Halstead Hero 30 Quick guide

Hero
Lightweight Cast Iron boiler
30, 40, 50, 60, 75, 90
0086 EC 0087/BN/41
Installation and Service Instruction
To be left with user adjacent to gas meter
G. C. APPLIANCE No:
Hero 30: 41-260-01 Hero 60: 41-260-04 Hero 40 PROPANE: 41-260-07
Hero 40: 41-260-02 Hero 75: 41-260-05 Hero 60 PROPANE: 41-260-08
Hero 50: 41-260-03 Hero 90: 41-260-06
Halstead Hero cover 8/5/03 8:39 am Page 2

CONTENTS INTRODUCTION
1
The Halstead Hero range consists of six different outputs. The outputs
are available from 30,000 to 90,000 BTU/h and spot rated (non
modulating). All versions are wall mounted, fan assisted balanced flue
natural gas boilers incorporating a cast iron heat exchanger.
The HERO range is for use in fully pumped open-vented or sealed water
central heating systems. The appliances are NOT suitable for semi
gravity systems.
The appliance is fitted with an electronic control device to combine and
provide functions for ignition, manually adjustable central heating
temperature control, pump over-run, frost protection and basic diagnostic
information.
It features an attractive white casing hinged with front door panel. The
hinged front door panel has to be removed if the appliance is to be
fitted within a standard kitchen wall unit.
The appliances are supplied with a standard concentric flue terminal
which is suitable for rear wall thicknesses up to 340mm. For side
horizontal or vertical flueing application the flue kit, part number
955080, is required.
Additional flue kits are available to extend the flue length to any length
as specified in clause 2.
For further information regarding vertical flue terminal installation please
refer to Halstead’s Flue Guide.
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.
Manual Handling Guidance
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.
Insulation material
The insulation material is made of Superwool 612 BB and can cause
irritation to skin, eyes and the respiratory tract.
High dust levels are usually only if the material is broken. Normal
handling shouldn’t cause any discomfort, but it is advised to follow
normal hygiene and wash your hands immediately after working with the
material.
If you do suffer irritations to the eyes or to the skin seek medical
attention.
The adhesives and sealants used in this appliance are cured and give no
hazard in this state.
Note: British standard BS7593: 1992 stresses the
importance of cleansing and flushing of the system to
ensure it continues to run efficiently with the minimum of
maintenance necessary. Halstead Boilers fully support this
professional approach and recommend that the system is
cleansed with an effective chemical cleanser and protected
long term with a suitable inhibitor. Such products are
available from Fernox and Sentinel.
1GENERAL DESCRIPTION
2TECHNICAL SPECIFICATIONS . . . . . . . . . . . . . . .1
2.1 Gas Categories . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
2.2 Performance data . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
2.3 Connection Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
2.4 General specifications . . . . . . . . . . . . . . . . . . . . . . . . .1
2.5 Overall dimensions and minimum clearances . . . . . . . . . .2
2.6 Air/flue duct specification . . . . . . . . . . . . . . . . . . . . . .2
2.7 Se-duct applications . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2.8 Exploded diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3INSTALLATION REQUIREMENTS . . . . . . . . . . . . . .5
3.1 Statutory requirements . . . . . . . . . . . . . . . . . . . . . . . . .5
3.2 Boiler location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3.3 Flue terminal position . . . . . . . . . . . . . . . . . . . . . . . . . .6
3.4 Ventilation requirements . . . . . . . . . . . . . . . . . . . . . . . .6
3.5 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3.6 Data supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3.7 Electricity supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3.8 Central heating water systems . . . . . . . . . . . . . . . . . . . .7
3.8.1 Open vented systems . . . . . . . . . . . . . . . . . . . . . . . . . .7
3.8.2 Sealed systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
4.0 INSTALLING THE APPLIANCE . . . . . . . . . . . . . . . .9
4.1 Unpacking the appliance . . . . . . . . . . . . . . . . . . . . . . .9
4.2 Preparing the wall . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
4.2.1 Rear outlet flue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
4.2.2 Top outlet flue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
4.3 Air/flue duct installation . . . . . . . . . . . . . . . . . . . . . . .11
4.3.1 Preparing the horizontal duct . . . . . . . . . . . . . . . . . . . .12
4.3.2 Installing the horizontal duct from inside the building . . . .13
4.3.3 Installing the horizontal duct from outside the building . . .13
4.3.4 Preparing and installing the vertical duct . . . . . . . . . . . .14
4.4 Gas connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
4.5 Water connections . . . . . . . . . . . . . . . . . . . . . . . . . . .14
4.6 Wiring instructions . . . . . . . . . . . . . . . . . . . . . . . . . . .15
5COMMISSIONING AND TESTING . . . . . . . . . . . .17
5.1 Open vented water systems . . . . . . . . . . . . . . . . . . . . .17
5.2 Sealed water systems . . . . . . . . . . . . . . . . . . . . . . . . .18
5.3 Users instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
5.4 Boiler logbook . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
6ROUTINE SERVICING INSTRUCTIONS . . . . . . . . .19
6.1 Checking the operation of the appliance . . . . . . . . . . . .19
6.2 Commencing with servicing . . . . . . . . . . . . . . . . . . . . .19
6.3 Fan assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
6.4 Main burner assembly & combustion chamber insulation .20
6.5 Ignition and detection electrode insulation . . . . . . . . . . .20
6.6 Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
6.7 Air pressure switch tubes . . . . . . . . . . . . . . . . . . . . . . .20
6.8 Heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
6.9 Re-assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
6.10 Re-commisioning . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
7REPLACEMENT OF PARTS . . . . . . . . . . . . . . . . .21
7.1 Overheat cut off device . . . . . . . . . . . . . . . . . . . . . . .21
7.2 Flow temperature sensing device . . . . . . . . . . . . . . . . .21
7.3 Air pressure switch . . . . . . . . . . . . . . . . . . . . . . . . . . .21
7.4 Electronic diagnostic and ignition sequence control board 21
7.5 Fan assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
7.6 Main burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
7.7 Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
7.8 Gas valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
7.9 Igniton / Flame sensing electrode . . . . . . . . . . . . . . . . .22
7.10 Combustion chamber insulation . . . . . . . . . . . . . . . . . .23
7.10.1 Front panel insulation . . . . . . . . . . . . . . . . . . . . . . . . .23
7.10.2 Side panel insulation . . . . . . . . . . . . . . . . . . . . . . . . .23
8INTERNAL WIRING DIAGRAMS . . . . . . . . . . . . .23
9 FAULT FINDING . . . . . . . . . . . . . . . . . . . . . . . .24
10 SHORT PARTS LIST . . . . . . . . . . . . . . . . . . . . . .25
Halstead Hero cover 8/5/03 8:39 am Page 3

TECHNICAL SPECIFICATIONS
22.2 PERFORMANCE DATA
2.1 GAS CATEGORIES AND
APPLIANCE CLASSIFICATION
The Seasonal Efficiency (SEDBUK) conforms to Band D. The efficiency value is used in the
UK Government Standard Assessment (SAP) for energy rating of dwellings.
The appliance meets the essential requirements for Gas Appliance
(90/396/EEC) and the Efficiency directive (92/42/EEC). It also
meets the directive 73/23/EEC relating to electrical equipment
designed for use within certain voltage limits and directive
89/336/EEC relating to electromagnetic compatibility.
The appliances were certified by the Notified Body 0087.
Any alterations to the appliance not approved by Halstead Boilers
Ltd could invalidate the certification, boiler warranty and may
infringe the current issue of statutory requirements.
The appliances are marked as category I2H for use on Natural
Gas (G20) only. The HERO 40 and 60 are also approved to I3P
and available as separate boilers.
As defined in EN 483 the appliance classification may be any of
the following depending on the chosen flue option:
C12:concentric horizontal or
C22: SE-duct
C32: concentric vertical
2.3 CONNECTION SIZES
Gas connection Rc 1/2 “ BSP
CH connections 22 mm tail end
2.4 GENERAL SPECIFICATIONS
HERO
Heat
output
Heat
input
(gross)
Heat
input
(nett)
Burner
pressure
SEDBUK
30 40 40 P 50 60 60 P 75 90
kW 8.79 11.72 11.72 14.65 17.58 17.58 21.97 26.37
BTU/h 30000 40000 40000 50000 60000 60000 75000 90000
kW 10.85 14.47 14.47 18.1 21.7 21.7 27.2 32.6
BTU/h 37020 49372 49372 61757 74040 74040 92806 111231
kW 9.78 13.03 13.33 16.3 19.6 19.99 24.51 29.37
BTU/h 33369 44458 45495 55616 66875 68226 83628 100210
mbar 6.9 12.2 21.5 10.0 12.5 23 9.8 14.2
In.wg 2.8 4.9 8.6 4.0 5.0 9.2 3.9 5.7
%79.36 79.08 80.89 78.54 79.29 80.87 78.4 78.6
HERO 30 40 40 P 50 60 60 P 75 90
Main burner
Injector mm ø 3.0 3.0 2.1 3.5 3.7 2.5 4.4 4.4
Minimum Water Flow Rate
l/min 11.45 15.27 15.27 19.09 22.90 22.90 28.66 34.37
(galls/min) (2.51) (3.36) (3.36 (4.20) (5.04) (5.04) (6.30) (7.56)
Total Water Capacity
Litres 1.75 1.75 1.75 1.75 1.75 1.75 2.6 2.6
galls 0.385 0.385 0.385 0.385 0.385 0.385 0.572 0.572
Pressure loss
(mH2O) 0.18 0.32 0.32 0.48 0.7 0.7 0.8 1.1
@ 11°C _T
Static Head
Max metres 30 30 30 30 30 30 30 30
ft 100 100 100 100 100 100 100 100
Total weight
kg 44.2 44.2 44.2 44.2 44.2 44.2 57.35 57.35
lb 97.44 97.44 97.44 97.44 97.44 97.44 126.4 (126.4
Lift Weight
kg 36 36 36 36 36 36 48.3 48.3
lb 79.37 79.37 79.37 79.37 79.37 79.37 106.5 106.5
Electricity supply 230V 230V 230V 230V 230V 230V 230V 230V
50Hz 50Hz 0Hz 50Hz 50Hz 50Hz 50Hz 50Hz
Power consumption
watts 70 70 70 70 70 70 85 85
Internal Fuse
Amps 44444444
External Fuse
Amps 33333333
Water protection rating 22222222
* Gas consumption
1/min 17.23 22.98 13.5 28.75 34.46 9.0 43.2 51.77
ft
3
/hr (36.49) (48.69) (28.59) (60.91) (73.02) (19.1) (91.02) (109.7)
Rear Horizontal Flue System
Restrictor Diameter [RF] mm (Rear Exit) 27 30 30 35 37 37 38 40
Vertical Flue System
Restrictor Diameter [UF] mm 28 34 34 38 42 42 43 45
CO2 Value %6.0 6.0 7.0 6.5 7.0 7.7 7.0 7.0
* Gas consumption based on using Natural Gas with a C.V of 37.78 MJ/m3. **Using Propane with a CV of 95.65 MJ/m3 1
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2.6 AIR/FLUE DUCT SPECIFICATION
Variations upon these illustrations may be used providing that the
following rules are strictly obeyed:
a) Determine the type of flue applications and chose the appropriate
flue option requirements.
b) Ensure that the maximum allowable flue length of the flue
system doesn’t exceed:
HERO 30 - 75 HERO 90
a. 4000 mm vertical a. 3200 mm vertical
b. 3000 mm horizontal b. 2000 mm horizontal
c) The standard terminal must always be fitted horizontally. The
vertical terminal must always be used if a vertical roof outlet is
required.
d) The flue must only terminate in a horizontal or vertical
position. However 90° flue elbows may be used to drop the
height of the flue system by 500 mm.
e) For side outlet horizontal or vertical flue applications the flue
system must use either a flanged elbow or a flanged socket at
the entry/exit to the appliance.
f) All joints must be correctly made and secured in accordance
with the installation instructions.
Installation instructions for installing the appliance with a standard
flue (Fig 2) are included in the main text of these instructions
(section 4.5). Additional instructions for flue systems incorporating
vertical applications are given in the Halstead Flue Guide and
User Instructions as part of the flue kit.
The appliance is supplied complete with a standard flue terminal
which is suitable for a wall thickness up to 330mm. For wall
thicknesses in excess of 330mm use Rear Flue extension duct
(955081). Dimension as shown in Fig. 2a)
The following additional concentric flue kits are also available as
optional extras.
For side outlet horizontal (or raised) applications:
Top Outlet HORIZONTAL Connection Kit (955080) is
available as an optional extra. The kit comprises internal
connector elbow assembly, 90 degree flanged elbow, vertical flue
turret socket, telescopic flue outer and inner seal.
Extension duct (955065): each extension duct extends the
flue length by up-to 767 mm.
90° Extension Elbow (954011): This is an in-line elbow and
mechanically different from the flanged elbow, but has the same
equivalent length of 767 mm.
45° Extension Elbow (954010): Allows an additional bend in
the flue and has an equivalent length of 384 mm.
For vertical flue applications:
Top Outlet VERTICAL Connection kit ( 955082) is available
as an optional extra (For use with vertical flue kit 988378)
comprising internal connector elbow assembly and 425mm flue pipe.
Vertical Flue Kit (988378): For vertical roof terminal
applications. The kit comprises of vertical terminal, pitched roof
flashing, reducer sockets and vertical turret.
These optional flue kits may be used to produce an extensive
range of flue options.
1
2.5 OVERALL DIMENSIONS AND MINIMUM CLEARANCES
2
GAS COCK
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HERO A B C D E F G H I J K L M N O P Q R
30-60 200 6 6 100 300 325 275 432 105 353 249 285 122 197 107 400 540 104
75/90 200 6 6 100 300 405 355 432 105 353 249 365 162 277 107 400 540 104
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2SPECIFICATION FOR STANDARD AND SIDE HORIZONTAL FLUES
(Refer to section 2.6(b) for maximum allowable lengths)
3
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3SPECIFICATION FOR VERTICAL FLUES
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X3
X1 measured from centre line of rear outlet
to edge of boiler casing = 180 mm
X2 measured from centre line of rear outlet
to edge of boiler casing = 220 mm
X3 = 100 - 330 mm
‘X3’ can be extended to 820mm for Hero
30 - 75, but only extended to 630mm for
the Hero 90 with rear flue outlet extension
kit 955081
Note: For side horizontal flue application flue kit 955080 is required.
Note: For vertical flue application flue kit 955082 and 988378 is required.
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X1
X2
X1 = 365 - 820mm
X2 = 270 - 820mm
measured from the boiler outlet
centre line to the outside wall face
2(a) 2(b)
L
‘L’ measured from the top of
the boiler casing to the
underside of the air cowel.
Maximum allowable length of
‘L’ for:
Hero 32 - 75 = 4000mm
Hero 90 = 3200mm
Minimum allowable length of
‘L’ is 560mm ‘a‘ measured from the boiler outlet centre line
to the centre line of the extension elbow.
‘b‘measured from the centre line of the
extension elbow to the underside of the air
cowl.
Maximum allowable flue length of ‘a‘ + ‘b‘ =
Hero 30 - 75 2460mm, Hero 90 1666mm
a
b
3(a) 3(b)
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4
Important Note~ The HERO 30 IS NOT SUITABLE FOR SE-DUCT
APPLICATIONS.
SE-Ducts should conform to the requirements of BS 5440 part
1:2000 clause11.
The entry of the concentric air / flue duct should be as close to the
centre of the entry face of the SE-DUCT as possible. It is very
important that the concentric air / flue duct is not positioned in the
corner of the SE-DUCT.
The terminal flue duct kit supplied with the appliance is suitable for
installation in a SE-DUCT application. The Installation and
Servicing Instructions should be used for the complete installation
with the exception of the following:
a) The external wall flue sealing ring shall not be used.
b) Only horizontal flue installations are suitable for SE-DUCT
applications.
c) The minimum wall thickness flue length shall not be less
than 100mm.
d) The maximum wall thickness flue length shall not exceed
820mm. NOTE~ The HERO 90 is only suitable for a
maximum wall thickness flue length of 620mm.
e) It is important when installing the flue terminal duct into the
SE-DUCT that:
a) the air inlet duct shall protrude 10mm into the SE- DUCT
b) the terminal rain shield is inverted (up-side down).
(See Fig 4)
17
4FLUE SYSTEM APPLICATION
2.7 SE-DUCT APPLICATIONS
8EXPLODED DIAGRAM (for key no. references see spare parts catalogue)
5
Hero exploded
TERMINAL RAIN SHIELD
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Hero 1/03 TO PRINT 8/5/03 10:45 am Page 4

INSTALLATION REQUIREMENTS
3
The following limitations MUST be observed when siting the boiler:
a) The boiler 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 2.3 and
3.4).
b) This position MUST allow for a suitable flue system and
terminal position. The boiler 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 boiler is to be fitted in a timber framed building it
should be fitted in accordance with the British Gas
publication ‘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 a shower.
Attention is drawn to the requirements of the current
BS7671 (I.E.E Wiring Regulations, and in Scotland the
electrical provisions of the Building regulations applicable
in Scotland.
3.2 BOILER LOCATION
6FLUE 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
E From vertical drain pipes and 150mm 6in
soil pipes
FFrom internal or external corners 300mm 12in
G Above adjacent ground or
balcony level 300mm 12in
H From a surface facing the terminal 600mm 24in
I Facing terminals 1200mm 48in
J From opening (door/window) in 1200mm 48in
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
MAdjacent to opening 300mm 12in
NBelow carport 600mm 24in
OFrom adjacent wall 300mm 12in
PFrom adjacent opening window 1000mm 40in
QFrom another terminal 600mm 24in
R Minimum height 300mm 12in
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SPECIAL REQUIREMENTS FOR A
VERTICALLY BALANCED FLUE
3.1 STATUTORY REQUIREMENTS
5
300mm
Min
430mm
Min
The appliance is suitable only for installation in GB and IE and
should be installed in accordance with the rules in force.
In GB, the installation must be carried out by a CORGI Registered
Installer. 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 Fittings 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 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: BS5449, BS5546, BS5440:1, BS5440:2,
BS6798, BS6891, Institute of Gas Engineer document IGE/UP-7
and BS7074 (expansion vessel), and IS813 for IE.
IMPORTANT NOTE: Manufacturer’s instruction must NOT be
taken in any way as overriding statutory obligations.
GAS SAFETY (INSTALLATION AND USE) REGULATIONS (CURRENT EDITION)
Hero 1/03 TO PRINT 8/5/03 10:45 am Page 5

e) A compartment used to enclose the appliance MUST be designed
and constructed specifically for this purpose. An existing
cupboard, or compartment, may be used provided it is modified
accordingly. BS 6798 gives details of the essential features of
cupboard / compartment design, including airing cupboards.
f) Where installations will be in unusual locations, special
procedures may be necessary. BS 6798 gives detailed
guidance on this aspect.
Detailed recommendations for flue installations are given in BS 5440:
1 and :2. The following notes are for general guidance:
a) The boiler 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) If the terminal discharges into the pathway or passageway
check that combustion products will not cause nuisance and
that the terminal will not obstruct the passageway.
e) Where the lowest part of terminal is fitted less than 2m (78ins)
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 terminal guard (optional extra; Part- No.
951505)
f) The air inlet / flue outlet duct MUST NOT be closer than
25mm (1in) to combustible material.
g) In certain weather conditions the terminal may emit a plume
of steam. This is normal but positi
ons where this could cause a
nuisance should be avoided.
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 the appliance is installed.
b) If the boiler is to be installed in a wall cupboard permanent air
vents are required for cooling purposes in the cupboard at both
high and low levels. Both air vents must communicate with either
the same internal room / space or to be on the same wall to
external air. Each air vent communicating with another room or
internal space must have a minimum effective area of:
5625 mm2(Top and Bottom).
3.5 GAS SUPPLY
a) The Gas Supplier should be consulted at the installation planning
stage in order to establish the availability of an adequate supply
of gas.
b) The appliance is for use only on G 20 natural gas (HERO 40
and 60 are also available for LPG).
c) An existing service pipe MUST NOT be used without prior
consultation with the Gas Supplier.
d) A gas meter can only be connected by the Gas Supplier or
by their contractor.
e) An existing meter and / or pipework should be of sufficient size
to carry the maximum boiler input plus the demand of any other
installed appliances (gas consumption under Section 2) and in
accordance with BS 6891. A minimum of 22mm dia.
pipework is required to within 1metre of the
appliance gas cock.
f) The governor at the meter shall provide a constant working outlet
pressure of between 18 – 25 mbar ( 37 mbar for LPG) when all
appliances on the system are running. If the gas pressure is
outside that band the Gas Supplier has to be consulted.
g) The gas supply line must be purged. WARNING: Before
purging open all doors and windows, also extinguish any
cigarettes, pipes and any other naked lights.
h) The complete installation must be tested for gas soundness.
3.6 DATA LABEL
3.4 VENTILATION REQUIREMENTS
Heat output Burner
Pressure
kW Btu/h
Btu/h Btu/h
mbarin.wg
P=
11.72 40000 12.24.9
Heat input Q=
NETT GROSS
kW kW
13.0344458
14.47
49382
Hero 40
0086
L3NL2L1
3.7 ELECTRICAL SUPPLY
The mains supply required is 230 V – 50 Hz fused at 3 A, via a
fused double pole isolator with a contact separation of at least 3 mm
in both poles. This should be a permanent connection to the fixed
wiring of the system.
There must be only one common isolator for the boiler and its control
system, and it must be provide complete electrical isolation.
The power supply cable to the appliance should be at least 0.75
2mm (24 x 0.2 mm) PVC heat resistant, as specified in table 16 of
BS6500.
All external wiring to the boiler must be in accordance with the latest
I.E.E. Wiring Regulations, and any other local regulations which
apply.
The appliance must be earthed. .
In the event of any electrical fault after installation of the appliance,
preliminary electrical system checks must be carried out, i.e. Earth
Continuity, Short Circuit, Polarity and Resistance to earth.
All fuses must be ASTA approved to BS1362.
6
3.3 FLUE TERMINAL POSITION
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7
3.8 CENTRAL HEATING
WATER SYSTEMS
3.8.2
SEALED SYSTEMS
The boiler must not be used for direct hot water supply. The hot
water cylinder must be of the fully indirect (double feed) type, Self
priming (single feed) cylinders MUST NOT BE USED.
The boiler is supplied with 22mm copper tail ends for use with
copper tubing to BS2871 on fully pumped systems.
The boiler is NOT suitable for semi gravity systems.
Drain down devices must be fitted at the lowest points of the
system.
The boiler has a built-in frost protection function when in stand-by
mode. However, a system frost protection thermostat is
recommended if the boiler is installed in locations which are
vulnerable to freezing or away from the living area of the
building, e.g. garage.
The pump, with its isolation valves, should be fitted in the heating
flow pipework from the boiler. The flow rate should be set to
produce a temperature differential of 11°C between the flow and
return pipes at maximum heat output (Fig 7 – Heat exchanger
resistance curve).
All components of the central heating water system shall be
suitable for a working pressure of 3 bar and temperature of
110°C. Halstead boilers recommend that any plastic pipe used
should not terminate within 2 metres of the appliance. Care should
be taken to ensure that air locks are not present in the appliance
or pipe run.
The installation of a sealed system must comply with the
appropriate requirements of the current issue of BS4814, BS5449,
BS6759, BS6798 and BS7074 and recommendation R24.2 of the
Water Regulations Guide. For IE the current edition of I.S. 813.
A typical sealed water system is shown in Fig 9.
The following components and guidance have to be considered:
Safety Valve: It must comply with the requirements of BS759
and must be fitted to the flow pipe as near as possible to the
boiler with no restriction in the flow before the valve.
The valve should be so positioned so that any discharge of steam
or water cannot cause any harm to occupants or electrical
installations.
Pressure gauge: A pressure gauge with a range of 0 - 4 bar
must be fitted so that it is visible to the person filling or servicing
the system.
Expansion tank: The expansion tank must be connected close
to the inlet side of the pump and must suit the water volume of the
system.
The volume of water in the appliance is given in Section 2.
The system pressure should be not less than the static height, this
being the highest point in the system above the expansion tank.
Hot Water Cylinder: The cylinder should be of the indirect
type, suitable to operate at a total pressure 3 bar. It is also
recommended to use indirect cylinders with a heating coil
capacity of at least 30% above the maximum heat output of the
boiler. If the heating coil output is less than the boiler output it
makes the system less efficient and the recovery time gets poorer.
Filling Point: The system must be provided with a low level
filling point fitted with a shut off valve. The method filling the
system should comply with the Water Supply (Water Fittings)
Regulations – 1999 and the local Water Authority Regulations.
7HYDRAULIC FLOW GRAPH
0.0 10.0 20.0 30.0 40.0
1
0.8
0.6
0.4
0.2
0
7
5
-
9
0m
od
e
l
3
0
-
6
0
m
od
e
l
Water flow (l/min)
Water pressure loss (m)
Hydraulic resistance
3.8.1
OPEN VENTED SYSTEMS
A typical open vented system is shown in Fig 8. An open vent
pipe of 22 mm diameter must be fitted in the boiler flow and
terminated above the cold feed, discharging into the expansion
cistern.
The expansion cistern should not have a smaller capacity than
22 litres (5 gallons).
The cold feed pipe should be of 15 mm minimum diameter.
The expansion cistern should have a lid to prevent evaporation
loss and debris falling into.
The maximum height of the cistern to the boiler is 30 m (100 ft)
which is the equivalent of 3 bar static water pressure. The
minimum height is 1.2 m (47 in.) or 0.12 bars.
The combined heating and hot water pipes must be connected to
the 22 mm pipe tails. It is recommended to route the pipes
upwards for better venting and circulation. However, if the pipes
are routed downwards appropriate air vents at the highest point
of the boiler are required.
EXPANSION VESSEL REQUIREMENTS
Vessel charge and initial
system pressure
Total water content of system
using 8ltr. (1.54gal) capacity
expansion vessel
For systems having a larger
capacity multiply the total system capacity
in litres (gallons) by the factor to obtain the
total minimum expansion vessel capacity required litres (gallons)
bar 0.5 0.75 1.0 1.5
psi 7.3 11 14.5 21.8
96ltr 84ltr 73ltr 50ltr
21gal 18gal 16gal 11gal
0.0833 0.093 0.109 0.156
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8OPEN VENTED SYSTEM
9SEALED WATER SYSTEM
•
TO
DRAIN
OFF TAP
•
COLD
WATER
STORAGE
•
OPEN
VENT
•
INDIRECT
CYLINDER
•
AUTOMATIC
AIR VENT
•
STOP
VALV
•
DRAIN
•
LOCKSHIELD
VALVE •*MOTORISED
VALVE
•
ISOLATING
VALVES
•*3 WAY
MOTORISED
VALVE
•VALVED BY-PASS
LOOP WATER
CONTENT 7
LITRES MINIMUM
••PUMP
•
DRAIN
•
APPLIANCE
•
22mm
COPPER
•
15mm
COLD FEED
•
OPEN VENT
•
FEED AND
EXPANSION TANK •
•
MINIMUM
HEAD 1.2m
*Fit either two motorised
valves, or one 3 way
motorised valve
•
MAKE UP BOTTLE
Observe minimum
static head requirements
•
AUTOMATIC
AIR VENT
•
DRAIN
COCK
•
AIR
RELEASE
VALVE
•PUMP
•
FILL POINT
•PRESSURE
GAUGE
•
EXPANSION
VESSEL
•
SAFETY VALVE
•
BY-PASS WITH
LOCKSHIELD
VALVE WATER
CONTENT
7 LITRES MINIMUM
HOT WATER
CYLINDER
FLOW
HEATING
CIRCUIT
RETURN
•
22mm
COPPER
*MOTORISED
VALVE
•••
150mm
MAX.
•NON
RETURN VALVE
8
•
•
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9
Before installing the appliance ensure that the chosen location is
suitable (Section 3.2) and that the requirements for flue position
(Section 3.3) and minimum clearances (Section 2.4) are satisfied.
These minimum clearances are essential to provide access for
servicing.
a) Remove the wall plate from the boiler and use it as a template
to mark the wall in the desired position (Fig 10). Ensure that
the centre line is level.
b) The appliance is supplied ready assembled for rear outlet flue
installations. For all other flue options proceed to section 4.2.2
a) Mark the position of the flue exit hole if it is a new installation,
or hold the wall plate over the existing flue hole in the wall.
b) Mark the position of the six wall plate fixing holes. Drill the
holes using a 8mm masonry drill and fit the wall plugs
provided.
If outside access to flue is possible:
c) Cut a hole through the wall of at least 100mm (4 in) diameter
to accept the flue/air duct.
d) Accurately measure the wall thickness. The standard flue
terminal is suitable for a wall thickness up to 330mm. For a
wall thickness in excess of 330mm see section 2.6 for optional
extension duct kits.
e) Secure the wall mounting plate in position.
f) Fit the external sealing ring (grey) to the terminal as shown in
Fig 11. Measure from the inside of the external sealing ring,
the wall thickness + 30mm (Fig 11) and cut the air/flue
duct appropriately, ensuring that the cut is square and free of
burrs or debris.
g) Push the air/flue duct terminal through the wall and the wall
plate from the outside.
If outside access to flue is NOT possible (eg. second or higher
storey):
h) The drilled hole should be at least 130mm (5ins) diameter to
allow for insertion of a wall liner (available as an optional
extra).
i) Once the air/flue duct has been cut to length (as above), fit
the outer (grey) seal to the air/flue duct. Feed the air/flue duct
through the hole from inside of the room and ensure that the
seal is seated properly on the outer wall.
j) Ensure that a full 30mm protrudes from the inside wall, drill
through the air duct and fixing to the wall plate using the 3
self tapping screws provided. Ensure the terminal is fitted
horizontally and the correct way up with the rain shield at the
top (see Figure 11)
k) Slide the two 10mm thick silicon sponge flue seals over the
protruding 30mm of the air/flue duct.
l) Remove both casing panels from the boiler, (six screws). Fig 11
m) Lift the boiler into position; the rear bottom edge of the boiler
onto the bottom return edge of the wall plate. Push the top of
the appliance back ensuring that the fan outlet (Fig12)
correctly engages into the flue terminal. Secure the boiler
using the two ‘over centre’ clamps on the top rear of the
appliance. Fig 11.
The appliance and standard flue kit is supplied in a single
cardboard carton. In addition various optional flue kits are
available as described in Section 2.6.
Open the carton in accordance with the packaging details.
Remove the appliance, the terminal flue kit and other components
and check the contents against the following list:
Boiler Package:
Boiler (assembled, incl. wall plate) Installation and User
Benchmark Logbook. instructions.
Front panel door.
Plastic bag containing: 6 x fixing screws.
6 x wall plugs. Outer wall sealing ring (grey)
Outer wall sealing ring (white) 2 x self tapping screws
2 x hinges. 4 x screws.
Standard flue terminal.
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.
INSTALLING THE APPLIANCE
44.2
PREPARING THE WALL / APPLIANCE
4.1 UNPACKING THE APPLIANCE
16
10 WALL MOUNTING PLATE
4.2.1
REAR OUTLET FLUE
WALL FIXING HOLES
CENTRE LINE OF BOILER FLUE
WALL FIXING HOLES
50MM* CLEARANCE
ABOVE CASE FOR REAR FLUE
100 MM
CLEARANCE
BELOW CASE
*200mm clearance needed for
side flue application
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10
11 FITTING BOILER ONTO WALLBRACKET
17
12 FITTING THE ADAPTOR TUBE TO FAN
FLUE ADAPTOR FLUE TERMINAL
FAN
TO REMOVE
FRONT PANELS
UNSCREW THE
SIX SCREWS
13 FITTING THE FLUE RESTRICTOR
RESTRICTOR
•
•
FAN
ALUMINIUM
FAN OUTLET
•
•
••
•
•
•
••
•
••
SECURING
SCREWS
•
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11
4.2.2 TOP OUTLET FLUE
a) Having chosen the desired location for the boiler, for all top
outlet flue connections the appropriate (optional extra) kit(s) as
detailed in section 2.6 will be required.
b) The centre line for the flue system is slightly off-centre and
indicated on the wall plate with a notch. Draw a vertical line
from the notch as shown in Fig 14.
c) The Horizontal turret centre line for side outlet flues is
100mm above the wall plate, extend the line horizontally until
reaching the sidewall face, and then draw the position of the
air/flue duct hole. Cut a hole through the wall of at least
95mm (4 in) diameter to accept the flue/air duct. Note ~ if
access to the hole from outside is not possible the hole should
be at least 130mm (5 in) diameter to allow for insertion of the
wall liner (available as an optional extra).
d) For Vertical Flue Outlet, extend the line vertically until
reaching the ceiling/roof. The centre line of the flue from the
wall is 109 mm. Cut a hole through the ceiling / roof of at
least 100mm (4 in) diameter to accept the flue/air duct.
e) For Offset flue combinations and additional elbows
calculate from the dimensional details in section 2.5 And 2.6
Where the flue should be positioned. Make the necessary hole
in the wall / ceiling / roof.
f) Mark the position of the six wall plate fixing holes. Drill the
holes using a 8mm masonry drill and fit the wall plugs
provided.
g) Secure the wall mounting plate to the wall using the screws
provided.
4.3 AIR/FLUE DUCT
INSTALLATION (HORIZONTAL)
Note~ If the wall thickness is less than 800mm (31 in) the air/flue
duct may be fitted without access to the external wall providing
that the optional wall liner is used. (This is necessary to seal any
cavity and to allow the sealing ring to pass through from inside
but still open and provide an adequate seal). The wall liner has a
tube diameter of 130mm with a wall thickness of 0.8mm.
All flue duct lengths in excess of 1.5m (59 in) require
at least one support bracket in the middle of the duct.
(Available as optional extra Part No: 840516)
14 MARKING THE POSITION OF A
SIDE FLUE
17
15 MEASURING THE EXACT FLUE LENGTH
h) Remove both casing panels from the boiler, (6 screws).
i) Lift the boiler into position; the rear bottom edge of the boiler
locates onto the bottom return edge of the wall plate. Push the
top of the appliance back. Secure the boiler using the two
‘over centre’ clamps on the top rear of the appliance. (Fig 11)
j) Remove the fan assembly from the appliance (Refer to section
7.5).
k) Remove the appliance top outlet cover plate and relocate onto
the rear of the appliance to blank the rear outlet opening.
l) With the fan removed from the fan plate, reposition and
secure the fan so that the outlet is directed to the right hand
side of the appliance. Refit the fan assembly (Refer to section
7.5).
m) Fit and secure the 60mm Ø elbow (Fig 16) and all other
relevant boiler components relating to the flue kit(s) option
chosen (Full instructions included in the kits).
n) Ensure the flue duct restrictor ring is in accordance with the
the technical specifications in section 2. and is correctly fitted.
(Fig13)
•95mm
•
••
•
•
•
•
•
109mm
CORNER
OF WALL
WALL
MOUNTING
PLATE
POSITION OF
DUCT HOLE
•
•
TOTAL FLUE LENGTH FROM
FLUE OUTLET CENTRE TO
OUTSIDE WALL FACE:
=LENGTH L
L
WALL
NOTCH
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12
4.3.1 PREPARING THE
HORIZONTAL DUCT
a) Measure the required horizontal flue length as shown in
Fig 15.
b) Fit the external sealing ring (grey) to the terminal assembly
and assemble the air/flue ducts as shown in Fig 17.
c) Achieve the correct flue length using Fig 17 as a guide. Note
that the flue length is measured from the inside of the external
(grey) sealing ring. In most cases it will be possible to achieve
the required flue length without cutting the ducts. Where
necessary cut only the plain ends of extension ducts and
NEVER CUT THE SWAGED END. Ensure all cuts are square
and free from burrs and debris.
d) The horizontal terminal duct should never need to be cut as it
slides into both extension ducts and the standard duct. Ensure
at least a 50mm (2 in) overlap.
e) Assemble the flue using Fig 17 as a guide. It is important that
the steps are carried out in the order stated in Fig 17. Ensure
the internal sealing ring (white) is fitted to the system before
securing the ducts.
f) Prior to fitting the standard flue duct to the flanged elbow,
ensure all ‘O’-ring seals are correctly located and intact.
g) All ducts should be secured by drilling two 3.3mm diameter
holes and using the self-tapping screws supplied in the flue kit.
ENSURE THE HORIZONTAL TERMINAL IS FITTED
HORIZONTALLY AND THE CORRECT WAY UP WITH
THE RAINSHIELD AT THE TOP (SEE FIGURE 17)
17
16 FIT STRAIGHT AND ELBOW ADAPTOR
17
•
•
•
•
•
•
•
•
••
•
•
76mm
453mm
767mm
EXTENSION
17mm
INSIDE EDGE OF
EXTERNAL SEAL
IN POSITION ON
AIR DUCT
TOP
MAX. 319mm
MIN. OVERLAP
50mm (2in)
L•
•
ACHIEVING THE CORRECT LENGTH
AND ASSEMBLING THE FLUE
•
L
1SLIDE EXTERNAL
SEALING RING UP TO
FLUE TERMINAL
•
INTERNAL
SEALING
RING •
5 STANDARD
TERMINAL
Slide telescopic
section to achieve
length ‘L’
•
6 Drill and
screw
telescopic
overlap
•
3 EXTENSION
Push extension duct
(if required) over
standard duct,
engage fully.
Drill two 3·3mm dia.
holes and secure with
self-tapping screws
•
•
2 STANDARD DUCT
Push ducts fully over elbow
and drill two 3·3mm dia.
holes. Secure with self
tapping screws
4 Check terminal
is correctly aligned
•
•
60mm
ELBOW
AIR DEFLECTOR
PLATE
STRAIGHT
ADAPTOR •
•
•
FLUE HOOD
SECURING SCREWS
••
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4.3.2
(wall thickness up to 800mm (31 in) only – WALL LINER
REQUIRED)
a) Using Fig 18 as a step-by-step guide, insert the terminal end
of the flue system with external sealing ring (grey) through the
wall liner ensuring that the terminal is the correct way up.
b) Pull the flue system back towards the boiler to seat the external
sealing ring against the outside wall.
c) Ensure the necessary gasket and ‘O’-ring seal(s) are fitted to
the flanged elbow and secure to the boiler using the screws
provided (Fig 19).
d) Use the internal sealing ring (white) to make good the internal
wall face and check that the terminal is correctly fitted to the
outside wall.
e) Ensure all ducts are engaged correctly and secured with the
self-tapping screws provided in the kits.
INSTALLING THE HORIZONTAL
DUCT FROM INSIDE THE BUILDING 4.3.3
(Flue hole diameter 100mm – Wall liner not required)
a) Using Fig 19 as a step by step guide secure the turret elbow
to the boiler ensuring that the gasket and ‘O’-ring seal(s) are
correctly fitted.
b) From outside the building, insert the flue system with external
wall sealing ring (grey) fitted to the terminal through the wall.
Ensure the terminal is the correct way up.
c) From inside, fit the internal sealing ring (white) and pull the
flue system towards the boiler to seat the external sealing ring
on the outside wall.
d) Fit and secure the flue system to the turret elbow.
e) Make good the internal wall using the internal sealing ring,
and check that the terminal is correctly fitted to the outside
wall.
f) Ensure all ducts are engaged correctly and secured with the
self-tapping screws provided in the kits.
INSTALLING THE HORIZONTAL
DUCT FROM OUTSIDE THE BUILDING
18
••
•
2ALIGN ASSEMBLED FLUE
SYSTEM ELBOW TO
APPLIANCE AND SECURE
3SLIDE INTERNAL WALL
SEALING RING TO WALL TO
FORM A GOOD SEAL
1INSERT
ASSEMBLED FLUE
SYSTEM FROM
INSIDE THE
ROOM. EXTERNAL
WALL SEALING
RING OPENS
•
EXTERNAL WALL
SEALING RING
130mm Dia.
HOLE WITH
WALL LINER
INTERNAL WALL
SEALING RING •
TOP
•
FIBRE
SEAL FITTED
INSTALLING THE FLUE SYSTEM FROM
INSIDE THE ROOM
19
•
•
•
•
4REFIT AND SECURE
ELBOW TO AIR DUCT,
THEN TO APPLIANCE
3SLIDE INTERNAL
WALL SEALING RING
OVER AIRDUCT. PUSH
AGAINST THE WALL TO
FORM A GOOD SEAL
2INSERT FLUE
LENGTH FROM
OUTSIDE THE
ROOM. ENSURE
EXTERNAL WALL
SEALING RING
FORMS A GOOD
SEAL
•
EXTERNAL
WALL
SEALING
RING
100mm
Dia.HOLE
INTERNAL WALL
SEALING RING
TOP
•
FIBRE
SEAL FITTED
INSTALLING THE FLUE SYSTEM
FROM OUTSIDE THE BUILDING
•
1FIT ELBOW (AFTER
SETTING CORRECT
LENGTH AND
ALIGNMENT)
13
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14
4.3.4
a) The vertical flue terminal kit (Part No: 988378) contains full
assembly details.
b) Measure the vertical distance from the top of the appliance to
the roof line (Fig 20), and calculate the extension ducts
required.
c) Starting at the boiler, fit the vertical flue socket with gasket, the
standard duct and the required extensions. Ensure all ducts
are engaged correctly and secured using the self-tapping
screws provided in the kits.
d) Fit the vertical flue terminal adaptors.
e) Working from outside the building, fit the vertical flue terminal
ensuring correct engagement of the inner and outer ducts into
the flue adaptors.
f) Ensure that the roof flashing and sealing components are
secured to the roof.
PREPARING AND INSTALLING
THE VERTICAL DUCT
FLUE SYSTEM ASSEMBLY
AND DIMENSIONS
20
4.4
Connect the gas supply to the 1/2inch BSPF (located at the
bottom, right hand side of the appliance) isolation valve using a
suitable jointing compound. (Fig 21.)
GAS CONNECTION
4.5
a) Refer to section 3.8 for detailed information.
b) The appliance is supplied with two 22mm copper tail ends
suitable for compression or soldered fittings. Use extreme
care if soldering joints near to the appliance. If
boiler is located in tight space it is recommended to
remove the pipes from the boiler.
c) The system FLOW must be connected to the UPPER PIPE.
The system RETURN must be connected to the LOWER PIPE.
Note: It is recommended to connect Hero 90 to
28mm system pipes.
WATER CONNECTIONS
PIPEWORK
21
•BALANCED FLUE
ROOF TERMINAL
•ROOF LINE
•100/60mm TO
118/80mm DIA
ADAPTOR
•100/60mm DIA
EXTENSION DUCT
•100/60mm DIA
EXTENSION DUCT
•100/60mm DIA
EXTENSION DUCT
•STANDARD DUCT
•VERTICAL
SOCKET
•
425mm
•
•
50mm
767mm
767mm
•
•
•
•
•
•
767mm
30mm
1046mm
max
430mm
180mm
MAIN GAS
INLET
FLOW
PIPE
RETURN PIPE
•
•
•
•
Hero 1/03 TO PRINT 8/5/03 10:45 am Page 14

ELECTRICAL CONNECTIONS
22
4.6
This appliance must have a permanent mains supply and be
earthed.
Use standard colours for the supply:
Brown = Live (L)
Blue = Neutral (N)
Green/Yellow = Earth (E)
Note~ It is highly recommended that this appliance is connected
to an external control (timer / programmer) as part of the
Approved Code of Practice and guidance Safety and Good
Practice Guide 302.
a) Remove the mains supply plug from the appliance and connect
the electricity supply, the pump supply and appropriate
external controls (using suitable cable) as described below
and with reference to Fig 22.
b) Connect the mains supply Live to terminal L1.
c) Connect the pump Live to terminal L2.
d) Connect the external control (timer / programmer) Live to
terminal L3.
e) If not connecting an external control, it is necessary to link a
switched live between terminals L1 and L3.
f) Ensure all wires are clamped within the plug and that outer
insulation is not cut back beyond the clamp.
g) Ensure all Earth wires are longer than the Live and Neutral to
ensure it will be last to be disconnected should excessive strain
be put on cables.
WIRING INSTRUCTIONS
L1
L2
N
L3
If using 6-wire 28mm or 1” BSPV4043H on any circuit, white is not
needed and must be made electrically safe. The wiring shown is based
on the use of 10-way junction box (Honeywell Part No. 42002116-001).
Junction Box terminal 10 is switched live and terminal 9 is pump live.
CT200
ROOM
THERMOSTAT
L641A
CYLINDER
THERMOSTAT
V4043H
HEATING
VALVE
V4043H
HOT WATER
VALVE
230V mains
input
23
Room
thermostat
Cylinder
thermostat
Heating
valve
Hot water
valve
230V
mains input
A
B
C1
2
4
5
61
1
3
2
4
5
2
3
1
5
LN
8
5
9103 2 1 9 2 3 34567
ELN
891021
HW HTGN L
2
1
10
3
8
2
1
10
3
1
2
3
Not
used
Brown
Blue
Grey
Orange
Green/
yellow
Brown
Blue
Grey
Orange
Green/
yellow
CT200
L641A
V4043H
V4043H
Programmer
Or
Time
controller
Boiler Pump
N
E
L63
34NL
NL
Honeywell ST6998 1002
(Link L-5-3)ST 799A
2= Pump live
1=Switched live
L=Permanent live
ST6400 ST6300
ST6200
6432
21ENL LNE
1
Optional
T4360A
Frost thermostat
Opens heating
circuit only
T6360B Room thermostat
230V 50Hz
Pump Boiler
L2
L3
E
N
L1
Motor Motor
V4043H
Zone valve
heating
V4043H
Zone valve
DHW
T6360B
Room
thermostat
L641A
Cylinder
thermostat
213 1 C
Brown
Grey
Grey
Blue
Blue
Green Yellow Green
Yellow
Brown
Orange
Orange
Fully pumped 'S' Plan
FULLY PUMPED ‘S’ PLAN
15
PROGRAMMER
PUMP
MAINS
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16
The wiring plan shown is based on the use of 10-way junction box
(Honeywell Part No. 42002116-001).
Junction Box terminal 8 is switched live and terminal 9 is pump live.
CT200
ROOM
THERMOSTAT
L641A
CYLINDER
THERMOSTAT
V4043H
HEATING
VALVE
V4043H
HOT WATER
VALVE
T4360A
FROST
THERMOSTAT
Opens heating
circuit only-use
with programmers with spot switching
24
Room
thermostat
Cylinder
thermostat
Mid
position
valve
230V
mains input
A
B
C1
2
4
5
6
7
1
3
2
4
5
2LN
6
5
98321 923 34567
ELN
891021
HW
Off HTGHTG
On NL
2
7
8
3
1
2
3
White
Blue
Grey
Orange
Green/
yellow
CT200
T4360A
Frost
thermostat
Opens
heating
circuit only-use with
programmers with spot switching
1
3
1
5
L641A
V4073A
Programmer
Or
Time
controller
Boiler
V4073A
Mid
position
zone
valve
Pump
N
E
L
1
734
63
34 NL
NL
NLHoneywell ST6998 1002
(Link L-5-3)ST 799A
2= Pump live
1=Switched live
L=Permanent live
ST6400 ST6300
ST6200
7643
21ENL LNE
21
T6360B Room thermostat
230V 50Hz
Pump
Boiler L2
L3
E
N
L1
T6360B
Room
thermostat
L641A
Cylinder
thermostat
213 12
C
Fully pumped 'Y' Plan
Optional
Blue
Green/yellow
White
Grey
Orange
Pump live
Switched live
Permament live
FULLY PUMPED ‘Y’ PLAN
25
Internal
heater resistor
3mm air gap
Fuse
3A
Fuse 2.5A
Cylinder
thermostat
Room
thermostat
Frost
thermostat
Fused switched
isolator Boiler controls
or gas solenoid
Boiler pump
over run
N
N
L
L
L
L
C
C
C L
L
L
L
L
L
N
N
N
N
N L
N N
N
N
N
N
N/U
N/U
N
N/U
N/U
CH on
CH on
CH on
HW on
HW on
HW on
S/L
S/L
P/L
P/L
Boiler
HW Pump
CW Pump
Basic time clock
Programmer
CH/HW programmer
N/U
Earth terminals for
Controls,Boiler,Pumps,
Electrical mains supply.
N/U
N/U
a
n
d
D
e
m
a
a
a
n
d
D
e
m
a
a
a
n
d
ema
a
Dem
N
L
E
NO
NO
NO
UPP15-50 PUMP PLAN - WIRING
CENTRE CONNECTIONS
17
26 TYPICAL PROGRAMMER
Pump
Boiler
Terminals
Room
thermostat
L2
L3
E
N
L1
Pump live
Switched
live
Permament
live
Hot water
Earth
Neutral
230V fused 3 amp
Heating
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COMMISSIONING AND TESTING
5
5.1 OPEN VENTED WATER SYSTEMS
Checks to ensure electrical safety should be carried out by a
competent person.
The whole of the gas installation should be inspected, checked for
soundness and purged in accordance with the recommendations
of BS 6891.
Before carrying out the following procedures ensure that the main
inner seal casing panel is correctly fitted.
a) Fill and flush the system with all valves open. Refill the system
and check for water leakage. Vent the system including all
radiators and ensure the pump isolating valves, the bypass
and motorised valves (if fitted) are fully open.
b) Turn on the gas supply at the appliance service isolation
valve.
c) Slacken the burner pressure test point screw and connect a
suitable test pressure gauge. (see fig 27).
d) Ensure that all external controls (e.g timer, room thermostat
and cylinder thermostat where fitted) are turned to maximum.
e) Turn on the electrical supply and check the pump is working
and water is circulating through the system.
f) Turn the appliance control thermostat device fully clockwise to
the maximum setting. After a maximum of 10 seconds the
appliance should light. This is indicated by illumination of the
burner ‘on’ neon (see fig 28).
g) If the burner fails to light turn the boiler thermostat fully anti-
clockwise to the reset position and repeat (f).
h) Allow the appliance to operate for 10 minutes and check that
the burner pressure is in accordance with the performance
data detailed in section 2.2. If the burner pressure is incorrect,
check that an inlet pressure of between 18 - 25 mbar (7 – 10
in wg) is maintained at the gas meter when all appliances on
the system are operating.(For 40P and 60P inlet pressure of
37 mbar)
GAS VALVE
CONTROL BEZEL
BURNER ON
STAND BY
LOCK OUT
RESET
CONTROL BOX WITH VARIOUS NEON
LIGHTS
28
27
29
B
URNER
ON
L
OC
K
O
UT
RESET
BURNER PRESSURE
ADJUSTMENT
BURNER PRESSURE
FAN NEON
DEMAND NEON
FLAME FAILURE NEON
BURNER LIT NEON
OVERHEAT NEON
STANDBY NEON
•
•
•
•
•
•
•
•
17
TEMPERATURE
CONTROL KNOB
•
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18
5.2 SEALED WATER SYSTEMS
a) The whole of the system shall be thoroughly flushed with cold
water, filled, vented and pressurised to obtain 1.2 bar. Check
for leaks.
b) Carry out the procedures detailed in section 5.1 (b) to 5.1 (n).
c) Re-pressurise the system to the desired charge pressure.
d) Continue to perform procedures detailed in section 5.1 (o)
and (p).
FIT HINGED FRONT PANEL
i) Turn off the appliance and remove the test pressure gauge.
Tighten the burner pressure test screw and re-light the
appliance. Check for leaks around the screw using leak
detection fluid.
j) Ensure all external controls (e.g timer, room thermostat etc) are
set correctly. The boiler temperature control (Fig 28) can be set
between 64
o
c - 80
o
c.
k) Balance the system by adjusting the pump speed to obtain the
required flowrate (refer to section 3.8).
l) The appliance and the system should be allowed to operate in
order to obtain its maximum working temperature whilst
examining for water leaks.
m) Turn off the appliance and drain the heating system whilst still
hot.
n) Refill and vent to ensure all air is cleared from the system.
o) Refit the right hand side inner casing panel and secure using
the two screws.
p) Fit the appliance hinged front panel (if appropriate, Fig 30)
and adjust the appliance control bezel and all external
controls to the desired settings.
Note: If hinged front panel is not used it is required to block the
four hing fixing points using the screws provided.
30
5.3 USERS INSTRUCTRIONS
Upon completion of commissioning and testing the system, the
installer should draw 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 1996' (as amended).
a) Explain and demonstrate the lighting and shutdown
procedures.
b) Advise the householder on the efficient use of the system,
including the use and adjustment of all system controls for both
DHW and CH.
c) 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.
d) Explain the function of the boiler overheat thermostat, and
how to re-set it. Emphasise that if cut-out persists, the boiler
should be turned off and the installer or service engineer
consulted.
e) Stress the importance of an annual service by a registered
heating engineer.
f) The electrical mains supply to the appliance must remain ON
and the Main Switch must left either in the Hot Water or
Heating & Water mode for the frost protection circuit to
operate.
5.4 BOILER LOGBOOK
A logbook is supplied with this appliance to record installation
and commissioning details and 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.
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