appliance installation must be carried out by a competent person

and must be in accordance with the current legislation in force at
the time of installation, in the country of destination.

The manufacturer’s instructions must not be taken as overriding
any statutory requirements.

!

VENTILATE THE AREA BY OPENING DOORS AND
WINDOWS. CALL OUT YOUR LOCAL GAS SUPPLIER
TEL: [phone].

Control of Substances Hazardous to Health

Under Section 6 of the Health and Safety at Work Act 1974, it is
required to provide information on substances hazardous to health.

The adhesives and sealants used in this appliance are cured and
give no known hazard in this state.

Insulation Pads – These can cause irritation to skin, eye and the
respiratory tract. If you have a history of skin complaint 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
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 consumer help line
number: 08459 060708, or via their web site;
http://www.energywatch.org.uk.

IMPORTANT INFORMATION

GAS LEAKS. DO NOT OPERATE ANY
ELECTRICAL SWITCHES, OR USE A NAKED
FLAME. TURN OFF THE GAS SUPPLY.

1.2

The appliances incorporate a microprocessor based, fully
modulating air/gas ratio control system with direct burner
ignition, which provides a modulated heat output to either central
heating (CH) or domestic hot water (DHW) demands, and with
internal frost protection provided as standard. The heat exchanger
is constructed from stainless steel encased in high temperature
polymer.

A combined circulating pump, diverter valve and automatic air
vent assembly, pressure gauge, safety valve and system
expansion vessel are included. Isolation valves are fitted to the
service connections. The appliances have a DHW flow detection
device, which gives priority to DHW demand and proportions the
required heating load to the DHW flow rate, an electro­mechanical 24 hour time clock is also fitted as standard.

The appliances may be used with any certified mains voltage
room thermostat, and can operate without the need for an
automatic bypass valve, however if thermostatic radiator valves
are installed it is recommended that one radiator is fitted with
lockshield valves, to allow the pump overrun facility to operate
correctly. A separate CH expansion vessel is not required if the
total CH system content is less than 84 litres, but one is required
for systems with volumes greater than 84 litres; refer to section

3.7. A separate DHW expansion vessel is not required.
It is recommended that a drain cock is fitted at the lowest point in

the system.

GENERAL DESCRIPTION

1

751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:44 Page 4

TECHNICAL SPECIFICATIONS

2

2.1

These appliances are certified to comply with the requirements of
EN 483, EN 677, and EN 625 for use in GB and IE (Great
Britain and Ireland) using gas category 2H (G20 with a governed
gas supply at 20 mbar (8 in.wg) inlet pressure).

2.2

Appliance Ace HE24 Ace HE30 Ace HE35

Mode Rate
Central Heating Output Max

(non-condensing)
(80 - 60 °C)

Central Heating Output (condensing)
(50 - 30 °C) (Btu/h) (67300) (86700) (88700)

Central Heating Input
Max Rate

Central Heating Input
Min Rate

Domestic Hot Water Output Max

Domestic Hot Water Input
Max Rate

Domestic Hot Water Input
Min rate

Central Heating Gas Rate
(after 10 min operation - hot)

GAS CATEGORIES

PERFORMANCE DATA

Min

Max

Net

Gross

Net

Gross

Min

Net

Gross

Net

Gross

Max

The appliance classification (as defined in EN 483) may be any
of the following depending on the chosen flue option: C13, C33,
C53, or B23

kW 18.0 23.1 24

(Btu/h) (61500) (78900) (81900)

kW 6.0 7.2 8.3

(Btu/h) (20500) (24600) (28300)

kW 19.7 25.4 26

kW 18.4 23.9 24.5

(Btu/h) (62800) (81600) (83600)

kW 20.4 24.8 27.2

(Btu/h) (69700) (84700) (92800)

kW 5.6 6.9 8.5

(Btu/h) (19100) (23600) (29000)

kW 6.2 7.5 9.4

(Btu/h) (21200) (25600) (32100)

kW 24.0 30.0 35.0

(Btu/h) (82000) (102400) (119400)

kW 6.0 7.2 8.3

(Btu/h) (20500) (24600) (28300)

kW 24.6 31.3 35.7

(Btu/h) (84000) (106900) (121800)

kW 27.3 34.8 39.6

(Btu/h) (93200) (118900) (135200)

kW 5.6 6.9 8.5

(Btu/h) (19100) (23600) (29000)

kW 6.2 7.5 9.4

(Btu/h) (21200) (25600) (32100)

m3/h 1.95 2.49 2.59

ft3/h (68.9) (87.9) (91.5)

Domestic Hot Water Gas Rate
(after 10 min operation - hot)

Seasonal Efficiency % 90.1 90.1 90.1
Seasonal Efficiency (SEDBUK) Band “A”
Nox Classification Class “5”

Max

m3/h 2.6 3.31 3.78

ft3/h (91.8) (116.9) (133.5)

2

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Appliance Ace HE24 Ace HE30 Ace HE35
Design Domestic Hot Water Ltr/min 9.8 12.3 14.3
Performance raised 35°C
DHW Specific Rate (D) EN 625 Ltr/min 10.9 14.7 16.7
Min Mains Water Inlet Pressure for Max Heat Output Bar 1.0

Min Mains Water Inlet Pressure for Operation Bar 0.3

Max Mains Water Inlet Pressure Bar 10

Min Domestic Hot Water Flow Rate for Operation Ltr/min 2.0

Min Central Heating System Pressure Bar 0.5
Max Central Heating System Pressure Bar 2.5
Max Domestic Hot Water Temperature °C 55
Min Domestic Hot Water Temperature °C 40
Max Central Heating Flow Temperature °C 80
Min Central Heating Flow Temperature °C 30

(gpm) (2.2) (2.8) (3.1)

(psi) (14.5)

(psi) (4.4)

(psi) (145)

(gpm) (0.45)

2.3

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 weight kg 42.0 48.0 48.0
Total water capacity Ltr 1.8 2.1 21.1
Integral expansion vessel capacity Ltr 8
Maximum heating system water content

using fitted expansion vessel, @ 0.75 bar
Electrical supply 230V 50Hz Fuse at 3A
Internal fuse T4H 4A 250V
Maximum power consumption W 140 160 145
IP Rating IP20
Flue gas temperature Nat Gas 50/30 °C 53 49 56

CO
CO2value min rate (Nat Gas) ref only (G20) % 8.6 ± 0.3 8.6 ± 0.3 8.6 ± 0.3

CO/CO2Ratio max rate (Nat Gas) (G20) 0.0005 + 0.005 0.0003 + 0.005 0.0003 + 0.005
Flue products mass flow rate (Nat Gas) (G20) g/s 14.7 11.0 16.0
Gas Valve Offset @ min rate Pa -5.0

GENERAL SPECIFICATIONS

value max rate (Nat Gas) (G20) %

2

Ltr 84

9.2 ± 0.3 case on

9.0 ± 0.2 case off

Connections

Ace HE24 Ace HE30 Ace HE35
Gas 15 mm compression 22 mm compression
CH flow 22 mm compression
CH return 22 mm compression
DHW inlet 15 mm compression
DHW outlet 15 mm compression
Pressure relief valve outlet 15 mm compression
Condensate Drain 21.5 - 22 mm plastic overflow pipe

NOTE: THE STATED HEAT INPUT AND CO2VALUES ARE NOMINAL AND MAY VARY BY
RUN WITH LINE GAS, DUE TO FLUCTUATIONS IN GAS QUALITY.

± 5-10% WHEN THE APPLIANCE IS

3

751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:44 Page 6

2.4

1

758mm

OVERALL DIMENSIONS AND MINIMUM CLEARANCES

327mm

136mm

173mm

446mm

Ø100mm

97mm

907mm

200mm

5mm

SEE NOTE

200mm

5mm

NOTE:
5mm for normal
operation.
450mm for
installation and
servicing

2.5

CONCENTRIC AIR / FLUE DUCT SPECIFICATIONS

The Ace HE24, HE30 and HE35 can be installed to a number of
different concentric flue systems. The different flue applications as
shown in Figure 2 are available as kits usually comprising the

8

2

FLUE OPTIONS

connecting parts to the appliance and end terminal. Flue
extension ducts and extension elbows are available as
accessories.

The following flue systems are available for the ACE HE range

4

751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:44 Page 7

2.5.1

3a

KIT A + TELESCOPIC HORIZONTAL WALL
TERMINAL (C13) - PART NO.956120

Standard concentric (ø100/60) vertical flue application, Figures
3b, 3c, through roof attics with a maximum length of 12000mm.
The kit comprises of the roof terminal, flashing kit, vertical
adaptor with sampling point and bracket.

The maximum length is measured from the top of the appliance
casing to the underside of the air cowl.

For installation details refer to the flue kit instructions.

a

3c

Roof terminal
with rain cover
and pitched roof
flashing kit.

b

Traditional concentric flue system, Figure 3a, with a maximum length of
5000mm. The flanged flue elbow is designed with 3° slope towards the
appliance so that the condensate can easily drain off. It has to be
considered that for every metre horizontal flue length the terminal exit
centreline is approx. 45 mm higher than the elbow’s centreline.

The standard telescopic terminal is 615mm max length and 430mm min
length, but can be cut to a minimum flue length of 250mm, which is
suitable for single, 100mm (4"), brick walls.

2.5.2

KIT B VERTICAL CONCENTRIC FLUE
TERMINAL (C33) - HBL PART 956081

3b

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

2.5.3

2.5.3 KIT C: HORIZONTAL ANTI-PLUME
FLUE KIT (C13) – PART NO. 956084

If the standard horizontal terminal is likely to cause nuisance to a
neighbour or buildings, because of excess pluming, then this
particular flue kit raises the flue gas outlet point to a higher
elevation with the minimum amount of changes. The flue gas duct
is teed-off from the concentric part and covered by an 80mm
outer tube to protect the flue duct from freezing. The air in-take
remains at the lower level (see Figure 3d).

If choosing this option then the external flue duct length should be
taken into account when calculating equivalent flue length.

For installation details refer to the flue kit instructions.

Dimensions from vertical terminals to opening
windows should be in line with Figure 5.

5

751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:44 Page 8

3d

flue will 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.

2.6

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 chimney, a flexible plastic flue liner
with connection parts and chimney terminal (see Figure 3f). Where an
open flue system is used, then an air vent must be provided in the same
room or internal space as the flue duct air inlet, see section 3.4.

For installation details refer to the flue kit instructions.
Maximum flue resistive length = 30m.

KIT E CHIMNEY FLUE LINER KIT
(B23) – PART NO. 956082

3f

2.5.4

3e

KIT D EXTERNAL VERTICAL FLUE - (C33)
PART NO: 956085

A flue system can be built up from the components
detailed in the table, but the total flue resistance must
not exceed the maximum stated.

Suitable for installations if the appliance can’t be repositioned
and where other horizontal flue options may causes some
nuisance to neighbours or buildings. The flue kit contains some
additional 45° elbows and extension ducts as well as a special
wall bracket to pass the guttering (see Figure 3e). The concentric

6

751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:44 Page 9

FLUE LENGTHS

Length supplied in standard kit - horizontal 815mm
Max horizontal length
Min horizontal length
Max vertical length
Min vertical length
Length supplied in standard kit - vertical

FLEXITUBE MUST BE PURCHASED AS AN ACCESSORY TO COMPLETE THE KIT

Flexi tube min length 5m
Flexi tube max length 30m

(from boiler to chimney - 60/100mm)

(from boiler to chimney - 60/100mm)

(from boiler to chimney - 60/100mm)

(from boiler to chimney - 60/100mm)

(available in 10m, 20m and 30m length)

ACCESSORIES

Description Part No. Resistive Length

HORIZONTAL - 60/100 Accessories

Flue extension duct - 500mm 956092 450mm
Flue extension duct - 1000mm (Incl. 1 x support bracket) 956093 950mm
93°extension elbow 956091 1550mm
45°extension elbow (pair) 956090 775mm
Air inlet duct - included in kit N/A N/A
Straight adapter (60/80) - included in kit N/A N/A

91.5°adapter elbow (80/80) - included in kit N/A N/A
Support bracket - 100mm 840517 N/A
93°flanged elbow - included in kit 956082 N/A
Vertical turret socket 956087 N/A

VERTICAL - Accessories

Flexi tube - 10m 956110 10m
Flexi tube - 20m 956111 20m
Flexi tube - 30m 956112 30m
Straight duct (80) - included in kit N/A N/A
Chimney terminal - included in kit N/A N/A

2000mm

100mm

2000mm

200mm

N/A

(See below)

NOTE:

THE CORRUGATED (FLEXI TUBE) FLUE PARTS ARE FIXED AND ALL PARTS ARE REQUIRED
FOR EVERY APPLICATION.

2.7

This flue system kit is designed for installations where the air intake position
is different than the flue duct exit point. The kit comprises of a twin adaptor
from which the air intake is taken from the adjacent outside wall (see
example Figure 3g) and the flue duct is routed vertically through the roof.

It has to be noted that the flue duct is under pressure when the
appliance is in operation and the duct can leak poisonous carbon
monoxide if the duct components are not correctly assembled. It is not
recommended to route the flue duct through living space areas, i.e.
bed rooms, living rooms etc.

For installation details refer to the instructions provided with the twin
flued kit.

For C53 flue systems the terminal for the supply of combustion air and
for the evacuation of combustion products shall not be installed on
opposite walls of the building.

RESISTIVE LENGTH INFORMATION ONLY REQUIRED FOR COAXIAL FLUE PARTS.

KIT F: TWIN FLUE SYSTEM (C53) –
PART NO. 956080

Maximum flue resistance permitted for a twin flued
system = 52 Pa

Minimum flue resistance permitted for a twin flued
system = 23.5 Pa

Flue Component Flue Resistance (Pa) Part Number

Twin Flue Adaptor (required) 9.5 ­Air Inlet Terminal (required) 3 ­Chimney Terminal (required) 0.5 ­80 mm dia straight duct 1 metre 1 956101
80 mm dia straight duct 2 metre 2 956102
90° Elbow (80/80) 8 956100
45° Elbow (80/80) 4 956099

7

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

3g

2.8

!

A flue system can be built up from the components
detailed in the table, but the total flue resistance must
not exceed the maximum stated.

!

ADDITIONAL CONCENTRIC FLUE KITS

Horizontal flue terminal (all orientations) maximum 5000 mm (197 in)
Horizontal flue terminal (rear exit) minimum 250 mm (10 in)
Vertical flue terminal maximum 12000 mm (472 in)
Vertical flue terminal minimum 600 mm (23

The 'equivalent' flue length must not exceed the
maximum values stated.

b) The standard terminal must always be fitted horizontally;
horizontal ducts must have a continuous fall towards the
appliance of 2.5°. This ensures condensate runs back into the
appliance from the flue system. The vertical terminal must always
be used if a vertical outlet is required.

c) The concentric flue system must use either a flanged elbow or
a vertical flue turret socket at the entry/exit to the appliance.

d) All joints must be correctly made and secured in accordance
with the installation instructions. When cutting ducts, avoid swarf,
uneven and sharp edges to maintain duct integrity.

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).

2.8.1

PLUME DIVERTER TERMINAL

1

/2 in)

INSTALLATION

The following 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 - Allows an additional bend in the flue,
and has an 'equivalent length' of 1550 mm. This elbow is
mechanically different from the flanged elbow supplied as
standard with the appliance, but has the same equivalent length.

45° Extension Elbow - Allows an additional bend in the flue
and has an 'equivalent length' of 775 mm.

Vertical Turret Socket - For use with elevated horizontal flues
and vertical terminals.

Vertical Roof Terminal - For use where an external wall is not
available, or where it is desirable to route the ducts vertically.

For installation details refer to the instructions
provided with the individual flue kits.

These optional kits may be used with the standard flue kits to
produce an extensive range of flue options, providing that the
following rules are strictly obeyed.

a) The maximum/minimum permissible length of the room sealed
flue system are:

Plume Diverter Kit Part No: 956103

(For use with Standard horizontal telescopic flue kit - Part no
956120 - only)

This kit is provided to assist in fitting a condensing boiler with
reduced clearances when fitted in good practice according to the
Guide to Condensing Boiler Installation published by
DEFRA/HMSO.

This kit allows the boiler flue outlet to be directed to the left or to
the right only.

Under certain operating conditions condensing appliances have a
tendency to form a plume of water vapour at the terminal.
Therefore consideration should be given when fitting the Plume
Diverter in terms of plume dispersal onto adjacent surfaces and
neighbouring properties.

a) Refer to section 2.5 for instructions on fitting the flue system.

Also see Figure 5 for all other clearances.

INSTALLATION INSTRUCTIONS

The resistance of the diverter is equivalent to 0.5
metre of flue length. Ensure this is used when
calculating the maximum allowable flue length.
(maximum horizontal flue length restricted to 4.5
metres when using the plume diverter).

8

751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:45 Page 11

3h

3i

The diverter allows the terminal clearance to be reduced as
follows (see diagrams below):

Clearance H – From a surface facing the terminal - 600mm.
Clearance 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
provided. Do not use a power tool to fit screw.

Note.
The Plume Diverter terminal must not under
any circumstances deflect flue products
downwards.

9

751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:45 Page 12

2.9

4

APPLIANCE HYDRAULIC CIRCUITS

MANUAL

BLEED VALVE

EXPANSION

VESSEL

CH RETURN

THERMISTOR

AUTOMATIC

AIR VENT

PUMP &

HYDROBLOCK

CH

RETURN

DHW COLD

INLET

DHW HOT

OUTLET

FLOW

SWITCH

THERMISTOR

DHW FLOW

THERMISTOR

FLUE

PRODUCTS

CH FLOW

PRIMARY HEAT
EXCHANGER

PRIMARY

PLATE HEAT
EXCHANGER

PRESSURE

RELIEF VALVE

CH MODE

BURNER &

BURNER

FLANGE

FLOW

CONDENSATE
TRAP

CONDENSATE

OUTLET

PRESSURE

GAUGE

3 BAR

EXPANSION

THERMISTOR

AUTOMATIC

HYDROBLOCK

CH

RETURN

DHW COLD

INLET

MANUAL

BLEED VALVE

VESSEL

CH RETURN

AIR VENT

PUMP &

DHW HOT

OUTLET

FLOW

SWITCH

PRODUCTS

CH FLOW

THERMISTOR

DHW FLOW

THERMISTOR

FLUE

CH

FLOW

PRIMARY HEAT
EXCHANGER

BURNER &

BURNER

FLANGE

PRIMARY

FLOW

PRIMARY

RETURN

PLATE HEAT
EXCHANGER

PRESSURE

3 BAR

PRESSURE

RELIEF VALVE

GAUGE

DHW MODE

CONDENSATE
TRAP

CONDENSATE

OUTLET

10

CH

FLOW

751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:45 Page 13

INSTALLATION REQUIREMENTS

3

3.1

GAS SAFETY (INSTALLATION AND USE) CURRENT
REGULATIONS

The appliance is suitable only for installation in GB and IE and
should be installed in accordance with the rules in force.

In GB, a CORGI Registered Installer must carry out the installation.
It must be carried out in accordance with the relevant requirements
of the:

Gas Safety (Installation and Use) Regulations

The appropriate Building Regulations either The Building
Regulations, The Building Regulations (Scotland), Building
Regulations (Northern Ireland).

The Water Fitting Regulations or Water Byelaws in Scotland.
The Current I.E.E Wiring Regulations.

Where no specific instructions are given, reference should be
made to the relevant British Standard code of Practice.

In Ireland (IE), the installation must be carried out by a Competent
Person and installed in accordance with the current edition of I.S.813
"Domestic Gas Installations", the current Building Regulations and
reference should be made to the current ETCI rules for electrical
installation.

It should also be in accordance with the relevant recommendations in
the current editions of the following British Standards and Codes of
Practice: BS 5449, BS 5546, BS 5440-1, BS 5440-2, BS 6798, BS
6891, Institute of Gas Engineer document IGE/UP-7, BS 7074
(expansion vessel) and IS813 for IE.

IMPORTANT NOTE: Manufacturer's instructions must NOT be
taken in any way as overriding statutory obligations.

3.2

The following limitations MUST be observed when
siting the appliance:

a) The appliance is not suitable for external installations. The

position selected for installation should be within the building,
unless otherwise protected by a suitable enclosure and MUST allow
adequate space for installation, servicing and operation of the
appliance and for air circulation around it (Section 2.4 and 3.4).

b) This position MUST allow for a suitable flue system and terminal
position. The appliance must be installed on a flat vertical wall,
which is capable of supporting the weight of the appliance and
any ancillary equipment.

c) If the appliance is to be fitted in a timber framed building it
should be fitted in accordance with the ‘Guide for Gas Installations
In Timber Frame Housing’, Institute of Gas Engineers document
IGE/UP-7. If in doubt, advice must be sought from the Local Gas
Supplier.

d) The appliance is approved to a protection rating of IP20.
Therefore if the appliance is to be installed in a room containing a
bath or a shower, any electrical switch or control utilising mains
electricity must be so situated that it cannot be touched by a person
using the bath or shower. Attention is drawn to the requirements of
the current BS 7671 (I.E.E Wiring Regulations) and in Scotland the

STATUTORY REQUIREMENTS

APPLIANCE LOCATION

electrical provisions of the Building Regulations applicable in
Scotland.

3.3

Detailed recommendations for flue installation are given
in BS 5440-1. The following notes are for general
guidance.

a) The appliance MUST be installed so that the terminal is exposed

to the external air.
b) It is important that the position of the terminal allows free

passage of air across it at all times.
c) It is ESSENTIAL TO ENSURE that products of combustion

discharging from the terminal cannot re-enter the building or any other
adjacent building, through ventilators, windows, doors, other sources
of natural air infiltration, or forced ventilation/air conditioning.

d) The minimum acceptable dimensions from the terminal to
obstructions and ventilation openings are specified in Figure 5.

e) If the terminal discharges into a pathway or passageway check
that combustion products will not cause nuisance and that the
terminal will not obstruct the passageway.

f) Where the lowest part of the terminal is fitted less than 2000 mm
(78 in) above the ground, above a balcony or above a flat roof to
which people have access, the terminal MUST 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 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
dispersal of the plume in terms of adjacent surfaces and
neighbouring properties. A special flue terminal, (Kit C), is available
to raise the flue discharge point; use of this terminal will limit the
maximum flue length available. For further information contact:
Halstead Boiler Ltd, Service Help Line: 08450 710780.

3.4

FLUE TERMINAL POSITION

VENTILATION REQUIREMENTS

Detailed recommendations for air supply are given in BS 5440-2.
The following notes are for general guidance.

a) It is not necessary to have a purpose provided air vent in the
room or internal space in which a room-sealed appliance is
installed.

b) Cupboard or compartment ventilation is not necessary for a
room-sealed appliance providing that the minimum clearances
are maintained.

c) Where an open flued, (B23), system is used, then an air vent
must be provided in the same room or internal space as the flue
duct air inlet, with a minimum free-area of at least:

Ace HE 30 121.5 cm
Ace HE 24 88 cm
Ace HE 35 143.5 cm

2

2

2

11

751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:45 Page 14

5

FLUE TERMINAL POSITION

•

•

C

A

•

•

•

•

•

H,I

•

•

•

R

D,N

•

•

F

•

J

•

•

SPECIAL REQUIREMENTS FOR A
VERTICALLY BALANCED FLUE

300mm

Min

430mm

Min

P

•

B ,C

•

G

•

K

M

•

•

•

•

A

E

•

•

•

G

•

•

•

Q

•

•

•

•

•

O

•

•

•

•

•

F

•

•

•

O

•

•

B ,C

K

F

•

•

•

•

•

•

K

•

•

G

•

L

•

•

L

K

•

•

Position Minimum spacing

A Directly below an openable window, 300mm 12in

air vent, or any other ventilation opening

B Below gutter, drain/soil pipe 75mm 3in
C Below eaves 200mm 8in
D Below a balcony *2500mm 98in
E From vertical drain pipes and soil pipes 150mm 6in
F From internal or external corners +300mm 12in

*1000mm 40in

G Above adjacent ground or

balcony level 300mm 12in

H From a surface facing the terminal +600mm 24in

*2500mm 98in

I Facing terminals +1200mm 48in

*2500mm 98in

J From opening (door/window) in *not recommended

carport into dwelling

K Vertically from a terminal on the 1500mm 60in

same wall

L Horizontally from a terminal on the 300mm 12in

same wall

M Adjacent to opening 300mm 12in
N Below carport *not recommended
O From adjacent wall 300mm 12in
P From adjacent opening window 1000mm 40in
Q From another terminal 600mm 24in
R Minimum height 300mm 12in

d) If the appliance is installed in a room or internal space with other

opened flued appliances, then the size of the air vent necessary
should be calculated in accordance with BS 5440-2 Table 2.

e) Where an open flued system is used, and the flue duct air inlet is
within a compartment then high and low level air vent are necessary
in the compartment, the size of the vents should be calculated in
accordance with BS 5440-2 Table 2.

3.5

CONDENSATE DISPOSAL

The condensate drain connection is suitable for either 21.5 mm or
22 mm plastic push fit or adhesive overflow pipes and fittings. It
should be piped to drain, preferably within the building,
maintaining 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 freezing in cold weather conditions is also advisable.

3.6

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
consultation with the Gas Supplier.

c) A gas meter can only be connected by the Gas Supplier or by their
contractor.

d) An existing meter and/or pipe work should be of sufficient size to
carry the maximum appliance input plus the demand of any other
installed appliance. (BS 6891: 1988).

A minimum of 22 mm diameter pipe work is
recommended within 1000 mm of the appliance gas cock.

e) Natural gas appliances: The governor at the meter must give a

constant outlet pressure of 20 mbar (8 in.wg) when all appliances on
the system are running.

f) The gas supply line should be 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
radiators, and a drain facility that must be provided at the lowest
point in the system to allow complete drain down.

b) The installation should be designed to operate with a flow
temperature of up to 95°C.

c) A sealed system must only be filled by a competent person.
d) The available pump head for the appliances are given in

Figure 6.

* Recommended by the boiler manufacturing industry to prevent
pluming nuisance and damage to buildings.
t

12

Distances can be reduced if plume diverter kit is fitted.

751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:45 Page 15

e) If thermostatic radiator valves are fitted, a radiator must be
fitted with two lock shield valves, to enable correct operation of
the pump over-run facility.

f) The following paragraphs outline the specifications of the
items fitted to the appliances.

PUMP – The available pump head shown in Figure 6 is that in
excess of the appliance hydraulic resistance, i.e. that available
for the system.

Expansion Vessel Requirements

Vessel charge and
initial system pressure

Total water content of system
using 8 L (1.54 gal) capacity
expansion vessel supplied
with appliance.

For systems having a larger
capacity multiply the total system

6

AVAILABLE PUMP HEADS

7

capacity in litres (gallons) by
these factors 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 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) regulations. A filling loop should be fitted
at some point to allow the CH system to be filled.
Two types are shown in Figure 7.

bar 0.5 0.75 1.0 1.5

L 96 84 73 50

0.0833 0.093 0.109 0.156

EXPANSION VESSEL – The integral expansion vessel is pre­charged to a pressure of between 0.5 and 1.0 bar. This should
be checked before the water system is filled. Details below show
the water system volume that is acceptable for this vessel. If the
system water volume is larger then an additional vessel must be
fitted to the system. BS 5449 and BS 6798 give further details
regarding expansion vessel sizing and sealed systems.

7

METHODS OF FILLING A SEALED SYSTEM

FLEXIBLE HOSE UNION
TEMPORARY CONNECTION
To be removed immediately after filling

STOP
VALVE

DOUBLE
CHECK
VALVE
ASSEMBLY

STOP
VALVE

WATER TREATMENT, CLEANSING AND FLUSHING THE
HEATING SYSTEM
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 Sentinal.

HEATING SYSTEM
RETURN

MAINS WATER
SUPPLY

RECOMMENDED AND APPROVED METHOD FOR
FILLING CLOSED CIRCUIT IN A HOUSE.
(R24-2a WATER REGULATIONS GUIDE)

MAINS
WATER SUPPLY

CISTERN &
OVERFLOW

PRESSURE PUMP &
REDUCING VALVE
IF REQUIRED

STOP
VALVE

HEATING
SYSTEM
RETURN

13

751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:45 Page 16

CONTROLS. As a minimum it is recommended that a room
thermostat be installed to control the appliance. Thermostatic
radiator valves may be fitted to the system, however they
must not be fitted in the room where the room thermostat is fitted.
There must be at least one radiator installed with lock shield

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 byelaws is suitable.

valves that should not be closed. Further guidance can be
obtained from the Domestic Heating and Hot Water Guide to the
building regulations.

3.9

a) Wiring external to the appliance must be in accordance with the

3.8

a) Check that the mains water pressure is sufficient (as stated in 2.2

"Performance Data") to produce the required DHW flow rate, but
does not exceed the maximum DHW pressure (10 bar). If necessary,
a pressure-reducing valve must be fitted to the mains supply before
the DHW inlet connection.

b) The final 600 mm (24 in) of the mains supply pipe to the boiler
must be copper.

c) Avoid long DHW pipe runs and several hot water draw off
points.

d) Insulate the hot water pipes if accessible to minimise the heat
losses within the pipes to keep the water hot longer.

e) A domestic hot water flow regulator is fitted within the

DOMESTIC HOT WATER SYSTEM

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 6500 table 16.

c) THIS APPLIANCE MUST BE EARTHED. Failure to provide a
satisfactory earth connection will result in appliance malfunction.

d) The method of connection to the mains supply must facilitate
complete electrical isolation of the appliance. Either a 3A fused three
pin plug and un-switched shuttered socket outlet, both complying with
BS 1363, or a 3A fused double pole switch having a 3 mm contact
separation in both poles and serving only the boiler (and its external
controls) may be used.

3.10

appliance to control the maximum water flow rate. This may be
removed to obtain higher flow rates. Higher flow rates will not
damage the appliance but may reduce the water temperature
below an acceptable level. (Refer to Figure 28).

The Ace HE appliances may be used with any certified mains voltage
room thermostat, as described in section 4. For further information
contact: Halstead Boilers Ltd, Service Helpline: 08450 710780.

ELECTRICITY SUPPLY

EXTERNAL CONTROLS

8

TYPICAL SYSTEM DESIGN

DRAIN COCK AT
LOWEST POINT
IN SYSTEM

ROOM
THERMOSTAT

RADIATOR WITH

2 LOCKSHIELD

VALVES IN OPEN

POSITION

APPLIANCE

MAINS
WATER IN

CH FLOW

CH RETURN

DOMESTIC
COLD WATER

Note: No automatic bypass required, however it is recommended to leave one radiator
open to ensure pump over-run function. It is also recommended to fit TRV’s on all
radiators except in the rooms with a room thermostat.

FOR FURTHER INFORMATION PLEASE CONTACT HALSTEAD BOILERS LTD
SERVICE HELPLINE TEL: [phone]

TIME
CLOCK

GAS SUPPLY

PRESSURE
RELIEF OUTLET
TO DRAIN

DOMESTIC
HOT WATER

PRESSURE REDUCING
VALVE (if required)

BS STOP VALVE
(Fixed Spindle)

MAINS WATER

14

751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:45 Page 17

APPLIANCE INSTALLATION

4

Before installing the appliance, check that the chosen location is
suitable (section 3.2) and that the requirements for flue position
(section 3.3) and minimum clearances (Figure 1b) are satisfied.

4.1

The appliance is supplied in one box. Flue kits are provided
separately, the various flue kits available as described in sections

2.5 - 2.7. If the appliance is to be installed without access to an
external wall, a wall liner kit is also required.

Unpack the boxes and check the contents:

 Complete appliance
 Paper wall mounting template
 Wall mounting plate
 Case Base
 Installation and Servicing Instruction
 User’s Instructions
Hardware pack containing:

6 x 65 mm wood screws – 2 off
Blue wall plugs – 2 off
15mm flanged nuts – 3 off
15mm Male flanged nut – 1 off
15mm Olives – 4 off
22mm flanged nuts – 2 off
22mm Olives – 2 off

UNPACKING THE APPLIANCE

Manual Handling Note: During the appliance
installation it will be necessary to employ caution and
assistance whilst lifting, as the appliance exceeds the
recommended weight for a one-man lift. Take care to
avoid trip hazards, slippery or wet surfaces.

WALL MOUNTING PLATE

4.2

a) Fix the paper template in the required position (ensuring that the

necessary clearances are achieved). Ensure squareness by hanging a
plumb line.

b) Mark the position of the largest wall fixing holes.
Refer to Figures 9 & 10.

c) Mark the position of the flue outlet. For side flue installation extend
the flue centre line on to the sidewall, where the flue length exceeds 775
mm, a flue slope angle of 2.5
Figure 10. Remove the paper template.

d) Cut the hole in the wall for the air/flue duct (preferably with a core­boring tool). The hole must be horizontal and not be less than 100 mm
in diameter. If the hole is not accessible from outside, its minimum
diameter must be sufficient to allow insertion of 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 the two large fixing screws
supplied, ensuring that it is level. Refer to Figure 10.

g) Fit any additional fixing screws into wall plugs and tighten all
screws.

PREPARING THE WALL

°

needs to be taken into account. Refer to

As standard the pipe work may only be routed
from below.

Note: Once the appliance has been installed and
all Gas and Water connections have been made,
the case base MUST be fitted on the underside of
the boiler. Instructions are provided on the base
panel.

9

15

751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:45 Page 18

10

REAR FLUE

SIDE FLUE

50

136

211

117

b) Connect the mains water supply to the DHW inlet isolating valve.

4.3

211

MOUNTING THE APPLIANCE

c) Connect the DHW supply pipe to the DHW outlet connection.

Lift the appliance into position as shown in Figure 11. Position the
top of the appliance approximately 20mm above the top of the
wall mounting plate and use the side wings on the plate to locate

Fill the central heating system and domestic hot water system, as

described in section 5.1, and then proceed to Section 4.5.
the appliance in a horizontal direction. Then carefully lower the
appliance, ensuring that the two top locating tabs are securely
engaged.

12

11

MOUNTING THE APPLIANCE

LOCATING TABS
SIDE WINGS

2.5º

50

211

211

VIEW OF CONNECTIONS ON REAR
OF BOILER

CONDENSATE

OUTLET

GAS

SUPPLY

FLOW

PRESSURE

RELIEF

CH

DHW COLD

INLET

DHW

OUTLETCHRETURN

117

4.4

CENTRAL HEATING & DOMESTIC HOT
WATER SERVICE CONNECTIONS

Refer to Figures 8 & 12.
a) Connect the central heating system pipes to the central heating

flow and return valves, using 22mm pipe work.

16

54mm

82mm
156mm
206mm
272mm
337mm
402mm

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.

751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:45 Page 19

4.6

CONDENSATE CONNECTION

Refer to Figure 13

Connect preferably a 22 mm plastic push fit or adhesive overflow pipe to
the condensate outlet. It should be piped to drain, preferably within the
building, maintaining a continuous 2° fall away from the appliance.
Note; if an additional “U” trap is fitted between the appliance and the
discharge point, then a visible air break is necessary between the
appliance and trap, because a trap is already provided within the
appliance. 32 mm pipe should be used for external pipe work, or if the
appliance is installed in a garage. If the drain is routed externally to a
drain or soak away, then the external length should be kept as short as
possible and not exceed 3000 mm. Protection from freezing in cold
weather conditions is also advisable. Ensure that the condensate
discharge system complies with any local regulations in force.
The drain pipe material should be resistant to acid with a pH less than

6.5. Suitable materials for the condensate drainage pipe are PVC, UPVC,
ABS, PP or PVC-C.
In exceptional circumstances, such as when a boiler is installed in a
basement without drainage, it may be necessary to install a condensate
pump to carry condensate up to ground/drain level. Such products are
available from Grundfos Pumps Ltd on: 01525 850000 and Pump
House on: 0115 922 2211.

13

4.7

PRESSURE RELIEF VALVE CONNECTION

The safety valve is located at the bottom RHS of the appliance.
Connect 15mm copper pipe using the male flanged nut and olive
provided, to the safety valve outlet, and then continue the discharge
pipe using 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 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 length as shown in Figure 14. Refer to

section 2.5 to determine whether any extension kits are required.
Installations using only the standard ducts or standard ducts with
straight extensions are described in this section. Installation instructions
for all other flue systems are included in the various flue kits.

b) Ensure that all (inner and outer tube) sealing rings are provided
and assemble the air/flue ducts as shown in the flue instructions.

c) Construct the correct flue length by building the flue out from the
appliance.

Ensure that the flue and air seals are correctly fitted
before assembly and that each section is fully engaged.

CONDENSATE DRAIN

MUST BE ≥ Ø22

MUST BE ≥ Ø22

CONDENSATE

DRAIN

2.5º

WASTE STACK

2.5º

14

The flue length is measured from the centreline of the
appliance flue outlet to the inside of the external wall­sealing 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. Never cut the swaged end, and always
ensure that the cut is square and free of burrs or debris.

NOTE IT IS ESSENTIAL THAT THE TERMINAL
IS FITTED THE CORRECT WAY UP

See flue kit Instructions (i.e. rain shield at the top).

MEASURING THE EXACT FLUE LENGTH

TOTAL FLUE LENGTH FROM
FLUE OUTLET CENTRE TO

•

WALL

OUTSIDE WALL FACE:
= LENGTH

L

L

•

SINK WASTE

EXTERNAL PIPE

MUST BE > ø 32mm

FAN OUTLET
EXTERNAL
Dia. 60mm

•

•

•

17

751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:45 Page 20

4.8.1

INSTALLING THE AIR/FLUE DUCT

4.8.2

FROM INSIDE THE ROOM

Wall thickness up to 800 mm (31 in) 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) Assemble the flue system extension ducts as necessary, referring to
Figure 15.

c) Pull the flue system towards the appliance to seat the external
sealing ring against the outside wall, ensuring that the duct joints are
not disturbed.

d) Use the internal sealing ring to make good the internal hole, and
check that the terminal is correctly located on the outside wall (Where
possible this should be visually checked from outside the building.)
Figure 15 shows a view of the flue system, correctly installed.

e) Finally locate and secure the elbow to the appliance using the four
screws provided.

15

INSTALLING THE FLUE SYSTEM FROM
INSIDE THE ROOM

(Flue hole diameter 100 mm – wall liner not necessary)
a) Secure the flue elbow with seal to the appliance using 4

screws.
b) Fit external wall sealing ring over flue and then from outside

the building, push the flue system through the wall taking care to
ensure that the terminal is the correct way around.

c) Loosely fit the internal wall sealing ring over the inside end of
the flue.

d) Assemble the flue system extension ducts as necessary,
referring 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 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.

INTERNAL WALL

SEALING RING

INSTALLING THE AIR/FLUE DUCT
FROM OUTSIDE THE BUILDING

130mm Dia.

HOLE WITH

WALL LINER

•

TOP

•

FIBRE
SEAL FITTED

2 ALIGN ASSEMBLED FLUE

SYSTEM ELBOW TO
APPLIANCE AND SECURE

•

4.9

ELECTRICAL CONNECTIONS

Connect the electricity supply and external controls (using suitable
mains cable) as follows:

Wire the cable(s) into the appropriate connections in the electrical
plug provided, referring to Figure 16. Live supply to L1, Neutral
and Earth as indicated. Check that L2 and L3 are linked.

To provide correct cable retention, fit the cable through the
clamping arrangement. The cable will be held in position as the
clamp is screwed into place.

If a programmer/room thermostat is to be fitted remove the red
link between L2 and L3 and connect the device across these
terminals. Any external controls fitted must be rated at 230V
50Hz and have volt free contacts.

L1 = Permanent Live N = Neutral
L2 = External Stat out = Earth
L3 = External Stat in (Switched Live)

18

•

3 SLIDE INTERNAL WALL

SEALING RING TO WALL TO
FORM A GOOD SEAL

16

•

•

EXTERNAL WALL
SEALING RING

1 INSERT

ASSEMBLED FLUE
SYSTEM FROM
INSIDE THE
ROOM. EXTERNAL
WALL SEALING
RING OPENS

NOTE: IF A ROOM
THERMOSTAT IS
TO BE FITTED
REMOVE THE RED
LINK WIRE AND
CONNECT ROOM
THERMOSTAT
ACROSS
L2 AND L3

751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:45 Page 21

COMMISSIONING & TESTING

5

5.1

Before commissioning the appliance, the whole gas installation
including the meter MUST be purged and tested for gas tightness
in accordance with BS 6891: 1998.

!

Before commencing the commissioning procedure, ensure that the
gas service cock is turned on, the electricity supply is isolated,
and that the CH and DHW pipe-work is complete. Fill the water
systems by following the procedure detailed below steps 1 to 5,
and referring to Figure 17.

FILLING THE WATER SYSTEM

Open all doors and windows, extinguish naked lights,
and DO NOT SMOKE whilst purging the gas line.

It is recommended, where possible, to flush the CH
system without the appliance connected, to avoid debris
and flux blocking the waterways within the appliance.

17

5) Drain the entire system using the manual drain valve 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 hot
water tap in turn to clear all the air from the pipes and the
appliance.

7) Remove the pump cap; use a screwdriver to rotate the pump
shaft. Replace the cap.

8) If a filling loop has been used, disconnect filling loop.

9) Prior to lighting the appliance check that the gas inlet

pressure measured at the appliance inlet pressure test point is
>20±1 mbar for natural gas. (as described in section 5.2 b), the
central heating system should also be checked for circulation by
operating the appliance with the gas turned off, this is to ensure
that no air locks occur. The appliance may go into ignition
lockout and require resetting (see section 5.5).

To aid venting, a manual air vent is provided on the top
LHS of the appliance, and an automatic air vent on the
pump assembly

18

CH

RETURN

WATER INCHFLOW

1) Check that the CH flow and return valves are in the open
position.

2) Fill the system with water using one of the approved methods
described in section 3.7 to about 2.0 bar. Vent the system via the
radiator valves and system air vents in accordance with normal
practice. Ensure that all system air vents are closed.

3) Check the system for soundness.

4) Check the operation of the pressure relief valve (Figure 18) by

pulling the lever out gently to ease the valve of its seat. Checking
that water is discharged, release the lever and ensure that the
valve seats correctly and does not leak.

COLD

DHW

FLOW

PRESSURE

RELIEF

CONDENSATE

WASTE OUTLET

GAS

SUPPLY

PRESSURE RELIEF VALVE ACTUATOR

Do not use the pressure relief valve to drain the system,
because dirt or debris could prevent the valve seating
correctly. If the valve leaks or sticks closed, then replace it.

To drain the system, open the manual drain on
the side of the CH flow cock shown in figure 18.

MAIN DRAIN VALVE

19

751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:45 Page 22

5.2

COMMISSIONING THE APPLIANCE

g) When the boiler has lit the display will show ‘H.’ Allow the
appliance to run for at least 10 minutes and check that the gas

If, at any time during the commissioning procedure, it
is required to prevent the appliance from modulating,
set the control knob to the Service position (fully
clockwise).

supply pressure measured at the appliance inlet pressure test point is
20 ± 1 mbar for natural gas.

h) Close the DHW tap and ensure that the burner goes out (the
display reads ‘o’) and the pump stops after an over-run period of 5
minutes.

Refer to Figures 19 & 20
a) Check that the gas supply is turned ON and the gas service cock

is OPEN.
b) Slacken the screw in the gas cock inlet pressure test point and

connect a suitable manometer. Refer to Figure 20.

c) Turn the control knob fully anticlockwise to the standby position.

i) Ensure 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).

d) Switch on the electrical supply. The display reads ‘o’.
e) Turn the control knob to the desired temperature position and fully

open any DHW tap. The fan should start and after a few seconds
ignition will commence.

f) If the burner fails to light the fan will stop. Initially this may be due
to air in the gas supply line. The boiler will automatically have five
attempts at ignition. It may be necessary to turn the control knob fully
anti-clockwise to the reset/Standby position and repeat (d). (See
section 5.4).

!

BOILERS LTD SERVICE HELPLINE: 08450 710780.
IF A COMBUSTION & GAS INLET RATE CHECK IS TO BE
CARRIED OUT THEN REFER TO SECTION 6.1

If the gas inlet pressure is outside the required value check
that the gas pipe is of the correct diameter or contact the
gas provider to adjust the gas meter governor.

THIS BOILER IS FACTORY SET, SO THAT NO
COMBUSTION OR GAS INLET RATE CHECK IS
REQUIRED. HOWEVER IF THE APPLIANCE FAILS TO
OPERATE CORRECTLY CONTACT THE HALSTEAD

19

PRESSURE GAUGE

24hr TIME CLOCK

20

TABS IN = OFF PERIOD

TABS OUT = ON PERIOD

7 SEGMENT DISPLAY

CONTROL KNOB

CLOCK OVERRIDE
SWITCH

CONTINUOUS ON

TIMED
OFF

ARROW INDICATES
CURRENT TIME

20

INLET PRESSURE TEST POINT

(REMOVE SCREW AND CONNECT
MANOMETER)

GAS VALVE

751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:45 Page 23

5.3

A flow regulator is supplied factory fitted to the appliance to
ensure that no adjustment is necessary. Should the mains flow rate
be below the minimum required, it is possible to remove the flow
regulator from the appliance as instructed in section 9. The
nominal pre-adjusted flow rate may vary by ± 5 % due to factory
tolerances and mains water pressure fluctuation.

5.4

a) Turn the control knob to standby.
b) Remove the manometer and tighten the appliance inlet

pressure test point screw. Re-light the burner and test for gas
tightness.

c) Fit the appliance front casing as illustrated in Figure 21 using
locating lugs at the top and screws underneath.

d) Set the heating and hot water control to the required setting.
Ensure that the clock override switch is in the timed position and
check that the time clock is set at the desired time periods. Set the
room thermostat (if fitted) to the required setting.

21

DHW FLOW RATE

FINAL CHECKS

LOCATING LUGS

5.6

The appliance is fitted with a frost protection device. In the event
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 supplies are maintained and the appliance is left ON.
The time clock can be switched to the OFF setting.

5.7

The appliance incorporates flow and return thermistors, 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

The following additional features are included in the appliance
specification:

When the appliance cycles on its central heating control
thermostat, a slow cycle device operates. The timer (set to 5
minutes) is activated after the end of each burn cycle to prevent
rapid cycling of the burner.

ANTI PUMP SEIZURE DEVICE:

Providing that a power supply is maintained, the pump will
operate for at least 20 seconds in every 23 hours (regardless of
heat demand) to prevent pump seizure during periods where the
appliance is not used.

FROST PROTECTION

OVERHEAT PROTECTION

OTHER FEATURES

CH SOFT START DEVICE:

After every burner start, in CH mode, the burner output stays at
low for 10 seconds, to ensure smooth heat up of the system and
maximum efficiency.

KEEP-HOT FACILITY:

This feature is designed to provide hot water very quickly without
wasting too much water. Therefore you may notice that after
EVERY hot water draw-off the burner may stay on for a short
period of a few seconds. This is to pre-heat the hot water circuit
and prepare the appliance for the next hot water draw-off.

SUMMER MODE:

To avoid resetting the control knob temperature to ‘standby’ in

TWO SCREWS

5.5

LOCKOUT INDICATION AND RESET

THE APPLIANCE

In the event of failure during an ignition sequence, (5 attempts), the

3

Digital display shows fault code ‘
the control knob anticlockwise to ‘STANDBY’ position and then back
to ‘ON’ within two seconds.

’. In order to reset the boiler, turn

summer when CH is not required, switch the clock over-ride
switch to the OFF position.

SERVICE MODE:

The appliance enters the SERVICE mode by turning the control
knob to ‘SERVICE’ (full clockwise). The LED displays a flashing
‘C’. In this mode the appliance runs at the minimum CH output.
This mode allows the gas valve offset and CO
measured. To increase the output to maximum turn the control
knob back on and return to Service within two seconds.

emissions to be

2

21

751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:45 Page 24

5.9

Upon completion of commissioning and testing the system, the
installer must instruct the user in how to operate the appliance by
drawing the user’s attention to the following.

a) Give the ‘Users Instructions’ to the householder and
emphasise their responsibilities under the ‘Gas Safety (Installation
and Use) Regulations or rules in force.

b) Explain and demonstrate the lighting and shutdown
procedures.

c) Advise the householder on the efficient use of the system,
including the use and adjustment of all system controls for both
CH and DHW.

d) Advise the user of the precautions necessary to prevent
damage to the system, and to the building, in the event of the
system remaining inoperative during 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.

USERS INSTRUCTIONS

5.10

A logbook is supplied in the back of this manual to record
installation and commissioning details and to make future
servicing of the appliance easier.

This logbook forms part of the industry’s Benchmark code of
practice for the installation, commissioning and servicing of
central heating systems.

Please ensure that the logbook is fully completed and left with
the customer for future reference, along with Users Instructions
and this Installation and Servicing Instruction manual.

APPLIANCE LOG BOOK

22

751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:45 Page 25

ROUTINE SERVICING

6

To ensure continued efficient operation of the appliance, it is
recommended that it is checked and serviced as necessary at
regular intervals. The frequency of servicing will depend upon the
particular installation conditions and usage, but in general once a

Operate in DHW mode, at full rate. After ten minutes operation
check the CO
those figures stated in section 2.3. Do not forget to replace the

sampling cap after use.
year should be adequate. It is the law that a competent person,
such as British Gas or other CORGI registered personnel, must
carry out any service work.

Service the appliance by following the full procedure detailed
below:

6.1

The appliance incorporates a flue sampling point on the
appliance flue elbow, or appliance 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.

COMBUSTION CHECK

When the appliance is operating at maximum output check that

the gas supply pressure is 20.0 mbar, using the inlet pressure 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.

22

MANUAL BLEED VALVE

values and CO/CO2 ratio and compare with

2

If the measured combustion values are significantly
outside the figures stated in section 2.3 contact
Halstead Boilers Ltd. Service Helpline:
08450 710780.

FLUE GAS SENSOR

EXPANSION VESSEL

BURNER ASSEMBLY

DETECTION ELECTRODE

FAN

CH FLOW THERMISTOR

CH RETURN

THERMISTOR

AUTO AIR VENT

GAS CONTROL VALVE

HYDRO BLOCK AND PUMP

FILTER

PLATE HEAT EXCHANGER

FLOW SENSOR

FLOW SWITCH

CONTROL PANEL

THERMAL CUT OUT

PRIMARY HEAT EXCHANGER

COMBUSTION CHAMBER
FRONT COVER

IGNITION ELECTRODE
IGNITION MODULE

OFFSET PRESSURE TEST POINT

MAX CO

GAS VALVE LEAD AND PLUG

CONDENSATE DRAIN PIPE

CONDENSATE TRAP

PRESSURE RELEIF VALVE

GAS ISOLATING COCK

CONTROL BOX

THROTTLE ADJUSTMENT

2

23

751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:45 Page 26

23

24

25

COMBUSTION CHAMBER

INSULATION

6.2

GAS CONTROL VALVE, FAN &
BURNER ASSEMBLY

Refer to Figures 22, 23, 24, and 25
a) Remove the casing front panel, (2 screws) and lift off.
b) Lower the controls panel (2 screws).
c) Remove the sealed chamber front panel (7 screws).
d) Disconnect the ignitor plug, earth lead and detection plug

from the ignitor and detection electrodes.

24

FRONT COVER

BURNER

FAN

GAS VALVE
FEED PIPE

GAS VALVE

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.

751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:45 Page 27

j) Remove the 4 nuts holding the combustion chamber front
cover in place.

k) Remove the gas control valve, fan & burner assembly, by
carefully pulling forward the combustion chamber front and
pivoting the assembly forward, then disengage the gas valve feed
pipe from the casing, by lifting up the assembly. Take care not to
damage the insulation.

l) The assembly may then be inspected. If the gas valve is to be
replaced refer to section 9.3.

m) Re-assemble in reverse order.

6.3

Inspect, and if necessary clean the main burner ports using a soft
brush or vacuum cleaner. Do not use a wire brush or any
abrasive material.

6.4

BURNER

IGNITION & DETECTION ELECTRODES

6.5

Inspect the inside of the combustion chamber for debris. If

necessary, clean the inside of the tubes with a soft brush. Do not

brush the insulation at the rear, check the integrity of the

combustion chamber insulation panels, if damaged they will

require replacement.

6.6

The condensate Drain has a removable cap, Figure 27, which

allows the removal of debris that may be caught within it. Place

a bowl under the cap to catch the condensate and remove the

cap. Any debris inside will be expelled at this point. Replace the

cap ensuring a good seal is made. Discard the condensate and

debris.

27

a) Inspect the ignition and detection electrodes in situ. If

necessary, clean using a soft brush. If either the electrode or the
ceramic insulation 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.

FLOW TUBE

COMBUSTION CHAMBER

& HEAT EXCHANGER

CONDENSATE DRAIN

26

±0.5

6mm

TO BURNER

4mm

±0.5

TRAP
TUBE

LOCK NUTS

DRAIN SUMP CAP

6.7

Close the water inlet isolating cock, open a domestic hot water

tap at the lowest point in the system and allow the pressure to

dissipate. Close this tap again. Undo the nut holding the flow

switch to the water inlet isolating cock to gain access. The filter

can now be removed, and cleaned as necessary by flushing with

water. Re-assemble in reverse order, ensuring all seals are

replaced correctly.

DOMESTIC COLD WATER INLET FILTER

CONDENSATE
DRAIN

10mm

±0.5

25

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

8

28

MAINS COLD INLET

CONICAL FILTER

SEALING WASHER

FLOW REGULATOR

FLOW SWITCH

6.8

a) Re-assemble all components in reverse order.
b) Check that all joints and seals are correctly fitted.
c) Turn on the gas and electricity supply and light the appliance,

as described in section 5.2.

d) Re-perform a combustion check, as described in section 6.1.
e) Check the operation of the appliance 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.

RE-ASSEMBLY & RE-COMMISSIONING

6.9

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.

FINAL CHECKS

26

751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:45 Page 29

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 30

FAULT FINDING

8

8.1

Before looking for a fault condition, check that:

 The mains electrical supply is turned on.
 The room thermostat and clock (where fitted) are calling for heat.

Radiators are bled and free of air.

 The gas service cock is open.
 The system is at design pressure.

Before attempting any electrical fault finding, always conduct the
preliminary electrical system checks as described in the Instructions
for the British Gas Multimeter, or other similar instrument.

On completion of any service or fault 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 described
in section 9 (Parts Replacement).

For further information contact: Halstead Boilers Ltd. Service Help
line: 08450 710780.

8.2

FASCIA PANEL - Refer to Figure 31.

The Digital Display shows error code ‘
To RESET the boiler turn the control knob fully anti-clockwise to the

GENERAL

DIAGNOSTIC DIGITAL DISPLAY

3

’ in a lockout condition.

RESET/STAND-BY position and then back to anywhere between
the ‘+’ and ‘–‘ within TWO seconds.

8.3

In the event of the appliance failing to light, refer to the
Diagnostics Chart.

8.4

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) Check that the DHW flow rate at the tap is greater than 2.5

litres/minute.

b) Check the operation of the DHW flow switch, Figure 28.
c) Check the wires to the DHW flow switch.
d) Check connector X8 is correctly connected to the PCB.
e) Check for water in the CH system etc.

If DHW temperature fluctuates heavily during a long draw off,
check the plate heat exchanger and the flow switch filters for
debris, clean and replace, (refer to section 6.7 and 9.17).

FAULT FINDING CODES

DHW FAULT FINDING

30

PRESSURE GAUGE

24hr TIME CLOCK

CONTROL KNOB (IN MAX POSITION)

DIGITAL DISPLAY

CONTROL KNOB

TABS IN = OFF PERIOD

TABS OUT = ON PERIOD

CLOCK OVERRIDE
SWITCH

CONTINUOUS ON

TIMED
OFF

ARROW INDICATES
CURRENT TIME

28

751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:45 Page 31

31

DIGITAL DISPLAY

‘BURNER LIT’
INDICATOR DOT

CONTROL KNOB IN
OPTIMUM CH POSITION

everything should be working correctly, if not contact Halstead

8.5

CONTROL KNOB IN
STANDBY/RESET POSITION

CENTRAL HEATING FAULT FINDING

Boilers Ltd Service Help Line: 08450 710780.
Upon a demand for Central Heating, (closure of the time clock
and room thermostat, where fitted), the controls should carry out
a set of start up checks, followed by an ignition sequence. Refer
to Section 5.2.

If the control has powered up correctly but does not respond to a
CH demand. Check voltage between pin 2 connector X1A
(orange wire) and pin 2 connector X1B (blue wire). If 0 V ac,
check room thermostat and clock. If 230 V ac, check control for
lockout or blocking codes, (refer to section 8.3), check operation
of the pump.

If room thermostat and clock are OK and no lockout or blocking
code exists and the control is not in anti cycle mode, then

CONTROL KNOB IN
IN SERVICE POSITION
(DISPLAY FLASHING)

Note: Whenever a CH demand is removed,
either by the timer, the room thermostat or by the
appliance’s internal temperature control, an anti
cycle mode is initiated which prevents the
appliance from firing in CH mode 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 CODES

LED CODE

1

2

3

4 Flue gas sensor/No flame Flue gas temperature greater than 95 °C

FAULT/EFFECT REASON ACTION

Overheated appliance Water temperature greater than 105°C

Differential check
faulty/Flame for

Zero check faulty DHW or CH

15 seconds

No gas or Lockout flame Low gas pressure.
signal/ No flame, Lockout No flame signal on ignition,
after 5 ignition attempts or loss of signal during operation

 Check no air is in heat exchanger/CH system
 Check plate heat exchanger is not blocked
 Check diverter valve operation
 Check flow/return thermistor

 Check flow/return thermistor
 Check water pressure
 Check pump/CH system blockage
 Check no air is in heat exchanger/CH system

 Check detection electrode/lead
 Check gas supply
 Check gas service cock
 Check gas valve and lead
 Check PCB/X2A & X2B connectors
 Check spark generator/spark electrode
 Check mains earth lead continuity

 Check no air is in heat exchanger/CH system

water pressure

29

751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:45 Page 32

BLOCKING CODES

LED CODE

5

FAULT/EFFECT REASON ACTION

 Check flow, return and flue sensors
 Check wiring to sensors
 Check PCB/X6 & X8 connectors
 CHECK THERMAL FUSE IS OPEN CIRCUIT.

Defective sensor or
thermal fuse blown

Defective flow, return or flue sensor
or heat exchanger reached maximum
safe working temperature

IF THAT IS THE CASE THE HEAT EXCHANGER
HAS TO BE REPLACED - SEE SECTION 9.8

Defective gas valve/

6 Flame continues after

demand ends

7 Defective fan/No flame Missing or Erroneous RPM signal

5 sec flame signal after burner
is switched off

Check gas valve and lead



Check PCB



 Check fan
 Check mains fan lead & connector
 Check low voltage fan lead & connector
 Check PCB/X3 connector

A PCB error/No flame Internal error  Check PCB

Activate BCC/No flame New BCC (If required)  Turn to reset to activate
Safety system failure/

No flame

Failure of internal self checking system

 Check PCB

E BCC error/No flame Incorrect /missing BCC  Reseat or replace BCC (if fitted)

 Check CH flow and return

Water flow failure

O

Flame for a short period
only

P

Power supply error/
No flame  Check PCB connectors

Sensor temperature differential
incorrect

Low mains voltage

DHW cold Defective DHW thermistor

or open circuit

(No display) No light indication Defective power supply

 Check pump
 Check no air is in heat exchanger/CH system
 Check pipe connections
 Check wires to flow and return sensors are not crossed

 Check mains voltage into boiler

 Check DHW flow switch & lead
 Check Diverter valve & lead
 Check PCB/X4 connector
 Check filter in flow switch

 Check power supply
 Check PCB/X1B connector
 Check PCB fuse

NOTE:

FAULT CODES 1 TO 4 CAN BE RESET BY FOLLOWING THE PROCEDURE ABOVE, HOWEVER IF ANY
OTHER FAULT CODE IS SHOWING PLEASE CONTACT YOUR INSTALLER OR HALSTEAD BOILERS LTD. SERVICE
HELP LINE: 08450 710780.

Note: All Lock-out and Blocking codes will flash if displayed.

A flashing '

C

' indicates that the boiler is in Service Mode and that the boiler will fire continuously at minimum input.

This setting is for the convenience of the Service engineer ONLY.

30

751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:46 Page 33

REPLACEMENT OF PARTS

9

Before commencing any service operation, ISOLATE the mains
electrical supply and TURN OFF the gas supply at the main
service cock.

Replacement of most parts first requires the removal of the sealed
chamber front panels; refer to section 6.2.

There may be some slight water spillage; so electrical components
should be protected.

It is the law that any service work must be carried out by a
registered person.

9.1

IGNITION AND DETECTION
ELECTRODES

Refer to Figure 32
a) Ensure supply 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) Unscrew the two screws holding the electrode, remove

electrode, and used gasket.

d) Fit the new electrode, and new gasket.
e) Check that electrode is aligned as detailed as appropriate in

Figure 26.
f) Re-assemble in reverse order. Ensure that all joints and seals

are correctly re-fitted.

9.2

Refer to Figure 33
a) Ensure supply voltage is isolated.
b) Remove the plug (if fitted) and earth lead from the ignition

electrode. Note: Newer electrodes will have an integral ignition
lead.

c) Remove 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 as shown in Figure 33, and that the brown electric
supply lead is fitted to position 1 on the ignitor unit.

IGNITOR UNIT AND IGNITION LEADS

32

ELECTRODE

(DETECTION)

33

EARTH LEAD

SCREW

ELECTRODE

PLUG

SCREWS
ELECTRODE

(IGNITION)

GASKET

IGNITION

ELECTRODE

IGNITION

LEAD

IGNITION
MODULE

SCREW

31

751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:46 Page 34

9.3

Refer to Figures 34, 35 & 36

9.3.1

a) Remove casing and control panels as described in section 6.2.
b) Unscrew the gas valve electrical plug and disconnect from the

gas valve.
c) Ensuring the gas isolating cock is in the off position, undo the

union nut holding the gas valve feed pipe to the gas isolating
cock and disconnect.

d) Disengage the gas valve feed pipe grommet from the casing
by pushing it upwards.

e) Remove the three Torx screws (T-25) of the air/gas channel
fixing to the combustion chamber door (figure 34).

f) Remove the gas control valve, fan and air/gas channel as one
complete assembly by carefully pulling forward and rotating
anticlockwise. Then disengage the gas valve feed pipe from the
casing by lifting the assembly upwards.

g) With the assembly on a bench, unscrew and remove the four
screws securing the gas valve feed pipe, (figure 35).
Note: Newer versions may have a single flange nut securing the
gas feed pipe.

h) Unscrew the three Torx screws (T-20) securing the gas valve
onto the fan (figure 36).

i) Replace the gas valve and re-assemble in reverse order.
j) Ensure all seals in particular the burner seal (figure 40) and

gas valve feed pipe seal are in good order and fitted correctly
then check for gas soundness.

GAS CONTROL VALVE

GAS CONTROL VALVE REMOVAL,
REPLACEMENT AND SET-UP

34

35

3 TORX SCREWS

9.3.2

!

pressure the engineer should first check that the gas
supply is metered and ascertain whether it is possible
to measure the gas rate. If the gas input rate can be
measured then the requirements of GSIUR 26(9) can be
met, including any specific requirements in
manufacturers’ instructions.

If gas input rate cannot be measured then, to satisfy
the intent of GSIUR 26(9), the engineer shall measure
the combustion quality of the appliance in accordance
with BS 7967 or the manufacturers’ instructions.

If the engineer does not have the required equipment
and no alternative test is specified by the manufacturer
then the appliance shall be turned off and disconnected
as an un-commissioned appliance until such time that
equipment is available to undertake such tests.

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
CO

32

COMBUSTION CHECK SET-UP

When installing, commissioning or servicing
a gas appliance that incorporates a pre-mix
burner and zero-set governor, because it is
not possible to measure an operating

.

2

4 SCREWS

36

3 TORX SCREWS

751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:46 Page 35

If the gas control valve is changed, then when the
appliance is running, the flue gas CO
measured, refer to section 6.1, and compared to the
values stated section 2.3. If the measured value does
not correspond to the Performance Data, then contact:
Halstead Boilers Ltd. Service Help line: 08450 710780.

Always seal the gas valve adjustment screw with paint
after adjustment

9.4

Refer to Figures 36 & 37
a) Ensure supply 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) Remove the gas control valve; refer to section 9.3.
d) Unscrew the three screws holding the gas valve mounting

plate, remove plate; refer to Figure 36.
e) Unscrew the four 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.

FAN

should be

2

9.5

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 to

section 6.2.
c) Unscrew the three Torx screws, (T-25), holding the manifold to the

combustion chamber door, and remove the manifold; refer to Figure

34.

d) Remove the gasket, and withdraw the burner; refer to Figure 37.
e) Fit replacement burner, taking care not to damage the insulation,

and ensure burner is correctly located by lining up the locating tab.

f) Fit new gasket; refer to Figure 40.
g) Re-assemble in reverse order; ensure that all joints and seals are

correctly re-fitted.

BURNER

38

37

4 SCREWS

GASKET

LOCATING TAB

39

33

751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:46 Page 36

9.6

COMBUSTION CHAMBER

41

FRONT INSULATION

The design of the appliance is such that the combustion chamber
insulation should not require replacement unless mechanically
damaged. It is recommended that to prevent dust, the insulation is
dampened prior to removal, and that a protective mask is worn
when changing or handling the insulation material.

Refer to Figure 40
a) Ensure supply 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) Remove the electrodes; refer to section 9.1.
d) Remove the burner: refer to section 9.5.
e) Replace the combustion chamber front insulation.
f) Re-assemble the burner and electrodes, using new gaskets.
g) Check the position of the electrodes: refer to section 6.4.
h) Re-assemble in reverse order; ensure that all joints and seals are

correctly re-fitted.

9.8

Refer to Figures 15, & 42

If thermal fuse has activated (open circuit and error code
‘5’) the heat exchanger must be replaced.

SCREW

WASHER

REAR

INSULATION

HEAT EXCHANGER

40

FRONT INSULATION

OUTER SEAL

9.7

COMBUSTION CHAMBER
REAR INSULATION

Refer to Figure 41
a) Ensure supply 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) Use an Allen key to undo the central screw holding the rear

insulation in place.
d) Remove old insulation and fit replacement, ensuring locating

washer is in front.
e) Re-assemble in reverse order; ensure that all joints and seals are

correctly re-fitted.

34

a) Ensure supply 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 Figure 15.
f) Remove the retaining clip from the heat exchanger flow outlet,

and undo the nut connecting the flow pipe to the plate-to-plate heat
exchanger.

g) Rotate the flow pipe anticlockwise and gently pull down to
disengage the flow pipe from the heat exchanger.

h) Remove the retaining clip from the heat exchanger return inlet,
and undo the nut connecting the return pipe to the hydroblock
adaptor fitting.

i) Rotate the return pipe clockwise and gently pull down to
disengage the return pipe from the heat exchanger.

j) Disconnect the condensate drainpipe from the condensate drain
adaptor; refer to section 6.6.

k) Undo the nut holding the manual air vent to the expansion vessel
and disengage the vent from the heat exchanger by removing the
clip and pulling upwards through the grommet at the top.

l) Remove the 2 screws retaining the spark generator to the right
hand saddle bracket.

m) Remove the 2 screws retaining the expansion vessel upper
bracket to the left hand saddle bracket.

n) Remove the 4 screws that retain both the left and right saddle
brackets to the heat exchanger mounting brackets; refer to Figure 44.

o) Remove the saddle brackets and slide the heat exchanger
forwards and out.

751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:46 Page 37

p) Re-assemble in reverse order; check integrity of the flow and
return pipe ‘O’ rings and fibre washers and replace as necessary.
Ensure that all joints and seals are correctly re-fitted.

42

EXPANSION VESSEL

HEAT EXCHANGER

SADDLE LH.

UPPER EXPANSION

VESSEL BRACKET

LOWER EXPANSION

VESSEL SUPPORT

MANUAL AIR VENT

EXPANSION VESSEL

LINK PIPE CLIP

LINK PIPE

q) Open the isolating cocks and vent air from the system using the
manual air vent. Re-pressurise the system as necessary and check for
water leaks.

HEAT EXCHANGER
SADDLE RH.

SPARK GENERATOR

HEAT EXCHANGER
MOUNTING BRACKET

9.9

Refer to Figure 43
a) Ensure supply voltage is isolated.
b) Disconnect the electrical lead to the pump head.
c) Drain down the appliance; refer to section 9.23.
d) Using a long Allen key unscrew the four screws holding the

pump head; refer to Figure 42.
e) Remove the pump head, and fit replacement pump head, using

a new ‘O’ ring seal.
f) Re-assemble in reverse order; ensure that all joints and seals are

correctly re-fitted.
g) Open the isolating cocks and vent air from the system using the

manual air vent. Re-pressurise the system as necessary and check for

PUMP (HEAD ONLY)

9.10

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 valve motorised head and slide it down to

disengage it from the hydroblock body.

e) Fit the replacement diverter valve motorised head.
f) Re-assemble in reverse order; ensure that all joints and seals are

correctly re-fitted.

44

water leaks.

43

CONDENSATE FLOW TUBE

DIVERTER VALVE MOTORISED HEAD

ELECTRICAL LEAD

4
SCREWS

ELECTRICAL CONNECTOR

Note: It is likely that there will still be some water
spillage when the head is removed.

PUSH CLIP

LOCATING SCREW

35

751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:46 Page 38

9.11

Refer to Figure 45
a) a) Ensure supply voltage is isolated.
b) Disconnect the electrical leads to the pump head and diverter

valve motorised head.

c) Drain down the appliance; refer to section 9.23.
d) Remove the flow and return pipes from the heat exchanger; refer

to section 9.8.
e) Remove the clip holding the hydroblock adaptor fitting in place,

and remove fitting.

f) Remove the clip holding the return pipe in place.
g) Undo the nut connecting the CH return pipe to the CH return

isolating cock, and disengage the CH return pipe from the hydroblock.
h) Undo the nut connecting the DHW return pipe to the plate heat

exchanger and disengage the DHW return pipe from the hydroblock.

HYDROBLOCK ASSEMBLY

9.12

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 retaining bracket.
e) Slide the expansion vessel forward and remove.
f) Slide the replacement expansion vessel in place.
g) Re-assemble in reverse order; ensure that all joints and seals are

correctly re-fitted.
h) Open the isolating cocks and vent air from the system using the

manual air vent. Re-pressurise the system as necessary and check for
water leaks.

i) Unscrew the three screws holding the hydroblock onto the
mounting studs, and remove the hydroblock.

j) Align the replacement hydroblock against the mounting studs and
secure using the three screws.

k) Re-assemble in reverse order; ensure that all joints and seals are
correctly re-fitted.

l) Open the isolating cocks and vent air from the system using the
manual air vent. Re-pressurise the system as necessary and check for
water leaks.

EXPANSION VESSEL

Note: It is likely that there will still be some water spillage when the Hydroblock is removed.

8

45

PUMP ELECTRICS COVER

PUMP ELECTRICAL

CONNECTOR

CH RETURN PIPE

PUMP AIR BLEED SCREW

PUMP HEAD

AUTO AIR VENT

LOCATING SCREW

PRIMARY HEAT EXCHANGER
RETURN PIPE

FIBRE WASHER

PIPEWORK ADAPTOR

SMALL OUTLET PLUG

LARGE PIPE CLIP

SMALL PIPE CLIP

HYDROBLOCK MOUNTING POINT

PIPE ‘O’ RING

PRIMARY RETURN PIPE

36

ELECTRICAL CONNECTOR

DIVERTER

DIVERTER MOTOR

751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:46 Page 39

9.13

Refer to Figures 18 & 22
a) Ensure supply voltage is isolated.
b) Drain down the appliance; refer to section 9.23.
c) Undo the nut securing the discharge tail pipe to the pressure relief

valve and remove. Undo the nut securing the pressure gauge capillary,
and remove.

d) Undo the nut securing the pressure relief valve to the CH flow pipe
and remove the pressure relief valve.

e) Fit the replacement pressure relief valve, using new fibre washers.
f) Re-assemble in reverse order; ensure that all joints and seals are

correctly re-fitted.
i) Open the isolating cocks and vent air from the system using the

manual air vent. Re-pressurise the system as necessary and check for
water leaks.

Note: the pressure relief valve should not be used to
drain the system.

9.14

PRESSURE RELIEF VALVE

!

47

WATER TEMPERATURE SENSORS

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.

FLUE SENSOR

THERMAL FUSE

Refer to Figure 46
a) Ensure supply voltage is isolated.
b) Disconnect the electrical lead from the sensor to be changed.
c) Unclip the sensor from the pipe and remove.
d) Clip the replacement sensor onto the pipe and position as

shown in Figure 46.

e) Reconnect the electrical lead.

46

FLOW THERMISTOR

RETURN THERMISTOR

DHW THERMISTOR

9.15

Refer to Figure 47
a) Ensure supply voltage is isolated.
b) Disconnect the electrical lead from the flue sensor.
c) Twist the flue sensor to release the bayonet connection and

remove from the heat exchanger.
d) Fit the replacement flue sensor and reconnect the electrical lead

(blue plug).

FLUE SENSOR

9.16

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 point in the system and allow the pressure to dissipate. Close
this tap again.

d) If it is suspected that the plate heat exchanger is blocked or is
leaking then proceed as follows:

e) Undo the nut connecting the flow pipe from the main heat
exchanger to the plate heat exchanger.

f) Undo the nut connecting the pipe from the hydroblock to the
plate heat exchanger, and rotate out of the way.

g) Undo the nut connecting the plate heat exchanger to the CH
flow water isolating cock pipe.

h) Undo the nut connecting the plate heat exchanger to the DHW
outlet pipe.

i) Undo the nut connecting the plate heat exchanger to the DHW
water isolating cock pipe.

j) Lift up the plate heat exchanger and remove.
k) Fit the replacement plate heat exchanger, using new case seals

as necessary, ensuring the filter is fitted correctly.
l) Re-assemble in reverse order; ensure that all joints and seals are

correctly re-fitted.
m) Open the isolating cocks and vent air from the system using the

manual air vent. Re-pressurise the system as necessary and check for
water leaks.

PLATE HEAT EXCHANGER

37

751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:46 Page 40

8

48

PRIMARY FLOW PIPE

FIBRE WASHER

FILTER

PLATE HEAT EXCHANGER

9.17

Refer to Figure 27
a) Ensure supply voltage is isolated.
b) Open the drain sump cap, while holding a receptacle beneath

to capture any condensate.

c) Disconnect the condensate drainpipe from the appliance.
d) Detach the condensate drainpipe from the heat exchanger sump

adaptor, by gently pulling down.
e) Remove the condensate drain system, clean or replace as

necessary.
f) Re-assemble in reverse order; ensure that all joints and seals are

correctly re-fitted.

49

CONDENSATE DRAIN SYSTEM

PRESSURE GAUGE

9.18

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 reverse order.
f) Open the isolating cocks and vent air from the system using the

manual air vent. Re-pressurise the system as necessary and check for
water leaks.

PRESSURE GAUGE

38

PRESSURE GAUGE CAPILLARY GLAND NUT

751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:46 Page 41

9.19

Refer to Figure 45
a) Ensure supply voltage is isolated.
b) Drain down the appliance; refer to section 9.23.
c) Disconnect the vent tube from the auto air vent and check that it

is free from blockage.

d) Unscrew the auto air vent, and fit replacement.
e) Re-assemble in reverse order; ensure that all joints and seals are

correctly re-fitted.
f) Open the isolating cocks and vent air from the system using the

manual air vent. Re-pressurise the system as necessary and check for
water leaks.

9.20

Refer to Figures 21, 29 & 50
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 to section 7.
d) Unplug the BCC if fitted.
e) Unscrew and remove the PCB plastic cover.
f) Unclip the user interface ribbon cable.
g) Unclip the PCB and withdraw.
h) Fit the new PCB and plug in the BCC if previously used.
i) Re-assemble in reverse order, ensuring user interface ribbon

cable is attached securely.
If the boiler requires resetting turn the control knob anti-clockwise to

'STANDBY' position and then back to 'ON' within two seconds.
Refer to section 5.4.

AUTO AIR VENT

CONTROL PCB

9.21

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 clock from

the control panel.

f) Fit the new clock and re-assemble in reverse order.

9.22

TIME CLOCK

DHW FLOW SWITCH, DHW FLOW
REGULATOR AND DHW FILTER

Refer to Figure 28
a) Ensure supply voltage is isolated.
b) Remove the electrical lead to the DHW flow switch.
c) Close the DHW inlet isolating cock, open a DHW tap at the

lowest point in the system and allow the pressure to dissipate. Close
this tap again.

d) Undo the nut connecting the DHW flow switch to the DHW inlet
isolating cock.

e) Undo the nut connecting the DHW flow switch to the water feed
pipe, and remove the DHW flow switch, (containing the DHW Flow
Regulator), and DHW Filter.

f) The assembly can now be flushed clean using water, and parts
replaced as necessary.

g) Re-assemble in reverse order, using a new fibre washer; ensure
that all joints and seals are correctly re-fitted.

h) Open the DHW inlet isolating cock and vent air from the system
by opening each hot water tap in the house in turn.

50

PCB HOUSING

BCC

Electrical
Connectors

•

Securing
Screws

•

39

751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:46 Page 42

51

24HR TIME CLOCK

52

DRAIN POINT

DRAIN TUBE

230Vac CLOCK MOTOR

2 BROWN CABLES

2 BLUE CABLES

N/O CONTACTS

RED CABLE

RED CABLE

9.23

DRAINING THE APPLIANCE

Refer to Figures 18, 42 & 52
a) Before draining, give the appliance a brief CH demand, to

ensure the diverter valve is in the CH position.

b) Ensure supply voltage is isolated.
c) If not draining the entire CH system, close the CH flow and CH

return water isolating cocks.

d) Close the DHW return water-isolating cock.
e) Drain down the CH system 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 dissipate. Close this tap again.

40

751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:46 Page 43

SHORT PARTS LIST

10

Refer to Figure 54

Key G C Part No. Description No off Makers Pt No.
1 H29-740 Electrode - Ignition c/w Gasket 1 988526
2 H38-213 Detection Electrode c/w Gasket 1 988540
3 H29-236 Spark Generator c/w Lead 1 500665
4a H38-214 Gas Control Valve Assy - NG (Ace HE24 & 30) 1 988541
4b Gas Control Valve Assembly - NG (Ace HE35) 1 988563
5 H38-215 Fan Assembly 1 601016
6A H29-171 Burner (Ace HE 24) 1 700600
6B H29-172 Burner (Ace HE 30) 1 700601
7 H38-216 Insulation - Burner Door 1 451106
8A H38-217 Heat Exchanger (Ace HE 24) 1 451101
8B H38-218 Heat Exchanger (Ace HE 30) 1 451100
9 H29-202 Pump Head 6m 1 500672
10 H29-203 Valve - Diverted - Motorised Head 1 500673
11 H29-201 Hydroblock Pump Assembly 1 500650
12 H29-237 Expansion Vessel 1 451020
13 H29-199 Valve 3Bar - Pressure Relief 1 300734
14 H29-213 Sensor - Water Temperature 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 988543
21c Control PCB c/w Box Assembly (Ace HE 35) 1 988562
22 H38-223 User Control Fascia Assermbly 1 988544
23 E23-671 Time Clock - Grasslin FM1STUH 1 600520
24 H38-224 Air Vent Pipe c/w Seal 1 988545
25 H38-225 Switch - Flow - DHW 1 300695
26a H08-702 DHW Flow Regulator (Ace HE 24) 1 300717
26b E23-692 DHW Flow Regulator (Ace HE 30) 1 300715
26c DHW Flow Regulator (Ace HE 35) 1 300718
27 H29-260 Filter - Conical - Mains Inlet 1 500497
28 H29-179 Valve - Manual Bleed 1 300730
29 H38-226 Heat Exchanger c/w Seals & Clip Kit 1 988546
30 H29-208 Kit - Hydroblock - O-Ring and Clip 1 988490

41

751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:46 Page 44

53

1 23 4

5678

9 10 11 12

13 14 15 16

17 18 19 20

42

21 22 23

25 26 27 28

24

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 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 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/CO2 RATIO READING N/A YES CO/CO2 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

PRINT CORGI ID No.

SIGN DATE

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

SERVICE INTERVAL RECORD

It is recommended that your heating system is serviced regularly

and that you complete the appropriate Service Interval Record below.

SERVICE PROVIDER

Before completing the appropriate Ser vice Inter val Record below, please ensure

you have carried out the ser vice as described in the boiler manufacturer’s instructions.

Always use the appliance manufacturer’s specified spare par t when replacing gas controls.

SERVICE 1 DATE:

ENGINEER NAME

COMPANY NAME

TEL No.

CORGI ID SERIAL No.

COMMENTS

SIGNATURE

SERVICE 2 DATE:

ENGINEER NAME

COMPANY NAME

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

SERVICE 7 DATE:

ENGINEER NAME

COMPANY NAME

TEL No.

CORGI ID SERIAL No.

COMMENTS

SIGNATURE

SERVICE 8 DATE:

ENGINEER NAME

COMPANY NAME

TEL No.

CORGI ID SERIAL No.

COMMENTS

SIGNATURE

SERVICE 9 DATE:

ENGINEER NAME

COMPANY NAME

TEL No.

CORGI ID SERIAL No.

COMMENTS

SIGNATURE

SERVICE 10 DATE:

ENGINEER NAME

COMPANY NAME

TEL No.

CORGI ID SERIAL No.

COMMENTS

SIGNATURE

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

751094 ACE HE INST MANUAL:751094 ACE HE 28/9/10 09:46 Page 48

Glen Dimplex Boilers, Stoney Lane, Prescot Merseyside L35 2XW.

For 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

SERVICE HELPLINE: 0844 371 1111