hamworthy Ensbury LT 120 User guide

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Ensbury LT Boilers

Gas/Oil Fired Low Temperature Steel Boilers

70kW to 580kW

INSTALLATION, COMMISSIONING AND

SERVICING INSTRUCTIONS

IMPORTANT NOTE

THESE INSTRUCTIONS MUST BE READ

AND UNDERSTOOD BEFORE INSTALLING,

COMMISSIONING, OPERATING OR

SERVICING EQUIPMENT

Ensbury LT Boilers

Gas/Oil Fired Low Temperature Steel Boilers

70kW to 580kW

Installation, Commissioning

and Servicing Instructions

NATURAL GAS

LPG PROPANE

CLASS D (35 sec fuel oil)

Dual Fuel

THE ENSBURY LT BOILER IS INTENDED FOR USE AS A COMMERCIAL APPLIANCE.

THE GAS FIRED VARIANTS ARE FOR USE ON GROUP H NATURAL GAS

FAMILY) I2H & LPG PROPANE (3RD FAMILY) I

3P.

THE OIL FIRED VARIANTS ARE FOR USE ON CLASS D (35 sec FUEL OIL) or CLASS C2 - KEROSENE (28 sec OIL) OR BLENDED BIO- FUEL (RME or FAME). PLEASE ENSURE RELEVANT INFORMATION REQUIRED WITHIN THE DOCUMENT IS FOUND RELATING TO THE SPECIFIC FUEL TO BE FIRED, BEFORE OPERATING THE BOILER.

THIS BOILER COMPLIES WITH ALL RELEVANT EUROPEAN DIRECTIVES. EC TYPE CERTIFICATE No. EC-0461

PUBLICATION NO. 500001192 ISSUE ‘B’ October 2011

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CONTENTS PAGE

1.0 INTRODUCTION ...................................................................................................................... 4

2.0 SUPPLY AND DELIVERY ........................................................................................................ 5

3.0 GENERAL REQUIREMENTS .................................................................................................. 7

4.0 SITE LOCATION AND PREPARATION .................................................................................. 9

5.0 BOILER ASSEMBLY .............................................................................................................. 15

6.0 PRE-COMMISSIONING ........................................................................................................ 17

7.0 BOILER CHECKS PRIOR TO LIGHTING .............................................................................. 18

8.0 CONTROLS AND OPERATION............................................................................................. 21

9.0 FAULT FINDING .................................................................................................................... 24

10.0 SERVICING ............................................................................................................................ 24

11.0 BURNER SELECTION ........................................................................................................... 24

12.0 RECOMMENDED SPARES ................................................................................................... 30

APPENDIX A PERFORMANCE DATA ......................................................................................................... 32

APPENDIX B ELECTRICAL CONNECTIONS AND CONTROLS ................................................................ 34

APPENDIX C FLUE DATA ........................................................................................................................... 35

APPENDIX D VENTILATION ........................................................................................................................ 36

APPENDIX E WATER DATA ........................................................................................................................ 37

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FIGURES PAGE

Figure 1.1 3 pass boiler ............................................................................................................................. 4

Figure 2.1 General overview ....................................................................................................................... 5

Figure 2.2 Boiler package dimensions ......................................................................................................... 6

Figure 3.1 Boiler connections .................................................................................................................... 7

Figure 3.2 Boiler dimensions ..................................................................................................................... 7

Figure 3.3 Installation clearances ................................................................................................................ 8

Figure 3.4 With / without vibration dampers .............................................................................................. 8

Figure 3.5 Clearance dimensions ................................................................................................................ 8

Figure 4.6 Electrical connections ............................................................................................................... 14

Figure 5.1 Cable route .............................................................................................................................. 15

Figure 5.2 Sensor pocket .......................................................................................................................... 15

Figure 5.3 Opening for burner cables ...................................................................................................... 15

Figure 5.4 Sensor location ........................................................................................................................ 15

Figure 5.5 Wiring diagram ......................................................................................................................... 16

Figure 5.6 Turbulators ............................................................................................................................... 17

Figure 8.1 Control panel dimensions ......................................................................................................... 22

Figure 8.2 Control identification ................................................................................................................. 22

Figure 11.1 Burner matchings Nat Gas ..................................................................................................... 24

Figure 11.2 Burner matchings LPG ............................................................................................................. 25

Figure 11.3 Burner matchings oil ................................................................................................................. 26

Figure 11.4 Burner matchings dual fuel ....................................................................................................... 27

Figure 11.5 Oil nozzle selection ................................................................................................................... 28

Figure 11.6 Target combustion figures ........................................................................................................ 28

Figure 11.7 Combustion chamber and burner data ...................................................................................... 29

Figure 12.1 Spares identification ................................................................................................................. 30

Figure 12.2 Control panel spares ................................................................................................................ 30

Figure A1 Performance data Nat Gas ..................................................................................................... 31

Figure A2 Performance data LPG ............................................................................................................. 31

Figure A3 Performance data Class D Fuel Oil ........................................................................................... 32

Figure B1 Electrical connections ............................................................................................................... 33

Figure D1 Mechanical Ventilation ............................................................................................................. 35

Figure E 1 Water data .............................................................................................................................. 36

Figure E 2 Typical boiler installation .......................................................................................................... 37

Figure E 3 Cold feed and vent sizes ........................................................................................................... 38

Figure E 4 Variable Temperature Heating Circuit ........................................................................................ 38

Figure E 5 Constant and Variable Temperature Heating Circuits, with Domestic Hot Water ........................ 39

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1.0 INTRODUCTION

1.1 The Ensbury LT boiler range consists of 14

models, gas, oil or dual fuel fired, welded carbon steel boilers with outputs ranging from 70kW to 580kW. Refer to Technical Data in Appendix A for details on Natural gas, Propane and Oil firing. For applications firing blended Bio Fuel (RME or FAME), please refer to Hamworthy Heating Ltd for confirmation and guidance on the fuel specification.

Ensbury LT boilers are three pass, smoke tube boilers with combustion chamber and flue way using Low-Nox technology. The geometry of the combustion chamber and it’s relatively low volume, coupled with a patented flame escape system, allows for lower emission values and safe operation. The third pass is equipped with turbulators. Their turbulent action further increases the heat exchange and allows the system to work at low combustion gas temperatures, optimising efficiencies.

Ensbury LT boilers are suitable for minimum return temperatures down to 15°C and as a result, are suitable for direct connection to mixed temperature heating systems, delivering a minimum flow temperature of 60°C (50°C for oil firing) with no minimum flow rate requirements.

Ensbury LT boilers can be used individually, or in a multi-boiler configuration, and are suitable for use on either open-vented or sealed low temperature hot water heating systems. For hot water production they can be used in conjunction with calorifiers or indirect hot water cylinders.

Chesil pressurisation units are available from Hamworthy Heating Ltd for sealed systems.

1.2 Ensbury LT boilers are supplied unassembled

ready for on-site assembly.

The consignment consists of: a. Boiler body b. Casing panels c. Control panel d. Burner assembly

1.3 Ensbury LT boilers have an operating efficiency

of over 86% part load based on gross CV.

The heat exchanger is mounted within a steel frame, to which the casing and controls assemblies are fitted, leaving access for cleaning the appliance from the front. The heat exchanger assembly is provided with 100mm of glass fibre insulation The flow / return and water drain connections are located at the rear of the boiler. Refer to Section 8 for details.

The Ensbury LT boiler can be fitted with either a high/low or modulating burner for operation on

Natural Gas I2H (Second Family) or Propane I3p (Third Family) or a high/low or modulating burner for operation on Class D (35 second) fuel oil. In addition dual fuel option burners are available - see figures

11.1,2,3 & 4.

The boiler is supplied with a pre-wired control panel which contains:

Control fuse 6.3 AT Limit thermostat 110°C manual reset Control thermostat 35°C to 90°C High fire control thermostat 35°C to 90°C Burner on off switch Limit thermostat test button Overheat indicator lamp Safety interlock indicator lamp Burner lock out lamp Water temperature thermometer High and low fire hours run meters 5 Volt free contacts for remote signalling

The boiler is housed in a powder coated sheet steel casing which is supplied flat-packed for on-site assembly. Refer to Section 10 for casing assembly procedure.

1.3 All Ensbury LT boilers are factory

hydraulically tested ensuring suitability for use on systems with maximum working pressures of up to 4 bar (55 psi).

Figure 1.1 - 3 pass boiler

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2.0 SUPPLY AND DELIVERY

2.1 The boiler is normally supplied as a set of equipment comprising the following:

a. Boiler body - with loose turbulators b. Casing panels c. Control panel d. Burner assembly - incl nozzles, where

applicable

Remove all packing material and inspect the equipment to ensure that all parts are present and undamaged. If in any doubt, DO NOT USE THE EQUIPMENT. , contact Hamworthy Heating Ltd.

All packaging materials are to be disposed of appropriately.

Warranty

Full warranty assistance will be covered when the appliance is commissioned by Hamworthy Heating Ltd, see Terms & Conditions for full details.

Hamworthy Heating Ltd will not accept any liability resulting from damage due to tampering, improper use, handling, installation errors, operation and maintenance. It is important to check for damage upon receipt of product, which if found must be notified to Hamworthy Heating Ltd immediately.

230V

Contents: Item 1 - lid Item 2 - side panel (2off) Item 3 - rear panel Item 4 - front panel Item 5 - controls panel (packed inside combustion chamber) A bag containing fasteners, items 7,9,10 & 11

17736

Matched Burner

Figure 2.1 General Overview

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Delivery Verification

When taking delivery please ensure that you have received the correct number of boilers and ancillary parts to fulfil your order. The boiler and ancillary items are shipped on one pallet. The burner is shipped separately. The control panel and fasteners are located in the combustion chamber. The casing panels are secured to the top of the boiler body.

If any item is missing please contact our after sales service team. Please provide details of your order such as order number and contract number as well as a detailed description of the missing item.

Figure 2.2 - Boiler Packaged Dimensions

Model H mm W mm L mm Weight (kg)

Excl. Burner

70/ 90 120/ 145 165/ 190

225 260/ 300 335/ 370

440/ 510/ 580

1300 900 1200 284

1380 950 1300 394

1380 1050 1500 448

1460 1050 1500 522

1460 1200 1750 607

1550 1200 1750 739

1600 1200 2100 980

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3.0 SIZE AND SPACE REQUIREMENTS

3.1 The Ensbury LT boiler range has been designed to utilise available space, therefore it is important that the plantroom has sufficient ceiling height to allow for installation and connection to the flue system allowing for sufficient access at the rear of the boiler for pipework connections and at the front of the boiler for access to the burner and combustion chamber. See Figure 3.3

9 10

2 3

160

168

60 l 69

L A/C

1 Supply PN6 4 Fill/drain connection 1" 7 Boiler control panel 10 Safety valve connection 2 Return PN6 5 Cleaning door 8 Outlet for burner cables 3 Flue discharge 6 Inspection window 9 Acoustic hood - optional

Figure 3.1 - Boiler Connections

4 5

on supply pipe

0001 AX

LRP NT plus 1234567891011121314

Ensbury LT

Boiler length L mm 1141 1141 1283 1283 1483 1483 1483 1742 1742 1742 1742 1998 1998 1998 Boiler feet length l mm 844 844 986 986 1186 1186 1186 1445 1445 1445 1445 1701 1701 1701 Boiler width B mm 770 770 870 870 870 870 920 920 920 1000 1000 1068 1068 1068 Boiler feet insert width * b mm 640 640 740 740 740 740 790 790 790 870 870 938 938 938 Boiler height h mm 880 880 955 955 955 955 1040 1040 1040 1120 1120 1208 1208 1208 Burner flange centre d1 mm 470 470 500 500 500 500 550 550 550 590 590 624 624 624 Distance supply / return s mm 250 250 250 250 250 250 275 275 275 355 355 374 374 374 ø supply / return PN6 k DN 1 1/2" 1 1/2" 50 50 50 50 65 65 65 65 65 80 80 80 ø safety valve connection q DN 3/4" 3/4" 1" 1" 1" 1" 1 1/4" 1 1/4" 1 1/4" 1 1/4" 1 1/4" 1 1/2" 1 1/2" 1 1/2" Height supply connection n mm 757 757 835 835 835 835 900 900 900 978 978 1053 1053 1053 Height return connection r mm 757 757 835 835 835 835 933 933 933 993 993 1069 1069 1069

Length supply & return

Lenght supply & return fmm6060707070708080808080909090 Height flue d2 mm 520 520 550 550 550 550 600 600 600 640 640 674 674 674 Flue outside diameter e mm 150 150 150 150 150 150 200 200 200 200 200 250 250 250 Discharge height m mm 100 100 88 88 88 88 103 103 103 104 104 104 104 104 Distance vent valve - supply Height vent valve Short sound-proof. hood A mm 535 535 605 605 605 605 605 605 605 605 605 1030 1030 1030 Long sound-proof. hood C mm 725 725 890 890 890 890 890 890 890 890 890 1280 1280 1280

Weight empty G kg 283 284 393 394 447 448 522 606 607 731 733 973 976 980 Boiler water content V L 130 130 185 185 220 220 260 315 315 360 360 540 540 540 Boiler gas content VG m³ 0.15 0.15 0.22 0.22 0.26 0.26 0.32 0.38 0.38 0.46 0.46 0.61 0.61 0.61 Furnace diameter DF mm 342 342 415 415 415 415 463 463 463 508 508 530 530 530 Furnace length LF mm 768 768 910 910 1110 1110 1107 1366 1366 1366 1366 1618 1618 1618 Furnace volume VF L 70.6 70.6 123.1 123.1 150.1 150.1 186.4 230.0 230.0 276.9 276.9 357.0 357.0 357.0 * without insulation material

Figure 3.2 - Boiler Dimensions

s1 mm 69 69 99 99 99 99

n1 mm 830 830 905 905 905 905

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120

145 165 190 225 260 300 335 370 440 510 580

144 144 144 144 144 144 144 144 989 989 989 1069 1069 1157 1157 1157

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Figure 3.3 - Clearances

C T D

200

A It should be possible to

open the furnace door, including burner, by 90° (door opening can be either to the left or to the right; right opening can be changed to left opening at the time of installing the boiler).

At least 200 mm of free

space should be provided to the right and to the left of the boiler to install boiler casing.

B After installing the casing,

the boiler can be moved closer to the wall, but at least 60 mm away from it.

C The boiler cleaning hole

behind the boiler must be easily accessible and should be 600 mm away from the wall.

150

A-A

ca. 30

Figure 3.4 - with vibration dampers without vibration dampers Note: -

It is possible to mount the boiler on vibration dampers (available as option) to reduce noise transmission caused by vibrations. The dampers must be fitted prior to connecting the boiler to the system pipe work. To fit the dampers, some form of lifting device is required to locate the damper pads under the steel frame. Once the boiler is filled with water, it will sink 2-3mm into the damper pads.

Ensbury LT

Front and rear

Boiler block length

Boiler feet length

Boiler feet width

Vibration damper length

Model 70 90 120 145 165 190 225 260 300 335 370 440 510 580

D mm T mm

l mm

b mm

e mm

1220 1220 1310 1310 1310 1310 1310 1310 1310 1310 1310 1600 1600 1600

1015 1015 1155 1155 1355 1355 1335 1615 1615 1615 1615 1870 1870 1870

844 844 986 986 1186 1186 1186 1445 1445 1445 1445 1701 1701 1701

640 640 740 740 740 740 790 790 790 870 870 938 938 938

130 130 130 130 130 130 130 274 274 274 274 274 274 274

B-B

Figure 3.5 - Clearance dimensions

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4.0 SITE LOCATION AND PREPARATION

4.1 Site Location.

• The floor or plinth for the boiler(s), must be both flat and level to ensure correct

alignment of fittings and connections.

• The floor or plinth must be sufficiently strong to support the weight of the boiler(s)

(when full of water) and pipework.

• The floor or plinth must be fire proof in accordance with BS 6644.

• The plantroom must have sufficient space for installation of boilers, pipework, pumps

controls, flues, ventilation, access and servicing and other items of plant.

• Sufficient space must be provided around the boiler to allow the removal of the

burner assembly and opening of the burner door for servicing/replacement, and at the rear for installation of pipes, valves and flue.

4.2 Fuel Supply.

• Gas supply pipes must be in accordance with BS 6891 or IGE/UP/2

• Gas supply connections to the boiler must not be smaller than the connection on the

burner

• Gas installation must be soundness tested to BS 6891 or IGE/UP/1 & IGE/UP/1A.

• Gas installation must be purged to BS 6891 or IGE/UP/1 & IGE/UP/1A.

• Inlet gas pressure to boiler measured at the gas valve, nominal 20mbar (minimum

17.5mbar) dynamic - refer to Appendix A

• Where it is necessary to employ a gas pressure booster, the controls must include a low pressure cut-off switch at the booster inlet. It may be necessary to install a governor between the booster and gas train should the inlet pressure to the gas train exceed 50mbar - consult HHL for advice. The local gas region must be consulted before a gas pressure booster is fitted.

• Boiler house gas isolation valve must be clearly identified and installed close to the entrance / exit.

• The oil storage and supply system should be designed and installed in accordance with BS.5410 Part 2, as appropriate.

• Oil Supply Lines - The oil supply line(s) between storage tank and burner should be run in copper, steel or aluminium pipe. Galvanised pipes and fittings should not be used.

• The supply line should terminate adjacent to the burner with an isolating valve and metal bowl filter (with replaceable filter element). All burners are supplied with flexible oil pipes to make the final connection between the oil supply pipe and the burner.

• Liquid Bio Fuel quality MUST be in accordance with EN 1423 - consult Hamworthy

Heating Ltd prior to installation and operation and seek assurances from the fuel supplier.

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4.3 Flueing

• Flue termination, routing and construction must comply with the requirements of the

Clean Air Act 1956, BS 6644, BS 5440 and IGE/UP/10 where applicable.

• Ensbur y LT boilers are suitable for open flue (type B

) installation, drawing combustion

air from the plant room - see section 5.2

• Due to the low flue gas temperature, (~180/200°C), upon start-up, condensation will

occur in the flue, flue materials must be non-corrosive and utilise fully sealing joints.

• it is recommended that the flue system shall be adapted to its design diameter as

soon as possible, after leaving the boiler.

•

Flue systems must be self supporting, contain access for cleaning and contain a maintenance joint near the boiler outlet to allow for removal of the flue box during servicing.

• Ensbury LT boilers are suitable for installation in a balanced compartment in

accordance with the requirements of BS 6644. Consult Hamworthy Heating Technical Department for help or assistance if in doubt.

• Existing chimneys should be thoroughly swept before use and any register plates,

dampers, or restrictions removed.

• Chimneys should be lined w ith a non-porous acid-resistant material in accordance

with BS.5854, e.g. a flexible flue liner or similar British Gas Approved material. The internal diameter of the liner must not be less than the recommended flue size and the number of joints should be kept to a minimum.

• It is recommended that a draught stabiliser is fitted to the flue system where the suction

is likely to exceed 0.3mbar. The flue system should be designed to maintain atmospheric pressure or a slight suction at the boiler flue connection at all times (0.1 - 0.3mbar).

• Combustible materials in the vicinity of the boiler and flue shall not exceed 65 °C during

boiler operation. The flue shall not be closer than 50mm to any combustible material, except where it passes through such material with a non-combustible sleeve when the air gap may not be less than 25mm.

• When designing the flue system, care must be taken to ensure that any condensate

which may form within the system, can be safely drained to a suitable waste point and, that the flue material used is resistant to the corrosive effects of that condensate.

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4.4 Water Supply

• The Ensbury LT boiler is suitable for operating on open vented or sealed (pressurised) heating systems.

• Pressurised system to comply with BS 7074.

• Feed Water Quality - The condition of the feed water quality must be controlled:

Hardness ............................................................................. - <100mg CaCO3/l.

pH ............................................................................ 8.3 - 9.5

Phosphates (PO4) ............................................................................. - <30 mg/l

Chlorides (CI) ............................................................................. - <50 mg/l

Oxygen (O2) .............................................................................. - <0.1 mg/l

• It is strongly recommended that the system pipework is flushed at least twice before adding water treatment and before installing the boiler.

• In hard water areas (>100mg CaCO3/litre) precautions such as water treatment are strongly recommended to prevent the build up of sludge and scale.

• Leaks in the system pipework must be repaired to prevent dilution of water treatment.

• Maximum working water pressure is 4bar.

• Minimum water pressure 0.5 bar

• Care must be taken to ensure that oxygen does not enter the system via the open

feed tank, or system materials which allow the transmission of oxygen into the system. If this cannot be prevented, additional measures are necessary in the form of correctly used oxygen binding agents or chemicals.

If it is not possible, consideration must be given for separation of the boiler from the system using for example plate heat exchangers.

• A coarse filter and dirt separator in the return to the boiler(s) MUST be fitted.

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4.4 General Requirements

• Related Documents - Gas Safety (Installation and Use) Regulations 1994 – (As

amended). It is the law that all gas appliances are installed by competent persons, in accordance with the above regulations. Failure to do so, could lead to

prosecution. It is in your own interest, and that of safety, to comply with the law. The installation of the boiler MUST be in accordance with the relevant requirements of the Gas Safety Regulations, Building Regulations, I.E.E. Regulations and the bylaws of the local water undertaking. The installation should also be in accordance with any relevant requirements of the local gas region and local authority and the relevant recommendations of the following documents :-

• BS5410 - Code of practice for oil firing. Part 2: Installations of 44 kW and above

capacity for space heating, hot water and steam supply purposes.

• BS.6644 - Specification for installation of gas fired hot water boilers of rated inputs

60kW - 2MW.

• BS 6700 Design, installation, testing and maintenance of services supplying water

for domestic use.

• BS 6891 Installation of low pressure gas pipe work of up to 35mm (R 1 ¼) in

domestic premises.

• BS 6880 Part 1, 2 & 3 Code of practice for low temperature hot water heating

systems of output greater than 45kW.

• BS 7074 Application, selection and installation of expansion vessels and ancillary

equipment for sealed water systems. Part 2 Code of practice for low and medium

temperature hot water systems.

• BS 7671 Requirements for electrical installations. IEE Wiring Regulations.

Seventeenth edition.

• BSEN 806-2 Specification for installations inside buildings conveying water for

human consumption. Design.

• BSEN 12828 Heating systems in buildings, Design for water-based heating

systems.

• I. Gas E. Publications

IGE/UP/1 Soundness testing and purging of industrial and commercial gas installations. IGE/UP/1A Soundness testing and direct purging of small low pressure industrial and commercial natural gas installations. IGE/UP/2 Gas installation pipe work, boosters and compressors in industrial and commercial premises. IGE/UP/10 Installation of gas appliances in industrial and commercial premises, Part 1 flued appliances.

• Health and Safety Executive

Guidance note PM5 - Automatically controlled steam and hot water boilers.

• CIBSE Publications

CIBSE Guide B Heating, ventilating, air conditioning and refrigeration. CIBSE Guide H Building Control Systems CIBSE Guide Energy Efficiency in Buildings CIBSE Commissioning Code B: 2002

• Dept Environment, Scottish Development Dept & Welsh Office

Third edition of the 1956 Clean Air Act Memorandum

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4.6 Electrical Supply

WARNING! THIS APPLIANCE MUST BE EARTHED IN ACCORDANCE WITH IEE

REGULATIONS

• Boiler electrical supplies must not be switched by a time clock.

• Boilers are suitable for 230Volt, 50Hz supply. Burners are suitable for either

415Volt, 50Hz– 3 phase or 230Volt, 50Hz single phase supplies

• External fuses should be rated for 6.3 amps

• Wiring must be completed in heat resistant cable size 1.0mm² csa.

• Each boiler MUST have individual means of isolation.

• Electrical isolators must facilitate complete electrical isolation.

• Electrical isolators must have contact separation of minimum 3mm in all poles.

• Electrical isolators must be installed in readily accessible locations.

• Electrical supplies to boiler modules should only serve the boiler.

• Wiring of ancillary circuits must be connected to the control panel via the knock-

outs in the rear of the panel, using suitable cable glands.

• Any pump controlled by the boiler must be installed using an adequate contactor.

• Where twin head pumps are installed a changeover control (not HHL supplied)

external to the boiler is required.

• Where an external alarm is required, the control panel has 5 volt free contacts for remote signalling.

• Time clock control should be via the remote enable circuit (volt free).

• Any interlock circuit must be in series with the time control for each circuit. The

interlock circuit must never be used to isolate the boiler electrical supply.

ADDITIONAL INFORMATION REGARDING ELECTRICAL SUPPLIES IS GIVEN IN BS EN60335, Part 1.

NOTE: The appliance must be isolated from the electrical supply if electric arc welding is carried out on connecting pipework.

FOR TYPICAL SCHEMATIC DETAILS SEE FIGURE 4.6

FOR DETAILED WIRING INSTRUCTIONS SEE FIGURE 5.5

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Figure 4.6—Electrical connections

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5.0 BOILER ASSEMBLY

Important; - fit the casing to the boiler body, before

connecting the flue system. Site equipment and accessories

MUST NOT be

secured to the casing panels. Ancillary equipment wiring

MUST be connected to the

control panel using suitable cable glands at the rear of the panel.

5.1 Assembly

Referring to figure 2.1;

a) Place the lid (1) onto the pins (6) on the boiler body.

Carefully remove the knock-out using a suitable tool, to provide a route for the burner cables and capillaries to pass through the lid - see arrow figure 5.1..

b) Place the boiler control panel (5) on the lid and

carefully introduce the thermostat sensors through the lid opening and into the pockets. Fit a foam sleeve into the empty pockets when only 1 or 2 sensors are used. Secure in place using the spring clip - see figure 5.2 &

5.4 Secure the control panel to the lid using the

screws provided

(2) -see figure 5.1

c) Route the burner cable(s) through the knock-out

hole, running between the side panels and the boiler

Ø8 foam insert

Tri-Lobe Sleeve. Do not

fill with oil

Spring Clip

Figure 5.2 - Sensor pocket

Figure 5.1 - Cable route

body insulation. Feed and secure the cable(s) through the lower front opening ready for connection to the burner wiring.

d) Fasten cables (depending on burner) in the holes

provided in the opening using the cable gland provided (

9).

e) Fold the tongues at the bottom of the side panels

(

2) by 90° towards the front. These serve as stops

for the magnets of the front panel.

f) Snap the side plates (2) to the lid and fasten them

to boiler feet with washers (

10) and screws (11).

g) Fasten the rear panel (3) to the lid and side

panels with the screws provided (

7).

h) Snap the front panel (4) to the front part of the lid

and slide it downwards between the side plates until the magnets click to the stops

5.2 Turbulators

The function of the turbulators is to control the flue gas temperature through the boiler.

All smoke tubes in the third pass must be fitted with turbulators. These smoke tubes are those located on the outer diameter, which are open at the rear, discharging into the flue gas collector.

Read and follow the instructions on the boiler door labels and the markings on the tube plate.

Control Thermostats

Important: - the

turbulators must be introduced and fed through

High Limit Thermostat

the tube up to the stop created by the bent tail, otherwise, the door insulation may get

damaged.

Figure 5.3—opening for burner cables

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Figure 5.4 - Sensor location

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: -for modulating burners, it is necessary to disconnect, remove

Burner Control

and discard the 4 pin plug connecting the burner to the control panel

IMPORTANT Note

Figure 5.5– Boiler Control Panel Wiring Diagram – Hi/Lo and Modulating

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Ensbury LT

Number of turbulators Outer diameter Wire diameter Pitch Length

Model 70 90 120 145 165 190 225 260 300 335 370 440 510 580

9 11 11 11 11 15 15 15 19 19 25 25 25

MM 36

MM 6

600 600 800 600 800 800 400 600 600 800 400 600 1000

400

Figure 5.6 - Turbulator

5.3 Mounting the Burner

Before attempting to mount the burner, firstly ensure that the hole in the mounting plate is a clearance size for the burner blast tube diameter, and that the mounting stud pattern is correct for the burner flange. The hole in the mounting plate acts as a template for the boiler door insulation.

It is advisable to establish which direction the hinge will operate before fitting the burner. Adjust the hinge locknuts and handles to provide the necessary opening and check that the door seals correctly on the combustion chamber front before fitting the burner.

6.0 PRE-COMMISSIONING

The following pre-commissioning check must be carried out before the boiler is commissioned.

6.1 Gas Supply.

Fit the burner gasket over the studs and carefully mount the burner. Secure with the washers and nuts provided and tighten to form an effective seal on the gasket.

Open the boiler door and check that the burner blast tube is sitting correctly through the insulation, it is clean internally and the insulation is undamaged. There should be a small gap between the blast tube and the insulation on the door, this gap should be sealed with the insulation provided in the accessory pack, prior to firing the burner, in order to prevent hot gases from travelling backwards behind the insulation of the boiler door.

Ensure that gas installation pipework and meter has been soundness tested and purged to IGE/UP/1 or IGE/ UP/1A as appropriate. Test and purge certificates should be available for viewing.

6.2 Ventilation

Ensure that ventilation and air supply to plantroom is correct.

6.3 Pipework, Valves and Pump

Ensure that;

• Pipework and valve arrangement is installed to Hamworthy Heating recommendations.

• Circulating system is full of water, vented and pressurised appropriately.

• Circulation pump is fitted, working and interlocked where required.

• Pipework connections to boiler are fitted correctly.

• All necessary isolation valves are open.

• Heat load is available.

• Safety valves are correctly rated and located.

6.4 Flue

Ensure that;

• Flue system is correctly designed and installed to suit boilers.

• Flue passages to chimney are clear.

6.5 Electrical

Ensure that;

• Electrical connections are correct and isolatable.

• External controls are operational.

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7.0 BOILER CHECKS PRIOR TO LIGHTING

7.1 BEFORE

starting the boiler, check the following:

Check that fuel supply is turned off.

•

• Check that electrical supply is isolated.

• Check that electrical installation conforms to the requirements of these Instructions, the IEE Wiring

Regulations for electrical installations, and any other local Regulations which apply.

• Check boiler casings are undamaged Open boiler door to check that the flue turbulators are fitted.

• Check all thermostat bulbs are correctly inserted in the appropriate pockets.

• Check for water leaks and ensure that both boiler and heating system is full of water and properly vented.

• Check that all drain cocks are closed, and that all isolating valves in flow and return pipework are open.

• For OIL; check that tank/s have been filled and oil supply pipework between tank and burner has been

primed.

• For GAS; Check that gas meter is operational and has been checked by the local gas supplier. If a gas

booster has been installed, ensure that it has been commissioned in accordance with the manufacturer’s instructions.

Check that gas meter and supply pipework is of sufficient size to meet the input rating of the burner/boiler. Refer to Figure 2.1.

• Check that burner output is correct for size of boiler in question, referring to Figure B.1, and the

manufacturer's technical information supplied with the burner.

• For GAS; Check that gas meter is operational and has been checked by the local gas supplier.

• Check that gas meter and supply pipework is of sufficient size to meet the input rating of the burner/boiler.

Refer to Figure 2.1.

• Check that burner output is correct for size of boiler in question, referring to Figure B.1, and the

manufacturer's technical information supplied with the burner.

NOTE: - ALL FUELS. Refer to the commissioning procedure in the burner manufacturers literature, before firing the boiler.

Always adjust the fuel supply upwards from a low position to ensure that a fuel rich mixture is not achieved.

7.2 Commissioning Oil fired Boilers

• Check flexible oil lines are tightly jointed and are not twisted or kinked to form an obstruction.

• Check correct nozzles are fitted to burner (See Fig. B.4, B.5 & B.6) and that they are tight.

NOTE:- Some burners are despatched with a test nozzle/s fitted. In these cases, the correct nozzle/s is despatched in a separate package with the boiler and boiler.

• Check electrodes and ensure porcelain insulation is not cracked.

MUST be fitted to the burner before attempting to fire the

• Check electrodes are correctly positioned and gap is correctly set, as specified in the manufacturer's

technical information supplied with the burner.

• Check blast tube is correctly located and securely fastened in place.

• Check burner seats correctly onto burner mounting plate and is securely fastened in place.

• Set burner for the required fuel and air throughputs, as specified in the manufacturer's technical information

supplied with the burner.

• Fit a pressure gauge on burner oil pump to check pump pressure is correctly set.

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• Check that temperature limiter manual reset button is pushed in, and that boiler control thermostat and

control system are set to call for heat. Switch the boiler on and start the burner.

• The burner control will first operate the fan to pre-purge the boiler, then produce an ignition spark and finally

open the oil solenoid valve and the flame should ignite.

• Purge air from oil pump through pressure gauge port.

IF BURNER LOCKS OUT WAIT 45 SECONDS BEFORE PRESSING RESET BUTTON ON BURNER CONTROL BOX.

• With burner firing, check the atomising pressure on gauge and adjust as necessary using the pressure

regulator on burner oil pump. Refer to technical information supplied with burner.

• After allowing burner to reach stable firing conditions for approximately 15 minutes, carry out combustion

gas check.

Measure CO2, CO, smoke number, flue gas temperature and circulating water temperature rise across the boiler. The readings obtained should be as indicated in Figure B.7, target appliance readings.

Readings should be taken at both High and Low settings. A switch is provided on the burner to hold the burner on low fire.

• Switch off boiler. Remove oil pressure gauge and replace sealing plug complete with gasket.

• Restart boiler and cycle it on and off several times to ensure reliable burner ignition and boiler operation.

Check for oil, water and flue gas leakage. Tighten all access flue box and burner mounting bolts and nuts.

• Set boiler control thermostats to required setting, and check operation of heating control system.

• Fully familiarise the user with the boiler operating controls, the main component functions and the safety

features.

THESE INSTALLATION AND SERVICING INSTRUCTIONS SHOULD BE LEFT WITH THE USERS OF THE BOILER FOR THEIR FUTURE REFERENCE.

7.3 Commissioning Gas fired Boilers

• Check that ignition electrode and rectification probe are correctly positioned. Refer to manufacturer's

technical information supplied with the burner.

• Check that ignition electrode and rectification probe leads are connected.

• Check blast tube is correctly located, and securely fastened in place.

• Check burner seats correctly onto burner mounting plate and is securely fastened in place.

• With firing head separate from burner adjust air and gas settings, as specified in the manufacturer's

technical information supplied with the burner.

• Determine minimum burner gas pressure which corresponds to required burner output (boiler input), as

follows: - From the manufacturer's technical information (supplied with the burner) take burner pressure corresponding to required burner output.

Add combustion resistance (in mbar), given in Appendix A for the boiler in question, to obtain gas pressure value to be measured at burner test point.

• Open main isolating valve in gas supply to boiler. Check for leaks throughout gas train and pipework to

burner.

• Adjust gas supply governor to achieve at least 17.5 mbar (7.0 in.wg.) at inlet to boiler gas train. Ensure that

maximum pressure of gas train governor is not exceeded. If a gas booster is to be fitted, commission in accordance with the manufacturer’s instructions.

• Adjust start and main output gas rates as detailed in the manufacturer's technical information supplied with

the gas burner.

• Check that temperature limiter manual reset button is pushed in, and that boiler control thermostat and

control system are set to call for heat.

• Close main isolating valve in gas supply, switch the boiler on and start the burner. The burner control will

first operate the fan to pre-purge the boiler, then produce an ignition spark and attempt to ignite the burner. The flame should fail to ignite and the burner should go to lockout.

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•

Open main isolating valve in gas supply. If gas train has separate pilot gas line, open pilot gas isolating valve and close main gas isolating valve. Restart boiler/burner. The burner control will pre-purge, produce an ignition spark and ignite pilot flame. The main flame should fail to light, and burner will continue running on ignition flame only. The pilot gas rate can be checked and adjusted as detailed in the manufacturer's technical information supplied with the gas burner.

IF BURNER FAILS TO LIGHT, BOILER MUST BE PRE-PURGED BEFORE ATTEMPTING TO RESTART BURNER. IF BURNER REPEATEDLY FAILS TO LIGHT, A FULL INVESTIGATION TO FIND CAUSE SHOULD BE MADE.

• Stop boiler/burner. Open main gas isolating valve and restart burner. The burner will pre-purge, ignite pilot

flame and, after a short delay of several seconds, the main flame will light. Adjust the main gas rate as detailed in the manufacturer's technical information supplied with the gas burner.

• After allowing burner to reach stable firing conditions for approximately 15 minutes, carry out combustion

gas check.

Measure CO2, CO, flue gas temperature, and circulating water temperature rise across the boiler. The readings obtained for the appropriate gas should be as indicated in Figure B.7, target appliance readings. Readings should be taken at both High and Low settings. A switch is provided on the burner to hold the burner on low fire.

• After all other adjustments have been made, set burner air pressure switch as instructed in manufacturer's

technical information supplied with burner.

• Check gas pressure at burner head corresponds with value determined from burner manufacturer's

technical information - as detailed in (f) above.

• Check gas flow rate at meter. Ensure that all other appliances served by the meter are isolated whilst flow

rate is checked.

• Cycle boiler on and off several times to ensure reliable burner ignition and boiler operation. Check for gas,

water and flue gas leakage. Tighten all access, flue box and burner mounting bolts and nuts.

• Set boiler control thermostats to required setting, and check operation of heating control system.

• Fully familiarise the user with the boiler operating controls, the main component functions and the safety

features.

THESE INSTALLATION AND SERVICING INSTRUCTIONS SHOULD BE LEFT WITH THE USER OF THE BOILER FOR FUTURE REFERENCE.

7.4 External Controls

The external controls used in typical boiler installations, for both vented and unvented systems, are shown in Figure 3.3. If different systems or controls are to be used and there are any doubts as to the suitability, contact Hamworthy Heating Technical Department for advice.

7.5 Installation Noise

In order to avoid the possibility of noise from the installation, care should be taken to follow the manufacturer’s instructions. If acoustic insulation is added to the boiler, care must be taken not to impede combustion or ventilation air flow. If in doubt contact the manufacturer.

7.6 User Instructions

When the above is complete, the boiler owner or their representative should be made aware of the lighting and operating instructions. A practical demonstration should be given describing each functional step. This Installer's Guide and burner Operating Instructions and booster instructions (where fitted) should then be handed over and kept in a safe place for easy reference.

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8.0 CONTROLS AND OPERATION

8.1 Temperatures

An adjustable control thermostat is supplied with each boiler and should be set to operate within the range 3590°C for standard applications. For high / low applications a second control thermostat is supplied that should be set around 5°C lower than the main control thermostat. This will enable the burner to switch to a lower firing rate as the water temperature approaches the set point.

A temperature limiter, (hand reset limit thermostat) is also fitted to the boiler and must be set at 100°C.

If a modulating burner is fitted, an additional temperature sensor must be fitted in the flow pipework and wired back to the modulating control on the burner, following the manufacturer’s instructions. In this case, the high / low thermostat is superfluous and the appropriate 4 pin plug and flying lead can be disconnected from the boiler control panel. The thermostat sensor can be withdrawn from the pocket in the boiler flow pipe and the modulating temperature sensor can be inserted in the pocket. The 7 pin plug must remain connected in an unmodified condition in order to ensure that the temperature limiter remains in circuit. Set the boiler control thermostat to maximum. The boiler temperature control is carried out directly by the modulating controller on the burner to the temperature set point adjusted within the controller.

NOTE:- The minimum difference between control

thermostat and temperature limiter less than 10°C.

MUST NEVER be

Where the system is operating on a low temperature circuit care should be taken to ensure that the flow temperature set point does not fall below 60°C for gas or 50°C for oil.

8.2 Water Flow Controls

Due to the design of the Ensbury LT boiler, it is not necessary to maintain a minimum flow through the boiler, as the water content and thermal mass of the boiler allow for the control of residual heat, without the operation of the high limit thermostat. This allows for more flexibility and tolerance in heating system design and eliminates the requirement for primary circuit pumps or boiler shunt pumps, hence reducing energy consumption. However correctly sized circulating pumps and valves must be used in the system to provide the necessary performance.

8.3 Frost Protection

Consideration should be given to fitting a frost thermostat set at approximately 4°C.

8.4 Unvented Systems

See Figure E.3 for typical layout of a Unvented (Pressurised) Hot Water System. For system design refer to

BS 7074-2.

In order to correctly size a pressurisation unit for any heating system certain parameters are required :-

1) Static height of highest component in system

(metres).

2) System volume - if it is not known a general rule of

thumb of 10 litres/kW of installed boiler power can be used.

3) Maximum flow temperature (°C).

4) Maximum system hot working pressure, generally

given in bar g.

From the above information Hamworthy Heating can size the pressurisation unit and also the expansion vessel required. Care must be taken in sizing expansion vessels to ensure maximum acceptance factors are not exceeded. Normally manufacturers of vessels impose a limit of 0.5. This value must not be exceeded at any time during the operation of the boiler: this includes the over pressure condition should a safety valve lift.

Consideration should also be given to sizing of the safety valve/s in the system.

See BS EN ISO 4126-1, for information. See also BS 6880-1, for design considerations.

8.5 Multiple Boiler Control Schemes

For multiple boiler installations, Hamworthy Heating can supply a unique boiler management control system called the ‘Marshall HE’. This system comprises a wall mounted master control unit, which houses the main interface processor that will control up to 8 stages from a flow temperature sensor. Outside and room temperature sensors are optional. For further information, contact Hamworthy Heating for details.

8.6 Hours Run Meters

All Ensbury LT boilers are fitted as standard with hours run meters, to enable the duty at both low and high fire to be monitored. If the boiler is set up for Modulation, both counters will register the same cyclic duty.

8.7 Modulating Burners

The modulating burners from Riello are available as standard temperature control or optional 0-10v signal control.

IIMPORTANT; the specification must be identified

prior to delivery.

The temperature control version comes with a dedicated PT100 probe for insertion into the boiler flow pipe plus a bolt on control module, to influence the modulation rate of the burner as it approaches the desired set-point. To achieve this, the boiler control panel thermostats must be set to maximum.

The 0-10v signal version comes with a plug in module to convert a 0-10vdc control signal (input) to vary the position of the air damper servo motor and corresponding gas rate.

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500001192/B

8.8 Operation

1 - Thermometer provides the temperature within the boiler body

2 - Burner On/Off switch allows the burner to be switched, without affecting any other devices or functionality.

3 - Safety cut out test button allows the testing of the Limit thermostat. By pressing the button, the boiler temperature will increase and shut down on the Limit thermostat, switching off the burner and

Cable glands

registering an overheat alarm lamp.

9 - Limit thermostat is activated if the boiler temperature exceeds the setting. Once activated, the manual reset cannot function until the boiler temperature has dropped by approximately 20°C. Once this has occurred, insert a thin screw driver into the hole and depress the button. The lamp will switch off immediately.

Always investigate the cause of overheat.

Ensbury - boiler control panel

Width

Length

Height

B mm L mm H mm

325

530

129

3 4 5 6 7

8 9

Figure 8.2 - Control identification

1 - Thermometer - water temperature 2 - Burner On/Off switch 3 - Safety cut out test button 4 - Alarm lamp - boiler overheat 5 - Alarm lamp - external safety interlock 6 - Alarm lamp - burner lockout

Figure 8.1 - Control panel dimensions

7 - Remote reset for burner - optional 8 - Fuse 6.3AT 9 - Limit thermostat - manual reset 10 - Stage 1 Thermostat (On/Off) 11 - Stage 2 Thermostat (High/Low) 12 - Hours Run meter - High fire 13 - Hours Run meter - Low fire

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9.0 FAULT FINDING

9.1 Fault Finding

Fault finding on the burner control system is detailed in the burner manufacturers instructions. If the boiler still cannot be operated satisfactorily after following these instructions, consult Hamworthy Heating for assistance.

10.0 SERVICING

A qualified engineer registered for working on non domestic gas or oil appliances should check and ensure that the flue, its support and terminal, the ventilation to the boiler house, safety valve, drain, water filter if fitted, pressure gauge, etc.; are in a serviceable and working condition and still comply with the relevant standards and codes of practice - see

Section 3.1

The boiler should be serviced at regular intervals, not exceeding SIX months for oil fired boilers, or TWELVE months for gas fired boilers.

When carrying out boiler servicing always consider both your own safety and that of others. The use of protective equipment (e.g. eye protection, face mask, protective gloves, etc.) is recommended where necessary.

10.1 Initial Inspection

Operate boiler and check for any signs of

unsatisfactory operation, water leaks, gas leaks, oil leaks or unusual noise from burner oil pump or motor.

b. After allowing burner to reach stable firing

conditions for approximately 15 minutes, carry out combustion gas check. Measure CO

, CO, flue gas temperature, smoke

number (for oil) and water temperature rise across the boiler. The readings obtained should be noted for reference upon completion of the servicing procedure.

c. Measure either gas pressure at burner head, or

oil pressure at burner pump, as applicable, and check value is correct for size of boiler in question.

d. Check operation of both boiler and heating

system controls, then set boiler control thermostat to OFF. Allow the boiler/burner to cool.

10.2 Burner Service Procedure.

SWITCH OFF ELECTRICAL SUPPLY TO BOILER AT ISOLATOR AND SHUT OFF FUEL SUPPLY TO BOILER.

Clean and service the burner in accordance with the burner manufacturers instructions.

Disconnect electrical and fuel connections to

burner, as necessary.

b. Due to the design of the hinged door, it is

preferable to leave the burner attached to the door for servicing, so as not to interfere with the blast

tube seal between the burner and the door. If for any reason the burner has to be removed, take great care so as not to damage the burner door insulation.

c. Loosen and remove the two nuts securing the

burner door to the front of the boiler. Carefully hinge open the door with the burner attached to gain access to front of the combustion chamber and flue ways.

10.3 Boiler Service Procedure a

. With the burner door hinged open access to the burner head is provided and the burner should be cleaned and serviced in accordance with the burner manufacturers instructions.

. Carefully remove and store the turbulators. The

boiler combustion chamber and heat exchanger flueways are now accessible for cleaning with suitable brushes and a vacuum cleaner.

c. An access panel is provided in the rear flue

collector, to enable removal of any debris resultant from cleaning the heat exchanger tubes.

d. Carefully replace all turbulators as described in

section 5.2

e. Replace all access/cover plates, ensuring that all

gaskets and insulation panels are correctly fitted. Refit securing studs/nuts and tighten evenly.

f. Refit burner if removed—taking care to replace

the blast tube seal. Reconnect fuel and electrical supplies.

g. Turn on fuel supply and check soundness of fuel

supply pipework.

h. Check all flue joints for integrity. i. Check ventilation ducts/grilles to boiler room and

ensure they are clear.

j. Re-commission boiler as detailed in relevant

parts of

Section 7.0: COMMISSIONING & TESTING

11.0 BURNER SELECTION Only matched burners must be used with the

Ensbury LT boiler range. Refer to figures 11.1, 11.2,

11.3, & 11.4 . Burner maintenance must be carried out by a

competent person, in accordance with the manufacturer’s instructions

HAMWORTHY HEATING LTD

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500001192/B

FIGURE 11.7

BLAST TUBE

PENETRATION

REFER TO DIM. B

100

FIG 11.7

LENGTH –

REFER DIM. A

(mm) (mm) (mm)

DIAMETER

/hr

GAS RATE

(NETT)

MUST NOT OPERATE

MINIMUM HEAT INPUT

BELOW WHICH A BURNER

NOMINAL HEAT INPUTS/OUTPUTS DIMENSIONS

HIGH FIRE HEAT INPUT

HEAT

(kW)

/hr

GAS RATE

(NETT)

(kW) (kW)

OUTPUT

@ 1013mbar and 15

300 330 34.9 87 9.2 463 1366 100

335 368 39.0 87 9.2 508 1366 100

370 407 43.0 87 9.2 508 1366 100

440 483 51.2 100 10.6 530 1618 100

510 560 59.3 100 106 530 1618 100

580 637 67.4 100 10.6 530 1618 135

70 77 8.1 25 2.6 342 768 0

90 99 10.5 50 5.2 342 768

120 132 14.0 50 5.2 415 910 5

145 159 16.9 50 5.2 415 910 5

165 181 19.2 50 5.2 415 1110

190 209 22.1 60 6.3 415 1110 100

225 247 26.2 60 6.3 463 1110 100

260 286 30.2 60 6.3 463 1366 100



400V

SUPPLY

VOLTAGE

1Ph 230V - 3Ph

(in)

GAS

SIZE

TRAIN

BURNER DETAILS BOILER DETAILS COMBUSTION CHAMBER DETAILS

MAKE MODEL MODE

MODEL

BOILER



0.75

HI/LO

MODULATING

R40GS10D

R40GS10/M

RIELLO



0.75

HI/LO

MODULATING

R40GS20D

R40GS10/M

RIELLO



0.75

HI/LO

MODULATING

R40GS20D

R40GS20/M

RIELLO

120



1.0

0.75

HI/LO

MODULATING

R40GS20D

R40GS20/M

RIELLO

145



1.25

HI/LO

MODULATING

RS34 MZ

RS34/M MZ

RIELLO

REILLO

165

190



1.5

1.25

HI/LO

MODULATING

RS34 MZ

RS34/M MZ

RIELLO

REILLO

RIELLO

225

260

 

1.5

HI/LO

MODULATING

RS44 MZ

RS34/M MZ

REILLO

RS44 MZ

RS44/M MZ

RIELLO

300

335

MODULATING

RS44/M MZ

RIELLO

Figure 11.1 – Matched Burner Boiler Combinations (Natural Gas)

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ENSBURY



2.0

1.5

HI/LO

MODULATING

RS50

RS50M

RS44/M MZ

RIELLO

370

440

2.0

HI/LO

MODULATING

RS70

RS50M

RS70M

RIELLO

510

2.0

HI/LO

MODULATING

RS70

RS70M

RIELLO

580

Note To comply with the requirements of the Gas Appliance Directive, only the combinations listed below may be utilised for natural gas

applications. Heat input values quoted above are based on Natural Gas (G20) with a net CV of 34.06 MJ/m

500001192/B

DIM. B

REFER TO

BLAST TUBE

MINIMUM HEAT INPUT

FIGURE 11.7

PENETRATION

A FIG 11.7

LENGTH –

REFER DIM.

DIAMETER

BELOW WHICH A

OPERATE (NETT)

BURNER MUST NOT

(mm) (mm) (mm)

GAS RATE

(kW)

/hr m

100

BOILER DETAILS COMBUSTION CHAMBER DETAILS

NOMINAL HEAT INPUTS/OUTPUTS DIMENSIONS

HIGH FIRE HEAT INPUT

HEAT

SUPPLY VOLTAGE

GAS

TRAIN

(NETT)

OUTPUT

1Ph 230V - 3Ph 400V

(in)

SIZE

/hr

GAS RATE

70 79 3.2 25 1.0 342 768 0

(kW) (kW)

90 101 4.1 50 2.0 342 768

120 135 5.5 50 2.0 415 910 5

145 163 6.7 50 2.0 415 910 5

165 185 7.6 50 2.0 415 1110

190 213 8.7 60 2.5 415 1110 100

225 252 10.3 60 2.5 463 1110 100

260 292 11.9 60 2.5 463 1366 100



0.75

1.0

1.25

300 337 13.8 87 3.7 463 1366 100



1.25

335 376 15.4 87 3.7 508 1366 100

 

1.25

370 416 17.0 87 3.7 508 1366 100

 

1.25

440 494 20.2 100 4.0 530 1618 100

 

1.25

510 573 23.4 100 4.0 530 1618 100



1.25

580 651 26.6 100 4.0 530 1618 135



1.5

@ 1013mbar and 15

HI/LO

BURNER DETAILS

MODULATING

RS34MZ

R40GS10D

R40GS20D

RS34/M MZ

R40GS10/M

R40GS20/M

MAKE MODEL MODE

MODEL

BOILER

Figure 11.2 – Matched Burner Boiler Combinations (LPG Propane)

RIELLO

120

R40GS20/M

RIELLO

145

RS34/M MZ

RIELLO

REILLO

RIELLO

165

190

HAMWORTHY HEATING LTD

RS34MZ

RS34/M MZ

RIELLO

225

260

ENSBURY

HI/LO

MODULATING

RS34MZ

RS44MZ

RS34/M MZ

RIELLO

300

335

MODULATING

RS44/M MZ

RIELLO

HI/LO

MODULATING

RS44MZ

RS44/M MZ

RIELLO

370

440

HI/LO

MODULATING

RS70

RS70/M

RS44/M MZ

RIELLO

510

MODULATING

RS70/M

RIELLO

580

NOTE! To comply with the requirements of the Gas Appliance Directive, only the combinations listed below may be utilised for LPG applications.

Heat input values quoted above are based on Propane (G31) with a net CV of 88 MJ/m

500001192/B

FIGURE 11.7

BLAST TUBE

PENETRATION

REFER TO DIM. B

A FIG 11.7

LENGTH –

REFER DIM.

(mm) (mm) (mm)

DIAMETER

l/h

RATE

OIL FLOW

(NETT)

MUST NOT OPERATE

MINIMUM HEAT INPUT

BELOW WHICH A BURNER

(kW)

NOMINAL HEAT INPUTS/OUTPUTS DIMENSIONS

BURNER DETAILS BOILER DETAILS COMBUSTION CHAMBER DETAILS

(NETT)

HIGH FIRE HEAT INPUT

HEAT

OUTPUT

SUPPLY VOLTAGE

1Ph 230V - 3Ph 400V

RATE l/h

OIL FLOW

(kW) (kW)

300 341 34.6 133 13.5 463 1366 100

335 381 38.6 133 13.5 508 1366 100

370 421 42.7 133 13.5 508 1366 100

440 500 50.8 127 12.9 530 1618 100

510 580 58.8 127 12.9 530 1618 100

580 659 66.9 219 22.2 530 1618 135

70 80 8.1 38 3.7 342 768 0

90 102 10.4 61 6.1 342 768 5

120 136 13.8 61 6.1 415 910 5

145 165 16.7 61 6.1 415 910 5

165 188 19.0 83 8.4 415 1110 100

190 216 21.9 83 8.4 415 1110 100

225 256 26.0 83 8.4 463 1110 100

260 296 30.0 83 8.4 463 1366 100



HI/LO

MODULATING

RL28M

RL34 MZ

RL28M

RL34 MZ

RL44 MZ



HI/LO

MODULATING

RL38M

R44MZ



HI/LO

MODULATING

RL50

RL38M



HI/LO

MODULATING

RL50

RL50M



HI/LO

MODULATING

RL50

RL50M



HI/LO

MODULATING

RL70

RL70M

MAKE MODEL MODE

70 RIELLO R40G10I HI/LO

MODEL

BOILER

90 RIELLO R40G20D HI/LO

120 RIELLO R40G20D HI/LO

145 RIELLO R40G20D HI/LO

165 RIELLO

190 REILLO

225 RIELLO

260 RIELLO

300 RIELLO

Figure 11.3 – Matched Burner Boiler Combinations (Class D Oil)

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335 RIELLO

370 RIELLO

440 RIELLO

510 RIELLO

580 RIELLO

NOTE! Heat input values quoted above are based on class D Fuel Oil with a net CV of 35.47 MJ/litre @ 15

Operation on Class C2 Kerosene is achieved by setting the burner nozzle pressure to the appropriate level.

In the case of blended liquid Bio Fuel (RME or FAME), please consult with Hamworthy Heating Ltd, to

confirm the specification of the fuel, and the necessary settings to achieve optimum performance

The bio fuel MUST be manufactured in accordance with EN14213 .

500001192/B

FIGURE 11.7

BLAST TUBE

PENETRATION

REFER TO DIM. B

A FIG 11.7

LENGTH –

REFER DIM.

(mm) (mm) (mm)

DIAMETER

/hr

GAS RATE

(NETT)

MUST NOT OPERATE

MINIMUM HEAT INPUT

BELOW WHICH A BURNER

(kW)

@ 1013mbar and 15

NOMINAL HEAT INPUTS/OUTPUTS DIMENSIONS

BURNER DETAILS BOILER DETAILS COMBUSTION CHAMBER DETAILS

HIGH FIRE HEAT INPUT

HEAT

SUPPLY VOLTAGE

GAS

TRAIN

(NETT)

OUTPUT

1Ph 230V - 3Ph 400V

SIZE

/hr

GAS RATE

370 407 43.0 87 3.7 508 1366 100

440 483 51.2 100 4.0 530 1618 100

510 560 59.3 100 4.0 530 1618 135



2.0

580 637 67.4 100 4.0 530 1618 135



2.5

(kW) (kW)

165 181 19.2 50 2.0 415 1110 75

190 209 22.1 60 2.5 415 1110 75

225 247 26.2 60 2.5 463 1110 75

260 286 30.2 60 2.5 463 1366 75

300 330 34.9 87 3.7 463 1366 85

335 368 39.0 87 3.7 508 1366 85



(in)

1.25

1.5

2.0

1.5

MAKE MODEL MODE

120

145

165 RIELLO RLS28 HI/LO

190 REILLO RLS28 HI/LO

225 RIELLO RLS28 HI/LO

260 RIELLO RLS28 HI/L

300 RIELLO RLS38 HI/LO

335 RIELLO RLS38 HI/LO

370 RIELLO RLS50 HI/LO

440 RIELLO RLS70 HI/LO

510 RIELLO RLS70 HI/LO

MODEL

BOILER

Figure 11.4 – Matched Burner Boiler Combinations (Dual Fuel Nat Gas (modulating) /Oil (Hi/Lo))

HAMWORTHY HEATING LTD

ENSBURY

580 RIELLO RLS70 HI/LO

Note To comply with the requirements of the Gas Appliance Directive, only the combinations listed below may be utilised for natural gas

applications. Heat input values quoted above are based on Natural Gas (G20) with a net CV of 34.06 MJ/m

500001192/B

MAKE (type) MODEL MODE QUANTITY PART No. DESCRIPTION

70 HI/LO 1 532904014 1.5 x 60°

RIELLO MODULATING 1 532904077 20kg/hr

(Danfoss/ Berzano)

1 532904004 2.0 x 60° - (High)

MODULATING 1 532904077 20kg/hr

90 HI/LO 1 532904004 2.0 x 60°

120 HI/LO 1 532904005 2.5 x 60°

145 HI/LO 1 532904006 3.0 x 60°

165 HI/LO 1 532904004 2.0 x 60°- (Low)

1 532904056 1.75 x 60°- (High)

190 HI/LO 1 532904011 2.25 x 60° - (Low)

225 HI/LO 1 532904012 2.75 x 60° - (Low)

1 532904011 2.25 x 60° - (High)

MODULATING 1 532904078 30kg/hr

260 HI/LO 1 532904006 3.0 x 60° - (Low)

1 532904012 2.75 x 60° - (High)

MODULATING 1 532904078 30kg/hr

300 HI/LO 1 532904007 3.5 x 60° - (Low)

1 532904006 3.0 x 60° - (High)

MODULATING 1 532904078 30kg/hr

335 HI/LO 1 532904008 4.0 x 60° - (Low)

1 532904007 3.5 x 60° - (High)

MODULATING 1 532904118 40kg/hr

370 HI/LO 1 532904009 4.5 x 60° - (Low)

1 532904008 4.0 x 60° - (High)

MODULATING 1 532904118 40kg/hr

440 HI/LO 1 532904016 5.5 x 60° - (Low)

1 532904009 4.5 x 60° - (High)

MODULATING 1 532904103 50kg/hr

510 HI/LO 1 532904017 6.0 x 60° - (Low)

1 532904015 5.0 x 60° - (High)

MODULATING 1 532904103 50kg/hr

580 HI/LO 1 532904020 7.0 x 60° - (Low)

1 532904017 6.0 x 60° - ()High)

MODULATING 1 532904104 60kg/hr

Figure 11.5 – Oil Nozzle Selection

Fuel

Type

Natural Gas

G20

LPG

Propane

G31

Class D

Fuel

Oil

BOILER MODEL 70 90 120 145 165 190 225 260 300 335

CO2 (DRY) 9 - 10% CO Less than 100 ppm (air free)

Flue Gas Temp Rise OC 180 - 190 OC Temp Rise Across Boiler Less than 20OC

CO2 (DRY) 11 - 12% CO Less than 100 ppm (air free)

Flue Gas Temp Rise OC 180 - 190OC Temp Rise Across Boiler Less than 20OC

CO2 (DRY) 11 - 12% CO Less than 100 ppm (air free)

Flue Gas Temp Rise OC 180 - 190OC Temp Rise Across Boiler Less than 20OC

Smoke No Less than 1

370 440 510 580

Figure 11.6 – Target Appliance Readings. Note !

The above target values provide an approximate guide with which to attain nominal operation of the

appliance so as to satisfy the requirements of the Boiler Efficiency Directive

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ENSBURY

500001192/B

Figure 11.7 – Combustion Chamber and Burner Data - refer to figures 11.1, 11.2, 11.3 & 11.4

12.0 REPLACEMENT OF PARTS

There are a number of components listed below which can be replaced simply and quickly by following the given procedure. In each case the operation of each replaced component must be checked by carrying out the appropriate part of the commissioning procedure.

Section 11.0: COMMISSIONING & TESTING.

See

NOTE: Isolate all electrical supplies to the boiler and turn off the gas supply before removing controls cover and commencing any servicing or component exchange procedure.

Note :

to the burner manufacturers instructions.

12.1 Control and High/Low Thermostat(s)

Record the existing temperature setting of the thermostat for reference before removal.

NOTE: before attempting to hinge the fascia down,

the thermostat knobs must be pulled off and the temperature limiter (high limit) cover knob unscrewed and removed. Remove the upper front casing panel. Turn the two latches a quarter turn using a screwdriver or coin and lift off. The fascia can then be hinged downwards by unlatching the catch on the top right

-For replacement of burner components refer

hand using a screwdriver. Withdraw the appropriate thermostat bulb from the thermostat pocket and disconnect the electrical connections noting the terminal identifications. Remove the two screws securing the thermostat to its mounting bracket and withdraw the thermostat body whilst feeding the capillary through the hole in the control panel mounting plate. Fit the new thermostat and ensure the capillary is correctly located within the thermostat pocket. Close the fascia and run the boiler to check for correct operation. Set the thermostat to the previously noted setting.

12.2 Temperature Limiter (Limit Thermostat)

The temperature limiter replacement procedure follows that of the control thermostat with some minor differences as detailed below: With the plastic cover removed, unscrew the holding nut and carefully withdraw the thermostat body Prior to fitting the replacement thermostat, set to 100°C and check the operation of the device by carefully applying a heat source to the bulb.

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500001192/B

15. SPARE PARTS LIST

15.1 Boiler Spares

Figure 12.1 – Spares identification

ENSBURY LT model

No. Description HHL Part Number

Door insulation

moulding

Door outer seal

25 * 25 * L mm

Door outer seal

25 * 25 * L mm

Flue hood inspection

panel seal 10Ø * L mm

Turbulator

Number off

573410229 9 573410230 9 573410230

70 90 120 145 165 190 225 260 300 335 370 440 510 580

573410213 573410214 573410214 573410215 573410216 573410217

573401218 573410219 573410219 573410220 573410221 573410222

573410223 573410224 573410224 573410225 573410226 573410227

573410231

573410230

573410231

573410228

573410229

573410230

573410231

573410229

573410230

573410232

6 Thermostat channel 573410233

7 Brush 573410234

Nut for inspection

window G 3/4”

Inspection window

Ø 23 x 4

Inspection window

Seal Ø 24/20 x 1

11 Door key 573410238 573410239

573410235

573410236

573410237

Figure 12.2 Control Panel Spares - refer to figure 8.2 ITEM DESCRIPTION PART NO.

1 Thermometer ......................................................................................... 573410251

2 Burner On/Off switch ............................................................................. 573410241

3 & 7 Safety cut out test or remote reset button ............................................ 573410242

4,5 & 6 Alarm lamp (red) .................................................................................... 573410243

8. Fuse 6.3AT ............................................................................................ 573410245

9. Limit thermostat ..................................................................................... 573410247

10 & 11. Control thermostat ................................................................................. 573410249

12 Hours run meter ..................................................................................... 573410252

Fuse holder ........................................................................................... 573410244

Auxiliary relay 11 pole………………… ………………………………….573410248

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APPENDIX A - PERFORMANCE DATA

BOILER MODEL - ENSBURY LT 70 90 120 145 165 190 225 260 300 335 370 440 510 580 GENERAL DATA

BOILER INPUT(net) - maximum kW BOILER INPUT(gross) - maximum kW

77 99 132 159 181 209 247 286 330 368 407 483 560 637

85 110 146 177 201 232 274 317 366 409 451 537 622 707

BOILER OUTPUT - maximum kW BOILER OUTPUT - minimum kW FLUE DATA

NOMINAL FLUE DIA. mm COMBUSTION CHAMBER

RESISTANCE APPROX. FLUE GAS TEMP - (gross) °C

APPROX. FLUE GAS VOLUME @ NTP 15°C 9% CO

GAS DATA NOMINAL GAS INLET PRESSURE MAX. GAS INLET PRESSURE FOR BOOSTED SUPPLIES

GAS FLOW RATE m3/h GAS INLET CONNECTION

Figure A.1 – Performance and General Data Information (Natural Gas)

70 90 120 145 165 190 225 260 300 335 370 440 510 580

25 50 50 50 50 60 60 60 87 87 87 100 100 165

150

mbar

0.45 0.84 1.00 1.64 1.81 2.69 2.21 2.31 3.50 2.88 3.88 2.53 3.83 5.86

177 188 176 188 184 193 189 191 202 192 198 182 192 197

m3/h

92 123 154 215 241 271 301 361 430 461 523 615 707 830

mbar

8.1 10.5 14.0 16.9 19.2 22.1 26.2 30.2 34.9 39.0 43.0 51.2 59.3 67.4

3/4”

1-1/4” 1-1/2” 2” 1-1/2”

200 250

Note: For matched burner/boiler combinations, refer to Figures 11.1, 11.2 & 11.3

For combustion target figures, refer to Figure 11.5 For data relating to Propane and Oil refer to Appendices A2 & A3.

Net CV 34.02 MJ/m

- Gross CV 37.8 MJ/m

2”

BOILER MODEL - ENSBURY LT 70 90 120 145 165 190 225 260 300 335 370 440 510 580

GENERAL DATA

BOILER INPUT(net) - maximum kW BOILER INPUT(gross) - maximum kW BOILER OUTPUT - maximum kW BOILER OUTPUT - minimum kW

FLUE DATA COMBUSTION CHAMBER

RESISTANCE

APPROX. FLUE GAS TEMP - (gross) °C APPROX. FLUE GAS VOLUME

@ NTP 15°C 9% CO

GAS DATA NOMINAL GAS INLET PRESSURE mbar

GAS FLOW RATE m3/h GAS INLET CONNECTION

Figure A.2 – Performance and General Data Information (LPG Propane)

79 101 135 163 185 213 253 292 337 376 416 494 573 651

85 110 146 177 201 232 274 317 366 409 451 537 622 707

70 90 120 145 165 190 225 260 300 335 370 440 510 580

25 50 50 50 50 60 60 60 87 87 87 100 100 165

mbar

0.45 0.84 1.00 1.64 1.81 2.69 2.21 2.31 3.50 2.88 3.88 2.53 3.83 5.86

177 188 176 188 184 193 189 191 202 192 198 182 192 197

m3/h

92 123 154 215 241 271 301 361 430 461 523 615 707 830

3.2 4.1 5.5 6.7 7.6 8.7 10.3 11.9 13.8 15.4 17.0 20.2 23.4 26.6

3/4

”

1-1/4

”

1-1/2”

Note: For matched burner/boiler combinations, refer to Figures 11.1, 11.2, 11.3 & 11.4

For combustion target figures, refer to Figure 11.5

Net CV 88.0 MJ/m

- Gross CV 95.6 MJ/m

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BOILER MODEL - ENSBURY LT 70 90 120 145 165 190 225 260 300 335 370 440 510 580 GENERAL DATA

BOILER INPUT(net) - maximum kW BOILER INPUT(gross) - maximum kW BOILER OUTPUT - maximum kW BOILER OUTPUT - minimum kW

FLUE DATA COMBUSTION CHAMBER

RESISTANCE

80 102 136 165 188 216 256 296 341 381 421 500 580 659

85 110 146 177 201 232 274 317 366 409 451 537 622 707

70 90 120 145 165 190 225 260 300 335 370 440 510 580

38 61 61 61 83 83 83 83 133 133 133 127 127 219

mbar

0.45 0.84 1.00 1.64 1.81 2.69 2.21 2.31 3.50 2.88 3.88 2.53 3.83 5.86

APPROX. FLUE GAS TEMP - (gross) °C APPROX. FLUE GAS VOLUME

@ NTP 15°C 9% CO

GAS DATA OIL FLOW RATE L/h

Figure A.3 – Performance and General Data Information (Fuel Oil– class D 35 sec)

177 188 176 188 184 193 189 191 202 192 198 182 192 197

m3/h

92 123 154 215 241 271 301 361 430 461 523 615 707 830

8.1 10.4 13.8 16.7 19.0 21.9 26.0 30.0 34.6 38.6 42.7 50.8 58.8 66.9

Note: For matched burner/boiler combinations, refer to Figures 11.1, 11.2 & 11.3

For combustion target figures, refer to Figure 11.5

Net CV 42.66 MJ/ kg - Gross CV 45.36 MJ/kg

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500001192/B

APPENDIX B - ELECTRICAL CONNECTIONS AND CONTROLS B.1. Electrical Connections:

The following electrical connections are provided on each boiler panel.

• Supply: Live, Neutral and Earth. (230V ~50Hz) See Section 4.5 for details.

• Burner Lockout Alarm Signal Output

- volt free

• Burner Low Fire Signal Output - volt free

• Burner High Fire Signal Output - volt free

• Boiler Overheat Lockout Alarm Signal Output - volt free

• External Interlock Alarm Signal Output

- volt free

• Remote on/off Control Input

• Safety Interlock Circuit Input

• Emergency On/Off Button

Note: All wiring and electrical connections must be completed by a competent person in accordance with current

IEE regulations. Power supply required is 400V 50 Hz three phase, 4 wire. An isolator correctly fused should be sited close to the boiler. Refer to the burner instructions.

It should be noted the 3 phase supply should be wired direct to the burner and a separate 240V single phase supply derived from the burner should be wired to the panel.

Note: If a modulating burner is fitted to the boiler, some alterations to the wiring will be necessary. The burner

manufacturer’s instructions must be followed. It is likely that the second stage wiring (flying lead with four pin plug, hi/lo thermostat etc.) will become redundant and additional temperature sensor(s) will need to be added.

Warning: On no account must the route of the cables allow them to contact any unprotected or un-insulated sur-

face. For example; the burner mounting plate

Figure B.1 - Electrical connections

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APPENDIX C - FLUE DATA

C 1 General Requirments

Detailed recommendations for flue systems are given in

BS 6644, IGE/UP/10, "Flues for Commercial and Indus-

trial Gas-Fired Boilers and Air Heaters." The following notes are intended to give general guidance only.

The flue passages within the Ensbury LT operate under pressurised conditions and in order to eliminate any additional resistance, it is recommended that the flue system shall be adapted to its design diameter as soon as possible, after leaving the boiler. The boiler should be connected to a single flue system in the case of a single boiler, or a common flue header in the case of a multiple boiler installation. Flue systems must be self supporting, contain access for cleaning and contain a maintenance joint near the boiler outlet to allow for removal of the flue box during servicing. Ensbury LT boilers are suitable for installation in a balanced compartment in accordance with the requirements of

BS 6644. Consult Hamworthy Heat-

ing Technical Department for help or assistance if in doubt.

C.2 Design Waste Gas Volume and Temperature

It is recommended that the volume and temperature of the waste gases used for design of the flue system are as shown in Figures A1, A2 & A3

C.3 Materials

Materials used for the flue system must be mechanically robust, resistant to internal and external corrosion, noncombustible and durable under the conditions to which they are likely to be subjected. Consideration should be given to possible freezing of condense water traps and pipework. This must be avoided at all times. Insulate condense pipes if freezing temperatures are likely to be encountered. Chimneys should be lined with a non-porous acidresistant material in accordance with BS.5854, e.g. a flexible flue liner or similar British Gas Approved material. The internal diameter of the liner must not be less than the recommended flue size and the number of joints should be kept to a minimum. Any joint between the flexible liner and the flue pipe from the boiler should be made using a purpose made connector. Existing chimneys should be thoroughly swept before use and any register plates, dampers, or restrictions removed. If the boiler(s) is not connected to a chimney system, but is connected directly to outside by a standard stainless steel flue (either single or twin wall) it is particularly important to ensure that the point at which it exits the building is fully weatherproofed.

C.4 Suction

The flue system should be designed to maintain atmospheric pressure or a slight suction at the boiler flue connection at all times (0.1 - 0.3mbar). It is recommended that a draught stabiliser is fitted to the flue system where the suction is likely to exceed

0.3mbar.

C.5 Disconnection

Provisions should be made for disconnection of the flue pipe for servicing. It is advisable that bends are fitted with removable covers for inspection and cleaning as appropriate.

NOTE! The flue system must be self sup-

porting and not present a risk to people in or around the building. See

Section 13: SERVICING for further information.

C.6 Flue Discharge

The flue system must ensure safe and efficient operation of the boiler to which it is attached, protect the combustion process from wind effects and disperse the products of combustion to the external air. The flue must terminate in a freely exposed position and be situated so as to prevent the products of combustion entering any opening in a building. Consideration should be given to the fitting of a flue discharge terminal or grille to stop the ingress of birds etc. The flue system should be designed such that the flue terminates at least 1 metre above the roof surface, or above the level of any nearby structure which is within 2.5 metres of the flue.

C.7 Surface Temperatures

Combustible materials in the vicinity of the boiler and flue shall not exceed 65 °C during boiler operation. The flue shall not be closer than 50mm to any combustible material, except where it passes through such material with a non-combustible sleeve when the air gap may not be less than 25mm.

C.8 Flue System Location

The flue system must not be placed or fitted where there is undue risk of accidental damage to the flue pipe or undue danger to persons in the vicinity. flue

MUST be self supporting. Check that the flue and

NOTE! The

chimney are clear from any obstruction.

C.9 Condensate Discharge

When designing the flue system, care must be taken to ensure that any condensate which may form within the system, can be safely drained to a suitable waste point and, that the flue material used is resistant to the corrosive effects of that condensate.

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APPENDIX D - VENTILATION D1.1 Air Supply

Detailed recommendations for air supply are given in BS 6644 and BS5440 Pt 2. The following notes are intended to give general guidance. In all cases there must be provision for an adequate supply of air for both combustion and general ventilation, in addition to that required for any other appliance.

D1.2 Air Supply by Natural Ventilation - Open Flue applications

The boiler room must have, or be provided with, permanent air vents directly to the outside air, at high level and at low level. For an exposed boiler house, air vents should be fitted, preferably on all four sides, but at the least on two sides. Air vents should have negligible resistance and must not be sited in any position where they are likely to be easily blocked or flooded or in any position adjacent to an extraction system which is carrying flammable vapour. Grilles or louvres must be so designed that high velocity air streams do not occur within the space housing the boiler.

Boiler house ventilation

Low level (inlet) - 4cm² per kW of total rated input (Net) High level (output) - 2cm² per kW of total rated input (Net)

Compartment ventilation

Where the boiler is to be installed in a compartment, permanent high and low level ventilation is required which must communicate direct to outside, for cooling purposes.

Low level (inlet) - 10cm² per kW of total rated input (Net)

High level (output) - 5cm² per kW of total rated input (Net)

D1.3. Air Supply by Mechanical Ventilation

Air supplied to the boiler room by Mechanical means should be as follows:

1) Mechanical ventilation must be interlocked with the boilers to prevent operation in the event of ventilation fan failure

2) Mechanical inlet and mechanical extract can be utilised providing the design extraction rate does not exceed one third of the design inlet rate.

3) Mechanical extract ventilation with natural inlet ventilation

MUST NOT be used.

For Mechanical ventilation systems an automatic control should be provided to cut off the gas supply to the boiler, in the event of failure of air flow in either inlet or extract fans.

D 1.4. Boiler House Temperatures

The air supplied for boiler house ventilation shall be such that the maximum temperatures within the boiler house shall be as follows:

At floor level (or 100mm above floor level) = 25°C.

At mid-level (1.5m above floor level) = 32°C.

At ceiling level (or 100mm below ceiling level) = 40°C.

D 1.5. General Requirements

The air supply should be free from contamination such as building dust and insulation fibres from lagging. To avoid unnecessary cleaning and servicing of the boiler modules, the boilers should not be fired whilst building work is being undertaken. High and low level ventilation grilles shall be positioned as high and as low as practicably possible. Low level grilles should be located within 1 metre of the floor for Natural Gas and within 250mm of the floor for LPG. High level grilles should be positioned within 15% of the boiler room height from the ceiling. High and low level grilles shall communicate with the same room or space where compartment ventilation is used. Where grilles communicate directly with outside air, they shall be positioned on the same wall.

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Figure D1 Mechanical Ventilation Flow Rates

Flow rate per kW

total rated heat input (Net)

Inlet air

(Combustion

ventilation)

Difference between

Inlet & Extract air *

m³/h. m³/h.

Volume 2.6 1.35

Note * : Where the associated air extraction is also

by means of a fan, this shall be selected such as not to cause a negative pressure to develop in the boiler house and to maintain the difference between inlet and extract flow rates shown above. The calculated extract flow rate is the actual inlet flow rate minus the appropriate figure in the table above.

500001192/B

APPENDIX E - WATER DATA

Ensbury LT

Hydraulic resistance @ ∆T 10°C – mbar

Hydraulic resistance @ ∆T 20°C – mbar

Water flow rate maximum - m

Water flow rate minimum

Water pressure - maximum barg

Water pressure - minimum barg

Water flow temperature - maximum °C

Water flow temperature - minimum (gas) °C

Water flow temperature - minimum (oil) °C

Water return temperature - minimum °C

Water connections - flow & return (flange)

Safety valve connection

Drain connection

Water content - litres

Weight empty - without burner

Figure E.1 - Water data

70 90 120 145 165 190 225 260 300 335 370 440 510 580

43 71 40 58 76 100 48 66 87 108 132 81 108 140

11 18 10 15 19 25 12 17 22 27 33 20 27 35

6.0 7.7 10.3 12.3 14.2 16.3 19.3 22.3 25.8 28.8 31.8 37.8 43.8 49.8

No minimum flow rate

0.5

1 1/2”

3/4”

130 130 185 185 220 220 260 315 315 360 360 540 540 540

283 284 393 394 447 448 522 606 607 737 739 973 976 980

PN6 - DN50 PN6 - DN65 PN6 - DN80

1” 1-1/4” 1-1/2”

1”

E 1 Water circulation system

Recommendations for the water circulation system are given in

BS 6644 for gas fired boilers but the

same principals can be used for those using fuel oil. The following notes are of particular importance:-

E1.1 In a combined central heating and hot water

system, the hot water storage vessel must be of the indirect cylinder or calorifier type. The hot water storage vessel should be insulated preferably with not less than 75mm (3 in) thick mineral fibre, or its thermal equivalent.

E1.2 Circulating pipework not forming part of the

useful heating surface should be insulated to help prevent heat loss and possible freezing, particularly where pipes are run through roof spaces and ventilated cavities. Cisterns situated in areas, which may be exposed to freezing conditions, should also be insulated. Insulation exposed to the weather should be rendered waterproof.

E1.3 Each boiler has flanged flow and return

connections located on the rear section of the boiler.

E1.4 Multiple boilers should be connected by flow

and return headers. Headers should be connected to the system in a "reverse return" arrangement (the water flow in each header is in the same direction) to ensure equal flow in each boiler.

E1.5 E1.5 A coarse filter and dirt separator MUST be fitted in the return to both primary and secondary heat exchangers

E.2 Pressure Relief Valve (Safety Valve)

The most important single safety device fitted to a boiler is its safety valve and each boiler, or in the case of a multiple installation, each bank of boilers,

must be fitted with a pressure relief valve to

BSEN-

ISO 4126-1 and sized as shown in BS 6644.

Each Ensbury LT has a tapping on the flow pipe for the fitting of a safety valve to the boiler.

BS 6644 provides comprehensive information for

the selection and location of safety valves and attention is drawn to the higher capacity requirements of safety valves for pressurised hot water systems.

E.3 Open Vent and Cold Feed Pipe

(See BS 6644 for further information.)

Every boiler or group of boilers should have an open vent pipe and cold feed pipe installed between the boiler and the first water isolating valve. The minimum bore (mm) of these pipes per installation is shown in figure E.2.

The vent pipe must rise continually, must not be valved except by a design which when closed for maintenance the boiler is open to atmosphere. The pipe shall be protected against freezing where this might occur.

7.4 Altitude Gauge (Water Pressure Gauge)

Every boiler or group of boilers should be provided with a gauge complete with isolating valve. See Figure E.3 for typical position.

7.5 Thermometer

A thermometer complete with pocket should be fitted in the pipework to indicate water flow temperature. See Figure E.3 for typical position.

7.6 Drain Valves

Each boiler should have a drain valve fitted (not

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Figure E.2. Typical Boiler Installation

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H.H.L. supply), to drain the boiler only. An plugged Rc½ connection is provided for a drain valve on the flanged return connection.

The heating system in total should have drain valves as recommended by

BS 6644 which permit the

draining of the whole system, including the boiler and any hot water storage vessel. See Figure 3.3 for recommended positions.

7.7 Circulating Pump

One or more circulating pumps will be required to

Boiler Output Feed Vent

60kW - 150kW 25 32

150kW – 300kW 32 38

300kW – 600kW 38 50

Figure E.3 - Cold Feed and Vent Pipe Sizes (mm)

circulate water around the boilers and heating system. The pump should be sited to facilitate servicing.

7.9 Waterside Pressure Drop

The waterside hydraulic resistance (Pressure drop) is shown in Figure E1.

Figure E.4. Boiler Installation with Variable Temperature Heating Circuit

Compensation of the heating circuit must use an external mixing control and the minimum allowable flow temperature must be maintained.

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500001192/B

Figure E.5. Boiler Installation with Constant and Variable Temperature Heating Circuits With Domestic Hot Water

Compensation of the variable temperature heating circuit must use an external mixing control. Boiler operating temperatures should be set to meet the demands of the highest temperature circuit, but not set below the minimum boiler flow temperature. Where all circuits are required to operate below the minimum boiler flow temperature, then all circuits should incorporate mixing controls, to lower the temperature from the boiler before distribution to the circuit. Due to the thermal mass and water content of the boiler body, the temperature of the heating circuit return can be low. For minimum temperature details refer to figure E1

HAMWORTHY HEATING LTD

ENSBURY

500001192/B

USEFUL USER INFORMATION

INSTALLER SITE ADDRESS

BOILER TYPE BOILER SIZE(S) UNIT NO(S). SERIAL NO(S). FLUE

HAMWORTHY HEATING LTD

ENSBURY

500001192/B

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Telephone: 0845 450 2866 Fax: 01202 662522

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Hamworthy reserves the right to mak e changes and improvements which may necess itate alteration to the specification without prior no tice.

hamworthy Ensbury LT 120 User guide

Specifications and Main Features

Frequently Asked Questions

User Manual