Halstead CLUB HE 18 User guide

CLUB HE 18
SEALED SYSTEM CONDENSING BOILER
0087
Pin 87/BQ/44
G.C. Appliance No. 41-260-20 Club HE 18
INSTALLATION AND SERVICING INSTRUCTIONS
TO BE GIVEN TO THE USER

CNTENTS
1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
1.1 Important Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2TECHNICAL 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 . . . . . . . . . . . . . . . . . . . . . . . . . 9
3INSTALLATION REQUIREMENTS . . . . . . . . . . . . . . . . . 10
3.1 Statutory Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.2 Appliance Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.3 Flue Terminal Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.4 Ventilation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
3.5 Condensate Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.6 Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.7 Central Heating System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.8 Electricity Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.9 External Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4APPLIANCE INSTALLATION . . . . . . . . . . . . . . . . . . . . 16
4.1 Unpacking The Appliance . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.2 Preparing The Wall . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.3 Mounting The Appliance . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.4 Central Heating Service Connections . . . . . . . . . . . . . . . . . . .17
4.5 Gas Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.6 Condensate Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.7 Pressure Relief Valve Connection . . . . . . . . . . . . . . . . . . . . . 18
4.8 Air / Flue Duct Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.9 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
5COMMISSIONING AND TESTING . . . . . . . . . . . . . . . 20
5.1 Filling the Water System . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
5.2 Commissioning the Appliance . . . . . . . . . . . . . . . . . . . . . . . 21
5.3 Final Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.4 Lockout Indication and reset the appliance . . . . . . . . . . . . . . 22
5.5 Frost Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.6 Overheat Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.7 Users Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.8 Appliance Log Book . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6ROUTINE SERVICING . . . . . . . . . . . . . . . . . . . . . . . . 23
6.1 Combustion Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.2 Gas Control Valve, Fan & Burner Assembly . . . . . . . . . . . . . . 24
6.3 Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.4 Ignition & Detection Electrodes . . . . . . . . . . . . . . . . . . . . . . . 25
6.5 Combustion Chamber & Heat Exchanger . . . . . . . . . . . . . . . 25
6.6 Condensate Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.7 Re-assembly & Re-commissioning . . . . . . . . . . . . . . . . . . . . . 25
6.8 Final Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7INTERNAL WIRING DIAGRAM . . . . . . . . . . . . . . . . . 26
7.1 Functional Flow Wiring Diagram . . . . . . . . . . . . . . . . . . . . . 26
8FAULT FINDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8.2 Diagnostic Digital Display . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8.3 Faulting Finding Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
8.4 Central Heating Fault Finding . . . . . . . . . . . . . . . . . . . . . . . . 28
9REPLACEMENT OF PARTS . . . . . . . . . . . . . . . . . . . . . 30
9.1 Ignition and Detection Electrodes . . . . . . . . . . . . . . . . . . . . . 30
9.2 Igniter Unit and Ignition Leads . . . . . . . . . . . . . . . . . . . . . . . 30
9.3 Gas Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
9.4 Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
9.5 Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
9.6 Combustion Chamber Front Insulation . . . . . . . . . . . . . . . . . . 33
9.7 Combustion Chamber Rear Insulation . . . . . . . . . . . . . . . . . . 33
9.8 Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
9.9 Pump (Head Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
9.10 Hydroblock Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
9.11 Expansion Vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
9.12 Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
9.13 Water Temperature Sensors . . . . . . . . . . . . . . . . . . . . . . . . . 36
9.14 Flue Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
9.15 Condensate Drain System . . . . . . . . . . . . . . . . . . . . . . . . . . 36
9.16 Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
9.17 Auto Air Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
9.18 Control PCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
9.19 Draining The Appliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
10 SHORT PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Introduction
The Halstead Club HE 18 is a 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. The Club HE 18 is a sealed system condensing boiler
and is suitable to be connected to a central heating system
operating a standard ‘Y’ or ‘S’ plan system.
The appliance features an attractive white stove enamelled
casing, with inset control panels. The flue systems are in white
stove enamel to give a clean attractive appearance to the
installation.
A standard horizontal concentric air/flue duct terminal is
available, (maximum duct length of 755 mm (293⁄4in)), suitable
for room sealed applications. The duct assembly is connected to
the appliance via a turret, which can be orientated to provide
different horizontal duct directions. Extension ducts may be fitted
in accordance with and up to the maximum dimensions stated in
these instructions.
A vertical concentric outlet kit is also available for installations
where an outside wall is not accessible or where it is desired to fit
the duct ‘through the roof’. Installation using the horizontal duct is
described in the main text of these instructions and additional
information is provided in the vertical outlet kit for the vertical
installation option. (Note: If the vertical outlet kit is to be used,
access to the roof is necessary).
Other flue kits are available for open flued, B23, and twin flued,
C53, and special C13 & C33, applications, contact Halstead Boiler
Ltd Service Help Line: 01926 834834, for further details,
ONLY HALSTEAD APPROVED FLUE KITS OR
EXTENSIONS MAY BE USED WITH THESE APPLIANCES.
CONTENTS INTRODUCTION
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.
This appliance has 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 this appliance 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.
GAS LEAKS. DO NOT OPERATE ANY
ELECTRICAL SWITCHES, OR USE A NAKED
FLAME. TURN OFF THE GAS SUPPLY.
VENTILATE THE AREA BY OPENING DOORS AND
WINDOWS. CALL OUT YOUR LOCAL GAS SUPPLIER.
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.
This appliance incorporates a microprocessor based, fully
modulating air/gas ratio control system with direct burner
ignition, which provides a modulated heat output to central
heating (CH) demands, with internal frost protection provided as
standard. The heat exchanger is constructed from stainless steel
encased in high temperature polymer.
A combined circulating pump and automatic air vent assembly,
pressure gauge, safety valve and system expansion vessel are
included. Isolation valves are fitted to the service connections.
This appliance 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.
It is recommended that a drain cock is fitted at the lowest point in
the system.
1.1 IMPORTANT INFORMATION 1.2 GENERAL DESCRIPTION
!

2
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
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).
TECHNICAL SPECIFICATIONS
2
2.1 GAS CATEGORIES
2.2 PERFORMANCE DATA
Appliance Club HE 18
Mode Rate
Central Heating Output (non-condensing) (80 - 60 °C) Max kW 18.0
(Btu/h) (61500)
Min kW 6.0
(Btu/h) (20500)
Central Heating Output (condensing) (50 - 30 °C) Max kW 19.7
(Btu/h) (67300)
Net kW 18.4
Central Heating Input Max Rate (Btu/h) (62800)
Gross kW 20.4
(Btu/h) (69700)
Net kW 5.6
Central Heating Input Min Rate (Btu/h) (19100)
Gross kW 6.2
(Btu/h) (21200)
Central Heating Gas Rate (after 10 min operation - hot)
m3/h 1.95
Max ft3/h (68.9)
Seasonal Efficiency %90.1
Seasonal Efficiency (SEDBUK) Band “A”
Nox Classification Class “5”
Min Central Heating System Pressure Bar 0.5
Max Central Heating System Pressure Bar 3.0
Max Central Heating Flow Temperature °C80
Min Central Heating Flow Temperature °C30

2.3 GENERAL SPECIFICATIONS
Appliance Club HE 18
Total weight (full) kg 44.1
Total weight (empty) kg 42.0
Max lift weight kg 41.0
Total water capacity Ltr 1.8
Integral expansion vessel capacity Ltr 8
Maximum heating system water content
using fitted expansion vessel, @ 0.75 bar Ltr 84
Electrical supply 230V 50Hz
Internal fuse T4H 4A 250V
Maximum power consumption W106
IP Rating IP20
Flue gas temperature Nat Gas 50/30 °C53
CO2value max rate (Nat Gas) (G20) %9.2 ± 0.3 case on
9.0 ± 0.2 case off
CO2value min rate (Nat Gas) ref only (G20) %8.6 ± 0.3
CO/CO2Ratio max rate (Nat Gas) (G20) %0.0011 + 0.0014
Flue products mass flow rate (Nat Gas) (G20) g/s 14.7
Gas Valve Offset @ min rate Pa -5.0
Connections
Gas 15 mm compression
CH flow 22 mm compression
CH return 22 mm compression
Pressure relief valve outlet 15 mm compression
Condensate Drain 21.5 - 22 mm plastic overflow pipe
3
NOTE: THE STATED HEAT INPUT AND CO2 VALUES ARE NOMINAL AND MAY VARY BY ±5-10% WHEN THE APPLIANCE IS
RUN WITH LINE GAS, DUE TO FLUCTUATIONS IN GAS QUALITY.

4
2.4 OVERALL DIMENSIONS AND MINIMUM CLEARANCES
The Club HE 18 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 connecting
2.5 CONCENTRIC AIR / FLUE DUCT SPECIFICATIONS
8FLUE OPTIONS
2
Vertical flue kit - Part no. 956081
with flat roof flashing plate
Vertical flue kit - Part no. 956081
Flue system application
Vertical flue kit - Part no. 956081
Split pipe vertical flue outlet kit
- Part no. 956080
with flat roof flashing plate
Raised external flue outlet kit
- Part no. 956084
Chimney flue liner kit
- Part no. 956082
External vertical flue kit
- Part no. 956085
Standard horizontal flue kit
- Part no. 956083
parts to the appliance and end terminal. Flue extension ducts and
extension elbows are available as accessories.
1
The following flue systems are available for the Club HE 18

5
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 terminal is 755mm long but can be cut to a minimum flue
length of 250mm, which is suitable for single, 100mm (4"), brick walls.
Ø60/100mm concentric
standard horizontal wall
terminal.
Max. length 5000mm.
Min. length 250mm.
The pluming from the flue may
cause nuisance to neighbours
or other buildings.
Horizontal terminal has a
built-in fall in the flue to allow
condensate to drain away.
If horizontal flue requires
extension pipe, the flue
should be installed such
that there is no section less than
2.5º – 3º to the horizontal.
93 flanged elbow (concentric)
with sampling point
Standard horizontal flue kit - Part no. 956083
Kit A
60/100 flue accessories:
0.5m flue extension duct - 956092
1m flue extension duct - 956093
93 flue extension elbow - 956091
45 flue extension elbow (2x) - 956090
Vertical flue turret - 956087
3a
(C13) - PART NO.956083
2.5.1 KIT A HORIZONTAL WALL TERMINAL
TERMINAL (C33) - HBL PART 956081
2.5.2 KIT B VERTICAL CONCENTRIC FLUE
3b
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.
Fig 3(c) Offset vertical flue.
‘a’ measured from boiler flue outlet centre line to the centre line
of the extension elbow.
‘b’ measured from the top of the boiler to the underside of the air
cowl.
Maximum allowable length of a + b = 8900mm
3c
If the standard horizontal terminal is likely to causes 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.
FLUE KIT (C13) – PART NO. 956084
2.5.3
2.5.3 KIT C: HORIZONTAL ANTI-PLUME
Dimensions from vertical terminals to opening
windows should be in line with Figure 5.

6
PART NO: 956085
2.5.4 KIT D EXTERNAL VERTICAL FLUE - (C33)
3e
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
Maximum flue resistance permitted for an open flued system = 55 Pa.
Flue Component Flue Resistance Part
(Pa) Number
Air inlet Assembly (required) 2 -
60/80 Adaptor (required) 1 -
Terminal (required) 0.5 -
91.5° Elbow (80) (required) 2 -
80 diameter Corrugated (required) 1.5 per metre -
80 mm diameter straight duct 0.5 per metre -
93° Boiler to flue flanged elbow 3 956086
Vertical turret socket 0.5 956087
93° inline elbow (60/100) 3 956091
45° inline elbow (60/100) 1.5 956090
Centralising brackets
Chimney terminal
93 flanged elbow (concentric)
with sampling point
Ø60/100mm concentric
chimney adaptor pipe.
In replacement installations,
the chimney has to be
cleared of debris and
all flue parts.
Chimney
plate
Flexible corrugated plastic flue liner
Ø80mm according to EN 14471
Max. length 30m.
Min. length 5m.
KIT E
Chimney flue liner kit - Part no. 956082
3f
Aflue system can be built up from the components
detailed in the table, but the total flue resistance must
not exceed the maximum stated.
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.
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.
(B23) – PART NO. 956082
2.6 KIT E CHIMNEY FLUE LINER KIT

7
PART NO. 956080
2.7 KIT F: TWIN FLUE SYSTEM (C53) –
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.
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 -
Flue Outlet Terminal (required) 1 -
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
Ø80mm air intake
Split flue system
Roof terminal with pitched
roof flashing kit.
If the flue pipe passes
through compartment
from wall/floors, the
requirements set out
in Building Regulations
Part B must be followed.
Ø80mm twin adaptor
with sampling point.
If the flue pipe passes
through habitable rooms
within the same dwelling,
the flue pipe must be
routed through vented
air ducts.
Max. flue length 30m.
The flue resistance for the
following accessories has
to be considered.
Ø80mm flue extension
90 elbow
45 elbow
Split pipe vertical
flue outlet kit -
Part no. 956080
Kit F
3g
Aflue system can be built up from the components
detailed in the table, but the total flue resistance must
not exceed the maximum stated.
!!
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.
The 'equivalent' flue length must not exceed the
maximum values stated.
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:
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 (231/2in)
2.8 ADDITIONAL CONCENTRIC FLUE KITS
Refer to Figures 2 and 3 to determine which option
kits are required before commencing the installation.
Instructions for installing the appliance with a
horizontal flue and straight extension ducts are
included in the main text of these instructions
(section 4.8).
b) The standard 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.

8
Plume Diverter Kit Part No: 956103
(For use with Standard horizontal flue kit - Part no 956083 - 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
PLUME DIVERTER TERMINAL
INSTALLATION INSTRUCTIONS
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.
2.8.1
3h
3i
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).

2.9 APPLIANCE HYDRAULIC CIRCUITS
4
CH MODE
9

10
INSTALLATION REQUIREMENTS
3
3.1 STATUTORY REQUIREMENTS
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 I.S.813 for IE.
IMPORTANT NOTE: Manufacturer's instructions must NOT be
taken in any way as overriding statutory obligations.
3.3 FLUE TERMINAL POSITION
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: 01926 834834.
3.2 APPLIANCE LOCATION
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
electrical provisions of the Building Regulations applicable in
Scotland.
3.4 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:
Club HE 18 57 cm2

11
5FLUE TERMINAL POSITION
Position Minimum spacing
A Directly below an openable window, 300mm 12in
air vent, or any other ventilation opening
BBelow gutter, drain/soil pipe 75mm 3in
C Below eaves 200mm 8in
DBelow a balcony 200mm 8in
*2500mm 98in
E From vertical drain pipes and soil pipes 150mm 6in
FFrom internal or external corners 300mm 12in
*internal corners t1000mm 40in
G Above adjacent ground or
balcony level 300mm 12in
H From a surface facing the terminal 600mm 24in
t 2500mm 98in
I Facing terminals 1200mm 48in
*2500mm 98in
J From opening (door/window) in 1200mm 48in
carport into dwelling *not recommended
K Vertically from a terminal on the 1500mm 60in
same wall
L Horizontally from a terminal on the 300mm 12in
same wall
MAdjacent to opening 300mm 12in
NBelow carport600mm 24in
*not recommended
OFrom adjacent wall 300mm 12in
PFrom adjacent opening window 1000mm 40in
QFrom another terminal 600mm 24in
R Minimum height 300mm 12in
•
•
•
•
•
•
•
•
•
•
••
•
•
•
••
•
•
•
•
•
•
•
••
••
•
•
••
•
•
••
•
•
•
•
•
•
•
•
•
•••••
••
••
•
•
A
B,C
G
KM
A
EFF
K
B,C
GG
K
KLL
J
F
H,I D,N
C
Q
O
O
P
R
SPECIAL REQUIREMENTS FOR A
VERTICALLY BALANCED FLUE
300mm
Min
430mm
Min
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 appliance incorporates all the components necessary to
allow them to be connected to a sealed central heating system.
Refer to Figures 9 and 10 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.
tDistances can be reduced if plume diverter kit is fitted.

12
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.
BY-PASS – The boiler is not fitted with an internal by-pass. An
automatic by-pass is required if the boiler is installed to a ‘Y’ or
‘S’ plan system (See Figures 9 and 11) to ensure adequate pump
over-run function.
EXPANSION VESSEL – The integral expansion vessel is pre-
charged 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.
Expansion Vessel Requirements
Vessel charge and bar 0.5 0.75 1.0 1.5
initial system pressure
Total water content of system
using 8 L (1.54 gal) capacity L96847350
expansion vessel supplied
with appliance.
For systems having a larger
capacity multiply the total system
capacity in litres (gallons) by 0.0833 0.093 0.109 0.156
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.
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.
7ALTERNATIVE METHODS OF FILLING A SEALED SYSTEM
MAINS WATER
SUPPLY
FLEXIBLE HOSE UNION
TEMPORARY CONNECTION
To be removed immediately after filling
STOP
VALVE DOUBLE
CHECK
VALVE
ASSEMBLY
STOP
VALVE HEATING SYSTEM
RETURN
MAINS
WATER SUPPLY CISTERN &
OVERFLOW PRESSURE PUMP &
REDUCING VALVE
IF REQUIRED
STOP
VALVE
HEATING
SYSTEM
RETURN
RECOMMENDED AND APPROVED METHOD FOR
FILLING CLOSED CIRCUIT IN A HOUSE.
(R24-2a WATER REGULATIONS GUIDE)
AVAILABLE PUMP HEADS
6

13
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
valves that should not be closed. Further guidance can be
obtained from the Domestic Heating and Hot Water Guide to the
building regulations.
a) Wiring external to the appliance must be in accordance with the
current I.E.E Wiring regulations (BS 7671) for electrical installation and
any local regulations, which apply.
b) The mains cable must be at least 0.75 mm2 (24/0.2 mm) PVC
insulated to BS 6500 table 16.
3.8 ELECTRICITY SUPPLY
8‘S’ PLAN INSTALLATION
TIMED CH & DHW
FOR FURTHER INFORMATION PLEASE CONTACT HALSTEAD BOILERS LTD SERVICE HELPLINE TEL: [phone]
The Club HE 18 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:
01926 834834.
3.9 EXTERNAL CONTROLS
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.

FOR FURTHER INFORMATION PLEASE CONTACT HALSTEAD BOILERS LTD SERVICE HELPLINE TEL: [phone]
FOR FURTHER INFORMATION PLEASE CONTACT HALSTEAD BOILERS LTD SERVICE HELPLINE TEL: [phone]
14
9‘S’ PLAN INSTALLATION
TIMED CH & DHW
‘Y’ PLAN INSTALLATION
TIMED CH & DHW
10

15
FOR FURTHER INFORMATION PLEASE CONTACT HALSTEAD BOILERS LTD SERVICE HELPLINE TEL: [phone]
‘Y’ PLAN INSTALLATION
TIMED CH & DHW
11

16
12
APPLIANCE INSTALLATION
4
4.1 UNPACKING THE APPLIANCE
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 (See note)
●Installation and Servicing Instruction
●User’s Instructions
●Benchmark book
●Hardware pack containing:
6 x 65 mm wood screws – 2 off
Blue wall plugs – 2 off
15mm flanged nuts – 1 off
15mm Male flanged nut – 1 off
15mm Olives – 2 off
22mm flanged nuts – 2 off
22mm Olives – 2 off
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.
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.
4.2 PREPARING THE WALL
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 primary wall fixing holes. Refer to Figures
12 and 13.
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
° needs to be taken into account. Refer to
Figure 13. Remove the paper template.
d) Cut the hole in the wall for the air/flue duct (preferably with a core-
boring 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 primary 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 fixing screws supplied,
ensuring that it is level. Refer to Figure 13.
g) Fit any additional fixing screws into wall plugs and tighten all screws.
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.
WALL MOUNTING PLATE

17
4.3 MOUNTING THE APPLIANCE
Lift the appliance into position as shown in Figure 14. 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
the appliance in a horizontal direction. Then carefully lower the
appliance, ensuring that the two top locating tabs are securely
engaged.
14 MOUNTING THE APPLIANCE
13
SERVICE CONNECTIONS
4.4
CENTRAL HEATING
Refer to Figure 15.
a) Connect the central heating system pipes to the central heating
flow and return valves, using 22mm pipe work.
4.5 GAS CONNECTION
Refer to Figure 15.
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.
Fill the central heating system as described in section 5.1, and then
proceed to Section 4.5.
15 VIEW OF CONNECTIONS
ON REAR OF BOILER

18
4.6 CONDENSATE CONNECTION
Refer to Figure 16
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.
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 17. 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.
16
The flue length is measured from the centreline of the
appliance flue outlet to the inside of the external wall-
sealing ring. In most cases it will be possible to achieve
the required flue length without cutting the ducts, however
where necessary the plain ends of the extension ducts
may be cut. 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
FAN OUTLET
EXTERNAL
Dia. 60mm
•
TOTAL FLUE LENGTH FROM
FLUE OUTLET CENTRE TO
OUTSIDE WALL FACE:
= LENGTH
L
WALL
L
•
•
•
•
17