Hamworthy GM6, GM7, GM8, GM9, GM10 Installation, Comissioning And Servicing Instructions

...
Wimborne GM Boilers
Gas/Oil Fired Cast Iron Sectional Boilers
Installation, Commissioning
and Servicing Instructions
NATURAL GAS
CLASS D (35 sec fuel oil)
IMPORTANT NOTE
THESE INSTRUCTIONS MUST BE READ
AND UNDERSTOOD BEFORE INSTALLING,
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COMMISSIONING, OPERATING OR
SERVICING EQUIPMENT
Technical Enquiries 01202 662527/662528
To supplement the detailed technical brochures, technical advice on the application and use of products in the Hamworthy Heating range is available from our technical team in Poole and our accredited agents.
Site Assembly 01202 662555
Hamworthy offer a service of site assembly for many of our products in instances where plant room area is restricted. Using our trained staff we offer a higher quality of build and assurance of a boiler built and tested by the manufacturer.
Commissioning 01202 662555
Commissioning of equipment by our own engineers, accredited agents or specialist sub – contractors will ensure the equipment is operating safely and efficiently.
Maintenance Agreements 01202 662555
Regular routine servicing of equipment by Hamworthy service engineers inspects the safety and integrity of the plant, reducing the risk of failure and improving performance and efficiency. Maintenance agreements enable our customers to plan and budget more efficiently.
Breakdown service, repair, replacement 01202 662555
Hamworthy provide a rapid response breakdown, repair or replacement service through head office at Poole and accred­ited agents throughout the UK.
Spare Parts 01202 662525
A comprehensive spare parts service is operated from our factory in Poole, providing replacement parts for both current and discontinued products. Delivery of parts and components is normally from stock within seven days. However, a next day delivery service is available for breakdowns and emergencies.
Customer Services
Wimborne GM Boilers
Gas/Oil Fired Cast Iron Sectional Boilers
Installation, Commissioning
and Servicing Instructions
NATURAL GAS
CLASS D (35 sec fuel oil)
THE WIMBORNE BOILER IS INTENDED FOR USE AS A COMMERCIAL APPLIANCE.
THE GAS FIRED VARIANTS ARE FOR USE ON GROUP H NATURAL
ND
GAS (2
FAMILY) I2H . THE OIL FIRED VARIANTS ARE FOR USE ON CLASS D (35 sec FUEL OIL). PLEASE ENSURE RELEVANT INFORMATION REQUIRED WITHIN DOCUMENT IS FOUND RELATING TO SPECIFIC FUEL TO BE FIRED BEFORE OPERATING THE BOILER.
PUBLICATION NO. 500001113 ISSUE 'D’ FEBRUARY 2005
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CONTENTS PAGE
1.0 INTRODUCTION 1
1.2 Packing Lists
1.3 Sectional Boilers
1.4 Hydraulic Testing
1.5 Boiler Set
1.6 COSHH Information
2.0 TECHNICAL DATA 4
3.0 GENERAL REQUIREMENTS 6
3.1 Related documents
3.2 Feed water quality
3.3 Adequate water flow
3.4 Time clock control
3.5 Minimum system water pressure
4.0 LOCATION 7
5.0 GAS/OIL SUPPLY 8
5.1 Gas Service pipes
5.2 Gas Meters
5.3 Gas supply pipes
5.4 Boosted Gas supplies
5.5 Boiler house Gas control valve
5.6 Oil supply
6.0 FLUE SYSTEM 9
6.1 General requirements
6.2 Design waste gas volume and temperature
6.3 Materials
6.4 Suction
6.5 Disconnection
6.6 Flue discharge
6.7 Surface temperature
6.8 Flue system location
6.9 Condensate discharge
7.0 AIR SUPPLY 10
7.1 Air supply by natural ventilation
7.2 Air supply by mechanical ventilation
8.0 WATER CIRCULATION SYSTEM 11
8.1 General
8.2 Pressure relief valve
8.3 Open vent and cold feed pipe
8.4 Altitude gauge (Water pressure gauge)
8.5 Thermometer
8.6 Drain valves
8.7 Circulating pump
8.8 Minimum water flow rates
8.9 Waterside pressure drop
8.10 Control schemes
8.11 Unvented systems
8.12 Modular boiler control schemes
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CONTENTS PAGE
9.0 ELECTRICAL SUPPLY 13
9.1 Site wiring
9.2 Indication signals and volt free contacts
10.0 BOILER ASSEMBLY AND INSTALLATION 17
10.1 Preparation
10.2 Dismantling
10.3 Assembly of boiler casing
10.4 Fitting the Burner
11.0 COMMISSIONING AND TESTING 22
11.1 Electrical installation
11.2 Gas installation
11.3 Water circulation system
11.4 Commissioning the boiler
11.5 External Controls
11.6 Installation noise
11.7 Users instructions
12.0 FAULT FINDING 26
13.0 SERVICING 26
13.1 Initial Inspection
13.2 Burner Service Procedure
13.3 Boiler Service Procedure
14.0 REPLACEMENT OF FAILED COMPONENTS 27
14.1 Control & High / Low Thermostat/s
14.2 Temperature Limiter (Limit Thermostat)
15.0 RECOMMENDED SPARES 29
FIGURES PAGE
Figure A Typical schematic boiler installation layout 3 Figure B Performance and General Information 4 Figure C Boiler Dimensions 5 Figure D Water Connections 5 Figure E Mechanical ventilation flow-rates 10 Figure F Cold feed and vent pipe sizes 11 Figure G Control panel wiring details (High/ Low Burner Control) 14 Figure H Composition of sections within heat exchanger 15 Figure I Composition of heat exchanger assembly—exploded view 15 Figure J Applying the sealant 16 Figure K Composition of Boiler casing assembly 23 Figure L Exploded view of boiler 28 Figure M Matched burner/ boiler combinations gas 33 Figure N Matched burner/ boiler combinations oil 34 Figure O.1 Riello Oil nozzle selection 35 Figure O.2 Nu-Way Oil nozzle selection 35 Figure P Combustion target Figures 36 Figure Q Combustion chamber and burner data 36
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1.0 INTRODUCTION
1.1 Boiler Range
The Wimborne GM boiler range consists of 10 gas or oil fired cast iron sectional boilers with outputs ranging from 420kW to 1130kW. Refer to Section
2.0 for details on Natural Gas and Oil firing.
Wimborne GM 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.
Portland pressurisation units are available from Hamworthy Heating Ltd for sealed systems.
1.2 Packing Lists
Accessory Pack
Burner Model - Accessory Pack Quantities
Description
Guide Ring
`O` Ring
7.3mm
Boiler Cement Pack
Silicon Sealant Tube
Primer ­Silicon
Tie Bolt M12 x 230
Self-Tapping Screw
6 7 8 9 10 11 12 13 14 15
10 12 14 16 18 20 22 24 26 28
10 12 14 16 18 20 22 24 26 28
5 5 6 7 8 9 10 10 11 11
9 11 12 13 15 16 18 19 20 21
2 2 2 3 3 3 3 3 4 4
20 24 28 32 36 40 44 48 52 56
70 110 110 110 130 130 130 150 150 150
GM
Description
Intermediate section
Front section
Rear section
Rear flue cover 250mm dia.
Rear flue cover 350mm dia.
Hinged front door
Casing pack
Insulation Pieces
Flue tube insert pack (22 off)
Control Panel Assembly.
Installers Guide 500001113
Accessory pack
Burner Model - Packing List Quantities
GM
6 7 8 9 10 11 12 13 14 15
4 5 6 7 8 9 10 11 12 13
1 1 1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 1 1 1
1 1 1 1 - - - - - -
- - - - 1 1 1 1 1 1
1 1 1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 1 1 1
1 1 1 1 1 1 1 1 1 1
1.3 Sectional Boilers
Wimborne GM sectional boilers are supplied ready
for on-site assembly.
The heat exchanger consists of:
a. A front section
b. Plain intermediate sections.
c. A rear section
These sections are connected to each other using nipples and ‘O’ rings and are held together by short lacing bolts.
The section to section flue gas seal is made by a mastic strip located in a groove around the inner and outer perimeter of each section.
The boilers are of the reverse flame design with the first two passes in the combustion chamber. The final pass uses turbulator tubes to increase the heat exchange area and thus enhance thermal efficiency in use.
Packing List
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Wimborne GM boilers have an operating efficiency of over 82% based on gross CV.
The heat exchanger assembly is completed by cast iron front and rear combustion chamber plates and access plates for the cleaning and inspection of the heat exchanger flue ways (rear only), all of which are internally lined with a fibre insulation board. The burner mounts onto the front plate which is hinged, suitable for left or right hand operation.
The flow and return water connections are located on top and to the rear of the boiler. Refer to Figure D for details.
The Wimborne GM boiler is available with high/low burners for operation on Class D (35 second) fuel oil, Natural Gas I
(Second Family).
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The boiler is supplied with a pre-wired control panel which contains:
a. A fuse
b. An illuminated mains on/off switch
c. Boiler control thermostats (On/Off) & (High/Low)
d. Boiler run, (High/Low) and lockout lamps.
e. A temperature limiter (overheat thermostat) to shut
down the boiler should the water temperature in the heat exchanger exceed 110
°
C - with manual reset.
f. An overheat lamp
g. A water temperature thermometer (temp. gauge)
h. Flying leads and plugs to connect to the burner
i. Volt free relay contacts for normal run, overheat
and lockout.
The boiler is housed in a powder coated sheet steel casing which is supplied flat-packed for on-site assembly. Refer to Section 10.3 for casing assembly procedure.
1.4 Hydraulic Testing
All Wimborne GM boiler sections are hydraulically tested, ensuring the Wimborne GM boiler is suitable for use on systems with maximum working pressures of up to 6 bar.
1.5 Boiler Set
The boiler is normally supplied as a set of equipment comprising the following:
a. Cast iron sections mounted on pallets
b. Accessory kit and tie rods
c. Casing panels
d. Insulation blankets
e. Flue tubes - 22 off
f. Control panel
g. Matched burner: fuel oil or gas
h. Burner mounting plate, drilled ready to accept
burner
i. Oil burner nozzle/s where applicable.
1.6 COSHH Information
Irritant
The boiler insulation blankets are non­carcinogenic, mineral wool fibre, and may cause inflammation and irritation on
immediate or repeated or prolonged contact with the skin or if inhaled. The use of suitable protective clothing is highly recommended. Avoid contact with skin and direct inhalation
1.6.1 In case of contact with the eyes, rinse immediately with plenty of water and seek medical advice.
1.6.2 In case of contact with skin, wash immediately with plenty of water.
1.6.3 In case of inhalation, retire to clean air supply and seek medical advice.
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Expansion pipe
Float
Mains water
valve
Feed & expansion tank
'Hamworthy Marshall HE‘ boiler Sequence Control System
'Marshall HE‘ Outside Air Temperature Sensor
'Marshall HE‘ Room Temperature Sensor
Heating load
Pressure &
Safety valve
Temperature gauges
P
Drain
Automatic
T
Air Vent
T
‘Marshall HE‘
T
Temperature
Water Flow
T
Sensor
Val ve
Feed pipe
'Hamworthy Marshall HE‘ boiler Sequence Control System
Module1Module2Module
T
Hamworthy Modular Boilers
Circulation pump
'Marshall HE‘ Outside Air Temperature Sensor
'Marshall HE‘ Room Temperature Sensor
Heating load
Pressure &
Safety valve
Temperature gauges
P
Drain
Circulation pump
alternative
(
Module
3
4
position
(
Val ve
Drain valve
VENTED SYSTEM
Automatic
T
Air Vent
T
‘Marshall HE‘ Water Flow
T
T
Temperature Sensor
Val ve
Double check valve
Te mp o ra r y
fill line
Automatic Air Vent
Mains water
Lockshield
valve
Module1Module2Module
Hamworthy Modular Boilers
T
Circulation pump
Circulation pump
alternative
(
Module
3
4
position
Val ve
Drain valve
(
Boiler Safety Shutdown Circuit Connection
Val ve
Drain valve
Expansion
vessel
Lockshield
valve
LockshieldLockshield
valvevalve
Hamworthy Pressurisation Unit
UN-VENTED SYSTEM
Figure A - Typical schematic boiler installation layout
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2.0 TECHNICAL DATA
GM6 GM7 GM8 GM9 GM10 GM11 GM12 GM13 GM14 GM15
WIMBORNE GM
No. OF SECTIONS
BOILER OUTPUT Gas - maximum kW 420 480 550 630 720 800 880 950 1020 1070
INPUT RATE - Natural Gas (G20) m3/h 49.3 56.3 64.6 73.9 84.5 93.9 103.3 111.5 119.7 125.6
BOILER OUTPUT Oil - maximum kW 440 510 580 670 760 840 925 1000 1070 1130
INPUT RATE - Oil (35SR1) l/h 49.7 57.6 65.5 75.7 85.9 94.9 104.5 113.0 120.9 127.7
FLUE DATA
NOMINAL FLUE DIA. mm 258 358
FLUE DRAUGHT REQUIRED AT BOILER OUTLET
COMBUSTION CHAMBER RESISTANCE
APPROX. FLUE GAS TEMP (net) °C 200 (Gas) ~ 220 (Oil)
APPROX. FLUE GAS VOLUME @ NTP (wet) - (m3/h)
GAS DATA
WATER DATA
CONNECTIONS - FLOW and RETURN
HYDRAULIC RESISTANCE @ 11°C mbar 28 40 50 65 82 110 130 145 150 180
HYDRAULIC RESISTANCE @ 20°C mbar 4.8 6.1 6.8 7.5 8.6 9.8 11 11.5 11.8 12.4
DESIGN FLOW RATE @ 11°C l/m 547 625 717 821 938 1042 1147 1238 1329 1394
MINIMUM FLOW RATE @ 20°C l/m 301 344 394 452 516 573 631 681 731 767 MAXIMUM WATER PRESSURE bar g. 6 MAXIMUM FLOW TEMPERATURE °C 90 MINIMUMRETURN TEMPERATURE °C 50
WATER CONTENT l 285 330 375 420 465 510 555 600 645 690
WEIGHT (FULL) WITHOUT BURNER kg. 1745 1985 2225 2455 2695 2935 3175 3470 3710 3955
DIMENSION - L (boiler overall length) mm 1255 1435 1615 1795 1975 2155 2335 2515 2695 2875
DIMENSION - B (base overall length) mm 970 1150 1330 1510 1690 1870 2050 2230 2410 2590
ELECTRICAL SUPPLY
Matched Burner - Nuway (Hi/Lo)
Gas Booster Required - **
Matched Burner - Riello (Hi/Lo) Gas RS50 RS70 RS70 RS100 RS100 RS100 RS100 RS100 RS130 RS130
Gas Booster Required - **
CLEARANCES - refer to Figure D.
Dimension A - side of boiler (see note#)
Dimension B - in front of boiler
Dimension C - rear of boiler
6 7 8 9 10 11 12 13 14 15
mbar 0.1 - 0.3 suction in.wg 0.04 - 0.12 suction
mbar 3.75 3.75 5.5 7.3 5.7 7 6 7.2 5.6 6.2
in.wg 1.5 1.5 2.2 2.9 2.2 2.8 2.4 2.8 2.2 2.4
Gas 650 776 882 1008 1146 1246 1392 1505 1610 1700
Oil 753 899 1022 1168 1328 1444 1613 1744 1866 1970
consult burner manufacturers manual
Flanged PN6 80 Flanged PN6 100 Flanged PN6 125
400V 3 ph 50 Hz (Burner) – 230V 1 ph 50 Hz (Boiler Panel)
XGN 1000
NOL30
25T
Gas
Oil
XGN650 XGN650
NOL
25T
NOL
25T
Oil RL50 RL50 RL70 RL70 RL100 RL100 RL100 RL130 RL130 RL130
Riello
670 930 930 930 930 930 930 930 930 930
Nuway
Nuway
823 975 975 1275 1275 1275 1275 1275 1275 1275
Riello
1080 1340 1340 1340 1340 1340 1340 1340 1340 1340
1233 1385 1385 1683 1683 1683 1683 1683 1683 1683
XGN
BG 700 BG 700 BG 700 BG 700
1000
NOL30
NOL50
25T
28T
1000 - all models
XGN
NOL50
** ** **
34T
NOL50
NOL50
34T
34T
** ** ** **
2100
NOL50
34T
XGN 2100
NOL50
34T
Figure B - Performance and general information
Note:- For matched burner/boiler combinations refer to Figure M.
For combustion target figures, refer to Figure O. # if boilers are to be installed adjacent to each other, the minimum spacing can be reduced to 200mm, provided that the doors hinge in opposite directions.
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200
205
Flow connection(s)
195
C
B
1405
1070
100
Clean out covers
REAR VIEW SIDE VIEW FRONT VIEW
B
L
120 110
258
A
358
690
Return connection
Figure C - Boiler dimensions
Drain R
A
¾
4-7 sections
8-11 sections
12-15 sections
12-15 sections (alternative)
Figure D - water connections
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3.0 GENERAL REQUIREMENTS
3.1 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 install appliances correctly could lead to prosecution.
It is in your own interest, and that of safety, to ensure that this law is complied with.
The installation of the boiler MUST be in accordance with the relevant requirements of the Gas Safety Regulations, Building Regulations, Fire 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 :-
British Standards
BS 5410 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 5854 Code of practise for flues and flue structures in buildings. See paragraph 5 (3.6).
BS 6644 Specification for installation of gas fired hot water boilers of rated inputs between 60kW & 2MW.
BS 6700 Design, Installation, testing and maintenance of services supplying water for domestic use.
BS 6880 Code of practice for low temperature hot water heating systems of output greater than 45kW.
Part 1 Fundamentals & design considerations. Part 2 Selection of equipment. Part 3 Installation, commissioning and
maintenance.
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 CP342 Code of practice for centralised hot water supply.
Part 2 Buildings other than individual dwellings.
I. Gas. E. Publications
IGE/UP/1 Soundness testing and purging of
industrial and commercial gas I installations.
IGE/UP/1A Soundness testing and direct purging of small low pressure industrial and commercial natural gas installations.
IGE/UP/2 Gas installation pipework, boosters and compressors in industrial and commercial premises.
IGE/UP/10 Installation of gas appliances in industrial and commercial premises Pt 1 flued appliances.
Health and Safety Executive
Guidance note PM5 Automatically controlled steam
and hot water boilers.
CIBSE Publications
"CIBSE Guide"
It is impractical in this document to specify all relevant information, but the following extracts from the above references are emphasised since failure to comply with these requirements will almost certainly result in an unsatisfactory installation.
3.2 Feed Water Quality
If the boiler feed water has a high degree of hardness, it is recommended that the water be treated to prevent precipitation of scale or sludge in the boiler water passageways. Details of additives can be obtained from any reliable manufacturer of water treatment products or the local water authority.
It should be noted however, that even if the boiler water is of average hardness, not requiring treatment, subsequent draining of the system for repair or constant make-up water due to an undetected leak will cause additional deposits and gradual build-up of scale. It is essential therefore, that leaks are attended to promptly and draining is kept to an absolute minimum.
It is recommended that the system be flushed out at least twice before any water treatment is added. If any doubt exists regarding the internal cleanliness of an old system, consideration should be given to the fitting of a coarse filter in the return pipework to the boiler/s.
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3.3 Adequate Water Flow
Care should be taken in the initial design and layout having due regard for adequate water flow through the boilers and the influence of the system controls. It is recommended that the system design should ensure a minimum return temperature of 50 °C.
If the temperature/flow-rates of the application cannot meet those given in Figure B, it may be necessary to incorporate mixing valves and shunt pumps to ensure that the boiler will operate satisfactorily. Figure B shows recommended and minimum water flows required with the associated pressure losses. The control system and valves, where fitted, should be regulated to avoid lower flows occurring.
3.4 Time Clock Control
In order to avoid local overheating and progressive calcium deposition at zero flow conditions where boilers are operated from time clocks, provision should be made for a 5 minute circulating pump over-run after the last boiler has ceased firing.
NOTE:- Time clocks should not interrupt live, neutral or earth connections, see Section 9.0: Electrical Supply for details.
See Figure G for wiring details.
3.5 Minimum System Water Pressure
To comply with guidance note PM5 (Health and Safety Executive), the minimum pressure requirements at the
boiler are given below as examples :-
1) Single installed boiler running at 82°C flow temperature. Minimum head required is not less than 2 metres or 0.2 bar.
2) Single installed boiler running at 95°C flow temperature. Minimum head required = 5.1 metres or
0.5 bar. See Section 8.10.1 for details.
3) Modular boiler installation running at 82°C flow temperature and 11°C rise across system. Minimum head required = 4.3 metres or 0.42 bar.
4) Modular boiler installation running at 82°C flow temperature and 15°C rise across system. Minimum head required = 9.4 metres or 0.92 bar. See Section
8.11 for Pressurised Water Systems.
4.0 LOCATION
The boiler location must permit the provision of a satisfactory flue system, and provide adequate space around the boiler for servicing and air circulation.
Sufficient space must be provided at the front of the boiler to allow the removal of the burner assembly for servicing/replacement, and at the rear for installation of pipes, valves and flue.
Sufficient clearance around the boiler must also be provided to allow access for servicing. Refer to Figures C & D for recommended clearances.
The boiler room, or compartment, housing the boiler/ s - whether specifically constructed for the purpose, or a modification of an existing space - should be in accordance with the requirements of either BS 6644, or BS 5410 Part 2, as appropriate.
The compartment housing the boiler must have permanent air vents communicating directly with the outside air at both high and low level. Refer to Section 7.0 for details.
Where a separate purpose built boiler room is not available, measures should be taken to protect the boiler or boilers from damage, and the boiler should be sited such that extraneous material cannot be stored next to, or against it.
The boiler must be installed on a suitable level non­combustible surface, capable of withstanding temperatures of 65
°
C and able to support the weight of the boiler (including pipework and ancillary equipment) when filled with water. A steel sheet can be placed beneath the boiler cradle to facilitate movement of the boiler during assembly. The plinth must be level, non-combustible, 80mm nominal height, and must be equal in width to the boiler casing dimensions.
IMPORTANT:- the plinth must not protrude from the rear of the boiler to enable fitting of the extension turrets on the rear return connections.
See Figures C & D for plinth dimensions.
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5.0 GAS / OIL SUPPLY
5.1 Gas Service Pipes
The local gas region should be consulted at the installation planning stage to either determine the feasibility of providing a gas supply or, where there is an existing supply, to ensure that the meter capacity is adequate for the rated input of the proposed new boiler. An existing gas service pipe must not be used without prior consultation with the local gas region.
5.2 Gas Meters
A new gas meter will be connected to the service pipe by the local gas region, or a local gas region contractor. An existing meter should be checked, preferably by the gas region, to ensure that it is adequate to deal with the rate of gas supply required.
5.3 Gas Supply Pipes
Supply pipes must be fitted in accordance with IM/16. Pipework from the meter to the boiler must be of adequate size. Do not use pipes of a smaller size than the boiler gas connection. The complete installation must be purged and tested for soundness as described in IM/2 and IM/5 as appropriate. A manual shut off valve must be fitted on the incoming gas supply pipe, adjacent to each boiler, in an easily accessible position.
5.4 Boosted Gas Supplies
Where it is necessary to employ a gas pressure booster, the controls must include a low pressure cut-off switch at the booster inlet. The local gas region must be consulted before a gas pressure booster is fitted.
5.5 Boiler House Gas Control Valve
A manual valve for boiler house isolation shall be fitted in the gas supply line. It shall be clearly identified and readily accessible for operation, preferably by an exit.
5.6 Oil Supply
The oil storage & supply system should be designed and installed in accordance with BS5410:Pt.2, as appropriate.
The following notes are given as guidance :-
5.6.1 Oil Storage Tank
The oil storage tank should be of sufficient capacity to permit economic deliveries of oil to be taken. Reference should be made to oil distributor for advice.
The tank should be installed such that:
a. The oil outlet should be higher than the top of the oil burner pump. If site conditions prevent this, then a suction lift (or 'two-pipe') fuel supply system must be used.
b. The maximum head on the suction side of the oil pump should not exceed 4 metres (14 feet).
c. The base should be sloped away from the outlet and towards a drain cock to allow draining of any water or sediment from the tank.
d. It is sited outside, if possible, and complies fully with the requirements of the relevant British Standards and Local Authority Regulations.
5.6.2 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. All pipework and fittings must be oil-tight, with any screwed joints made good with an oil resistant compound. 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
5.6.3 Gravity Feed Supply
Where the delivery connection of the storage tank is above the level of the pump inlet on the burner a 'single pipe' gravity feed system can be used. At no point in this system should the supply pipework be higher than the lowest level of fuel in the tank.
5.6.4 Suction Lift Supply
Where the delivery connection of the tank is below the level of the pump inlet on the burner a 'two-pipe' fuel supply system MUST be used. This system uses the burner pump to provide a circulation of oil to and from the tank.
NOTE:- Burner pumps can be supplied ready for use on a 'single-pipe' system. For use on a 'two-pipe' system it may be necessary to fit the pump with a by-pass plug. Refer to technical information supplied with burner.
The return line should terminate within the oil tank at the same level as the suction line, in which case a non-return valve is not required. If the return line terminates above the fuel level, a non-return valve MUST be fitted.
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6.0 FLUE SYSTEM
6.1 General Requirements
Detailed recommendations for flue systems are given in BS 6644, & IGE UP/10. The following notes are intended to give general guidance only.
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.
6.2 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 Figure B.
6.3 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.
6.4 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 - 0.3 mbar).
It is recommended that a draught stabiliser is fitted to the flue system where the suction is likely to exceed 0.3 mbar.
6.5 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 supporting and not present a risk to people in or around the building.
See Section 13.0: Servicing for further information.
6.6 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.
6.7 Surface Temperature
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.
6.8 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.
NOTE:- The flue MUST be self supporting. Check that the flue and chimney are clear from any obstruction.
6.9 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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7.0 AIR SUPPLY
Detailed recommendations for air supply are given in BS 6644.
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.
7.1 Air Supply by Natural Ventilation
The boiler room must have, or be provided with, permanent air vents directly to the outside air, at high level and low level.
For an exposed boiler house, air vents should be fitted preferably on all four sides, but at 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.
The air supplied for boiler house ventilation shall be such that the maximum temperatures within the boiler house shall be as follows:
1) At floor level (or 100 mm above floor level) = 25 °C.
2) At mid-level (1.5 m above floor level) = 32 °C.
3) At ceiling level (or 100 mm below ceiling level) = 40°C
Where both low and high level openings are used, the grilles shall have a total minimum free area of :-
Low Level (inlet) 540cm
²
plus 4.5cm² per kW
in excess of 60 kW total rated input (gross).
High Level (outlet) 270cm
²
plus 2.25cm² per kW
in excess of 60kW total rated input (gross).
7.2 Air Supply By Mechanical Ventilation
Air supplied to the boiler room by mechanical means should be as follows :-
1) Mechanical inlet and mechanical extract can be utilised providing design extraction rate does not exceed one third of the design inlet rate.
2) Mechanical extract ventilation with natural inlet ventilation MUST NOT be used.
NOTE:- 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.
Flow Rate per 1000 kW
total rated heat input (gross)
Forced Draught
Boilers
Volume 0.9 0.6
Inlet air
(Combustion
Ventilation)
m3/s m3/s
(Ventilation)
Extract air
Figure E - Mechanical ventilation Flow Rates
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8.0 WATER CIRCULATION SYSTEM
8.1 General
Recommendations for the water circulation system are given in BS 6644 and CP 342. The following notes are of particular importance:-
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.
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.
3) Drain valves must be located in accessible positions which permit the draining of the whole system, including the boiler and hot water storage vessel.
4) Each boiler has PN6 Flanged flow and return connections located on the top/ rear section of the boiler.
5) 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 module.
Figure F - Cold Feed and Vent Pipe Sizes (mm)
Boiler Output Feed Vent
60kW to 150kW 25 32
150kW to 300kW 32 38
300kW to 600kW 38 50
600kW & above 50 65
8.2 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 modular installation, each bank of boilers, must be fitted with a pressure relief valve to BS 759 or BS 6759 Pt.1 (ISO 4126) and sized as shown in
BS 6644.
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.
8.3 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 as follows:-
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.
8.4 Altitude Gauge (Water Pressure Gauge)
Every boiler or group of boilers should be provided with a gauge complete with isolating valve. See Figure A for typical position.
8.5 Thermometer
See Figure A for typical position.
A thermometer complete with pocket should be fitted in the pipework to indicate water flow temperature.
8.6 Drain Valves
Each boiler should have ¾” NB drain valve fitted (not H.H.L. supply), to drain the boiler only. A plugged Rc ¾” connection is provided for a drain valve at the bottom of the front boiler section.
The heating system in total should have drain valves as recommended by BS 6644. See Figure A for recommended positions.
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8.7 Circulating Pump
One or more circulating pumps will be required to circulate water around the boilers and heating system. The pump should be sited to facilitate servicing. It is also important that the existing system be flushed through twice to remove any loose matter, which may have accumulated. If in any doubt regarding the cleanliness of the system, a coarse filter should be fitted in the return pipework to the boilers.
NOTE:- If boilers are run off time clock control, a pump overrun (not H.H.L. supply) should be fitted which must run for a minimum of 5 minutes on shut­down of the last boiler.
8.8 Minimum Water Flow Rates
Minimum water flow rates are shown in Figure B. These flow rates should be maintained through the boiler at all times whilst the boiler is firing. If the water flow rate is allowed to fall below the minimum, the boiler heat exchanger could fail due to the resultant scale formation. Particular attention should be paid to the restriction of external flow circuits during periods of low heat demand.
8.9 Waterside Pressure Drop
The waterside hydraulic resistance (Pressure drop) is shown in Figure B.
8.10 Control Schemes
8.10.1 Temperature Controls
An adjustable control thermostat is supplied with each boiler and should be set to operate within the range 65­90°C for standard applications. A temperature limiter, (hand reset limit thermostat) is also fitted to the boiler and must be set at 100°C.
NOTE:- The minimum difference between control thermostat and temperature limiter MUST NEVER be less than 10°C.
Where the system is operating on a T of 20°C, care should be taken to ensure that the return temperature does not fall below 50°C.
8.10.2 Water Flow Controls
Any external mixing valve/shunt pump or similar controls should ALWAYS ENSURE that the minimum water flow rate as shown in Figure B is maintained.
8.10.3 Frost Protection
Consideration should be given to fitting a frost thermostat set at approximately 4°C.
8.11 Unvented Systems
See Figure A for typical layout of a Unvented (Pressurised) Hot Water System.
For system design refer to BS 7074 Pt.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 6759:Pt.1, for information.
See also BS 6880:Pt.1, for design considerations.
8.12 Modular Boiler Control Schemes
For modular 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 and will control up to 8 stages. For further information, contact Hamworthy Heating for details.
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9.0 ELECTRICAL SUPPLY
WARNING: THIS APPLIANCE MUST BE EARTHED
9.1 Site Wiring
Wiring external to the boiler must be installed in accordance with the I.E.E Regulations and any local regulations which apply. Wiring must be completed in heat resistant cable. (For size, refer to the Technical Instructions supplied by the burner manufacturer). The boiler control panel requires a 230V, single phase 50 Hz supply.
Fuse ratings for individual boilers are marked on the appliance data plate. The control panel is supplied with flying lead and plugs for direct connection to corresponding sockets supplied with the burner. Should non-standard connecting wiring be necessary due to particular burners or contract conditions, space is provided in Appendix A of these instructions for a wiring diagram to be included.
Note a 3 phase 4 wire (including neutral) supply is required from which the 3 phase should be wired direct to the burner with a single phase and neutral spurred off to the boiler control panel.
The method of connection to the mains electricity supply must facilitate complete electrical isolation of the single boiler/battery with a contact separation of at least 3 mm in all poles.
The appliance must be isolated from the mains electricity supply in the event of electric arc welding being carried out on any connecting pipework.
A mains isolator must be provided adjacent to the boiler in a readily accessible position. The supply should only serve the boiler.
NOTE:- Volt free contact electrical supplies must also be isolatable where fitted (see note in control panel). Further details regarding connection to the electricity supply are given in BS EN 60335 Pt.1 or
BS 3456 Pt. 201.
9.2 Indication Signals and Volt Free Contacts
Control panels are fitted with v.f.c.’s (volt free contacts) to enable external indicator lights or alarms to derive signals for normal run, overheat and lockout.
NOTE:- These external circuits MUST be isolated before any service or maintenance procedures are carried out.
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Figure G - High / Low Burner Control Panel Wiring Diagram
YE
N
VOLT FREE CONTACTS (if fitted)
230V ~ 50Hz
through an isolator
in accordance with
SUPPLY IN
NORMAL RUN
LOCKOUT
OVERHEAT
Section 9.1
GN/YE
L
BLACK
9
14
G
/
6
YE
GN
/
8
7
HIGH FIRE
LOW FIRE
PLUG
MALE
4 PIN
CONNECTIONS
PLUG
MALE
7 PIN
BURNER
L1 E N T1 B4T2S3 T6B5 T8T7
8
METER
HOURS RUN
BLACK
7
METER
HOURS RUN
BLACK
LOW HIGH
C1 C2 C3 C4 9 11 12 13 14 15 16 L N E
8
N B4B5L1 E N T1T2 S3B4B5T6T7T8 N
7
LOCKOUT
COMMISSIONING
/ REMO TE LINKS
H2 LB5B4N
HIGH / LOW
1312115432
1
C
2
THERMOSTAT
H
21
CONTROL
THERMOSTAT
12
TEMPERATURE
LIMITER
BLACK
BLACK
BLACK
2
H
1
8
GREEN
CC
HIGH FIRE
BOILER ON/OFF
13
1
LOW FIRE
2
BLACK
7
GREEN
(RED)
POWER ON
RED
OVERHEAT
FUSE 6.3A MAX
NOTE:
THIS DIAGRAM SHOWS THE CONTROL
PANEL WIRING 230V ~ 50Hz. SUPPLY.
THE SUPPLY TO THE BURNER IS
DEPENDANT UPON THE MODEL
SELECTED; - REFER TO BURNER
MANUFACTURERS INSTRUCTIONS.
Note: For modulating burner operation the 4 pin burner plug must be disconnected from terminals B5, T6, T7 and T8 and discarded.
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Item Description
No. of sections
2
6
7
45
46
47
56
73
6 7 8 9 10 11 12 13 14 15
Intermediate section 4 5 6 7 8 9 10 11 12 13
Guide ring 10 12 14 16 18 20 22 24 26 28
‘O’ ring (7.3mm) 10 12 14 16 18 20 22 24 26 28
Boiler cement (packs) 5 5 6 7 8 9 10 10 11 11
Silicone sealant (tube) 9 11 12 13 15 16 18 19 20 21
Primer—silicone 2 2 2 3 3 3 3 3 4 4
Section tie bolts M12 x 230 20 24 28 32 36 40 44 48 52 56
Self tapping screw - casing 70 110 110 110 130 130 130 150 150 150
Figure H - Composition of heat exchanger
Figure I - Composition of heat exchanger assembly
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Apply boiler cement
to inner groove.
Spray primer on all
sealing grooves,
only apply sealant
when primer is dry.
Apply silicone sealant
in two outer grooves.
Smooth sealant into joint
after tightening up sections
‘O’ ring
Guide
ring
Tie bolts
Figure J - Applying the sealant
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10.0 BOILER ASSEMBLY
The following procedure should be adopted for the initial site build of the boiler or following any dismantling due to maintenance.
10.1 Preparation
The heat exchanger is made up from three different types of section, each section weighing around 190 kg. Due to the weight, this operation should be carried out by two operatives.
1) Check off all materials and parts (see Packing List Section 1.2) and that a sealant gun and adequate supply of sealants and primer have been provided.
Using a clean rag and kerosene, or similar, wipe the ‘O’ ring grooves and sockets on each section prior to assembly. Clean all sealing grooves on the casting face with a wire brush and apply the primer liquid using the applicator bottle provided.
Important:- Allow the primer to dry prior to applying the sealant (10 mins).
WARNING:- the sections are not self supporting until several sections have been assembled together. Precautions should be taken to adequately support sections to prevent injury or damage. Ensure that the position of the sections is aligned with the intended water and flue connections during assembly.
2) Select the rear and intermediate section and apply a bead of silicone rubber compound, 5mm proud, around each of the two outer sealing grooves, of the mating faces.
Apply boiler cement to the inner sealing groove mating faces.
3) Position the sections on the plinth, fit the guide and ‘O’ rings to the top and bottom sockets of the rear section. These may require careful tapping into position using a mallet.
Position the intermediate section directly in front of the rear section, and using a crow bar under the bottom of the intermediate section, gently lift the intermediate section to engage the upper guide ring and then manoeuvre onto the lower guide ring.
4) Insert the four tie bolts through the securing lugs and tighten diagonally to ensure an even pull up on the guide rings until a face to face contact has been achieved. A maximum torque of 20N/m should be applied. Alternate the tie bolts between upper and lower fixings on adjacent sections.
Only work with one section at a time when pulling together.
Smooth over the sealing compound to leave a clean bead but slightly proud of the casting.
5) Complete the boiler build by repeating steps 1-4. Once all waterway sections have been assembled, prepare the rear section and flue cover casting by applying primer and silicone to the outer grooves.
Secure the flue cover to the rear section using tie bolts.
6) Fitting the Inserts
WARNING: THE INSERTS MUST BE INSTALLED BEFORE THE BURNER IS FIRED OTHERWISE DAMAGE MAY OCCUR TO THE FLUE SYSTEM DUE TO HIGH EXHAUST GAS TEMPERATURES.
NOTE: Insert dimensions vary depending on boiler size. Ensure correct length tube is used prior to assembly.
a) Install the inserts with the pointed end,
incorporating the removal ring, pointing towards the front of the boiler whilst ensuring that inserts are pushed fully back.
b) The inserts must be positioned to ensure that
they sit on the support feet. If the inserts are not correctly installed burn out may occur.
7) Fit the boiler flow and return connections and cap off with blanking plates and gaskets, leaving a suitable fitting on top of the rear section to enable venting during filling and testing. Fit a drain connection to the lower flange on the front section.
8) On completion of assembly, the heat exchanger should be hydraulically pressure tested to 1.5 times the maximum system pressure for 30 minutes (BS779 - 1989, Amendment 1 - 1993).
9) Check carefully for any leaks, and if satisfactory, drain the boiler sections and remove the blanking plates.
10.2 Dismantling
IMPORTANT:- the boiler sections are not self
supporting, particularly when there are only a few sections remaining.
During dismantling, the sections must be supported to prevent injury or damage.
Dismantling the boiler is the reversal of the assembly procedure. Inserts should be removed using removal tool provided.
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10.3 Assembly of Boiler Casing
Installers must ensure compatibility between boiler body and burner by referring to Figure M. If in any doubt, contact Hamworthy Heating for assistance.
Picture 1: Completed Build
Items Required for Build:
M10 x 40 Stud 6 Off M10 x 20 Screw 3 Off M10 Nut 4 Off Pin 50 mm Long 12 Off Control Panel Bracket 2 Off Pack of Self-Tapping Screws Accessory Pack
Tools Required for Build:
Stanley Torx T25 Screwdriver or equivalent Ø10 mm Round File Ø4 mm Drill Bit & Drill Spanners 17 mm A/F & 36 mm A/F Gloves etc for handling Fibreglass
Note: In general the casing panels will be drilled ready for the self-tapping screws, thus the build instructions will assume all aligning holes will be locked together with these screws unless otherwise stated.
10.3.1 Fitting of Door & Front Casings
Attach and tighten the four hinges (Items 15 to 18 & 62 to 64) to the front section. Fit the locknuts to the studs on the hinge side.
Picture 2: RH Front Casing Fitted incl. Door
Fit the six hexagonal spacers to the front section and fit the LH & RH boiler front casing (2-piece construction) using the screws provided.
Position the hinged door casting for left or right opening. The two smaller of the four door fixing holes should be positioned on the hinge side. Using a jack, raise the door to align with the hinge brackets and engage the door holes with the appropriate hinge studs. Fit and tighten the fixing screws.
Close the door and fasten with the door securing nuts, open it, then check the impression of the sealing grooves in the braiding. There should be a uniform impression approximately 2mm in depth. Adjust the fixing nuts to obtain the correct impression. Tighten all fixings diagonally to ensure an even seal between the door and front section.
Picture 3: Both Casings Fitted incl. Door
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10.3.2 Fitting of Rear Casing
Fit the Insulation over the rear section , then fit the LH & RH boiler rear casing (2-piece construction). These are located with the Inspection Doors and Flue Connection Spigot. Ensure that the Flue Gasket is used. Lock to position using 3 off M10 X 20 Long screws and 2 off self– tapping screws.
Picture 3: RH Rear Casing Fitted
Fit the lower rear casings (2-piece construction) as shown using 1 off self-tapping screw each side.
Picture 5: Boiler Body Insulation
Note: It may will be necessary to trim the length of the insulation to suit therefore suitable protective apparel should be worn. (see Section 1.5)
Picture 6: Side Rail attachment.
Due to the sectional nature of the Boiler the Side Rails are supplied as 2 `L` shaped brackets, on larger boiler sections, which slide over one another to achieve the required length. When the Front and Rear Covers are in place these brackets should be
Picture 4: Lower Rear Casings
10.3.3 Boiler Body Insulation & Side Rails
Place the boiler body insulation over the sections and draw down equally on both sides to the base of the boiler. Make good any joints with the tape provided. The insulation should be cut-out around the front and rear top connection flanges.
attached on both sides using 2 off Self-Tapping Screws into the slotted holes. It will then be necessary to drill 4 off Ø4mm holes to attach these brackets together with an additional 4 off Self­Tapping Screws; these should be drilled through the existing Ø4mm holes on the brackets.
Note: It is easier to fit the top Side Rail, then to move it to the bottom position to achieve correct length matching.
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10.3.4 Side Cover Mounting
Picture 7: Side Plate attachment
Starting from the Rear the first side plate should be hung over the Top Side Rail and attached to the Rear Cover using 4 off Self-Tapping Screws. These will require drilling Ø4mm.
This should be repeated towards the front until all side panels are in position as shown.
10.3.5 Top Panel Mounting
Picture 8: Top Rear Plates
Attach the Rear Top Plate using 4 off Self-Tapping Screws. Position the 2 Rear Flange Top Plates as shown but do not secure, the Top Covers should be fitted from the front.
Note: It may be necessary to file the Rear Flange Top Plates as shown to fit, due to interference with the riser connection.
Picture 9: Top Cover Complete
Fit the Front Top Cover as shown using the Control Box as a guide to how far forward this plate should extend. This Control Box may be fitted at this time if required (see section 10.3.8).
Then fit top cover sections in turn from front locking them into position with Self-Tapping Screws drilled to position, as required.
10.3.6 Door Insulation
Picture 10: Door Casing Insulation
Fit the Door Casing Insulation by pushing onto the 4 off M10 x 40 Studs. Place the upper and lower Back Insulation pieces to position and pin using the 50mm Pins provided.
The two side Insulation Pieces should also be similarly located.
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10.3.7 Door Casing
Picture 11: Door Casing
Locate the door casing with the Burner Flange Mounting Screws then lock to position using the M10 bolts, spacer and the M10 nuts. Fit the Sight Glass assembly.
10.3.8 Control Box Fitting Procedure
Picture 12: Control Box
Fit the Control Box to position using 6 off Self­Tapping Screws, 4 along the top and 2 at bottom as shown.
Fit the Control Box Cover.
10.3.9 Control Panel Fitting Procedure
Picture 13: Control Panel Attachment
Fit brackets to control panel using 4 off M5 x 12 pozi screws. Position the assembly on the casing top panel, mark positions of the 4 fixing holes. Remove Control panel assembly and drill 4 holes 3mm dia. in casing. Place Control Panel assembly in position and secure with 4 off Self­Tapping Screws.
The control panel fascia can now be hinged down by unlatching the catch on the top right hand using a screwdriver. 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.
With the fascia hinged down, the terminals are exposed and the power supply can be connected to the appropriate terminals via the glands in a removable plate at the bottom right hand side. The upper front casing panel has a cut out appropriately positioned beneath the gland plate to allow the power supply cables to enter the casing and to allow the flying leads to the burner to exit.
A powered lock-out terminal and a remote control link C1-C2 are also provided together with an optional volt-free contact kit (see Fig G on page 14 of this manual) the terminals being adjacent to the power supply, and cables for these functions should be run in a similar manner. For remote control remove the wire link between C1-C2 and replace with control cables. If the panel is for High/Low burners an additional link C3-C4 is also supplied, removal of which holds the burner on low fire. This link can also be replaced by control cables if remote high/low operation is required. For ease of disconnection, the terminals used are of the plug and socket type and hence all external wiring can be easily removed by pulling the top half of the terminal rail upwards and threading cables through the gland plate once removed.
Depending on the type of burner fitted, the panel will provide a single flying lead terminating in a seven pin plug for connection to an on/off burner, or an additional flying lead terminating in a four pin plug for connection to a high/low burner. The panel for a high/low burner will also have an additional thermostat, hours run meter and run lamp.
When wiring is complete, raise hinged fascia and click into position by pushing on latch screw and replace thermostat knobs. Finally, locate control panel cover on brackets and secure with M5 nuts and shakeproof washers.
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10.4 Fitting the Burner
A burner mounting plate is supplied with each boiler specific to the burner requested. Fit the plate to the front door casting using four M12 countersunk screws. Secure the burner and gasket to the burner mounting plate using the four bolts supplied with the burner.
IMPORTANT: BEFORE SECURING THE BURNER MOUNTING PLATE TO THE FRONT DOOR CASTING, APPLY MASTIC TO THE RIM OF THE BURNER APERTURE ON THE CASTING. FAILURE TO SEAL THIS JOINT WILL RESULT IN LEAKAGE OF FLUE PRODUCTS AND HEAT STAINING OF THE SURROUNDING CASING PANELS.
Having secured the burner to the mounting plate, apply the Cafco Blaze burner sealant between the burner blast tube and door refractory lining. The compound should be gradually mixed with water until pliable ( the 2kg pack requires 4 litres of water). It is essential that the gap is filled and that the mix has been compressed and finished flush with the inner face of the door refractory lining.
Check that the weight of the burner has not affected the sealing of the door, especially after several opening and closings operations. Larger burners should be supported independently with a suitable device whilst still allowing the door to open.
NOTE:- All cables must exit the control via the cut­outs in the bottom and must be routed adjacent to the burner mounting plate.
The cables MUST NOT be routed across the burner or it’s mounting plate.
Following completion of the boiler assembly, the cleaning and assembly tools should be left on site in a safe place, preferably within the boiler room.
11.0 COMMISSIONING AND TESTING
11.1 Electrical Installation
Wiring MUST be checked by a suitably competent person. 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.
The boiler is supplied with a remote stop/start circuit for time clock operation. Any other interlocks, i.e.
Pressurisation unit, BEM System should be wired in series with the remote stop/start loop.
11.2 Gas Installation
For design see Section 5: Gas Supply.
The whole of the gas installation including the meter must be inspected and tested for soundness and purged in accordance with the recommendations of IGE/UP/1 or
IGE/UP/1A as appropriate.
11.3 Water Circulation System
For design see Section 8: Water System. The system should be thoroughly flushed out with cold water without the pump in position. Ensure all the valves are open.
With the pump fitted the system should be filled and air locks cleared. Vent the radiators and check for leaks. If the system is unvented the pressurisation unit should not be utilised for the initial filling. This should be carried out using a WRC approved double check valve and temporary filling loop. In order to comply with local Water Authority Regulations, this loop must be disconnected when filling is complete. Water treatments should not be fed through the pressurisation unit unless permitted by the manufacturer. Check the expansion vessel cushion pressure as detailed by the manufacturer's Installer's Guide.
11.4 Commissioning The Boiler
Only competent persons registered for working on non domestic gas appliances should attempt the following: Before attempting to commission any boiler, ensure that personnel involved are aware of what action is about to be taken and begin by making the following checks:-
1) Flue way passages to chimney are clear.
2) Adequate ventilation as per Section 7: Air Supply
exists in the boiler house.
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No. of Boiler sections
6
7
8
9
10
11
12
13
14
15
SIDE PANEL TOP REAR PANEL SUPPORT RAIL BOILER INSULATION
No. off * length (mm) No. off * length (mm) No. off * length (mm) No. off * width (m)
2 * 916 1 * 799 N/A 1 * 1.2
4 * 556 1 * 439 4 * 1057 1 * 1.2
2 * 556 1 * 619 4 * 1057 1 * 1.2
2 * 736 1 * 0.6
2 * 556 1 * 799
2 * 916
6 * 556 1 * 439
4 * 556 1 * 619 8 * 1520 2 * 1.2
2 * 736 1 * 0.6
4 * 556 1 * 799 8 * 1520 2 * 1.2
2 * 916 1 * 0.6
8 * 556 1 * 439 8 * 1520 2 * 1.2
6 * 556 1 * 619
2 * 736
4 * 556 1 * 799
4 * 736
Figure K - Composition of Boiler Casing Assembly
8 * 1057
8 * 1520
8 * 1520
8 * 1520
2 * 1.2
2 * 1.2
1 * 0.6
1 * 0.6
3 * 1.2
3 * 1.2
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3) The system is fully charged with water, ready to receive heat. All necessary valves are open and the pump is circulating water.
4) The pipework and valve arrangement is installed to Hamworthy Heating recommendations in such a way that water flow rates will be in accordance with Figure B.
5) The gas supply pipework is clear of any loose matter, tested for soundness and purged to IGE/UP/1 or
IGE/UP/1A as appropriate.
11.4.1 Boiler Checks Prior To Lighting
BEFORE starting the boiler, check the following:
a. Check that fuel supply is turned off.
b. Check that electrical supply is isolated.
c. 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.
d. Check boiler castings are undamaged Remove access plates to check flue inserts are fitted.
e. Check all thermostat bulbs are correctly inserted in the appropriate pocket.
f. Check for water leaks and ensure that both boiler and heating system is full of water and properly vented.
g. Check that all drain cocks are closed, and that all isolating valves in flow and return pipework are open.
h. For OIL; check that tank/s have been filled and oil supply pipework between tank and burner has been primed.
j. For GAS; check soundness of gas installation and that pipework is purged of air, as detailed in British Gas Publications IM/5 and IM/2 respectively.
Check that gas meter is operational and has been checked by the local region of British Gas. Check that gas meter and supply pipework is of sufficient size to meet the input rating of the burner/ boiler. Refer to Section 2.1.
k. Check that burner output is correct for size of boiler in question, referring to Figure M, 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.
11.4.2 Oil fired Boilers
a. Check flexible oil lines are tightly jointed and are
not twisted or kinked to form an obstruction.
b. Check correct nozzle/s is fitted to burner (Fig 11.4) and that it is 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 MUST be fitted to the burner before attempting to fire the boiler.
c. Check electrodes and ensure porcelain insulation is not cracked.
d. Check electrodes are correctly positioned, and gap is correctly set, as specified in the manufacturer's technical information supplied with the burner.
e. Check blast tube is correctly located, and securely fastened in place and firebrick at rear of combustion chamber is sound and correctly located.
.f. Check burner seats correctly onto burner mounting plate and is securely fastened in place.
g. Set burner for the required fuel and air throughputs, as specified in the manufacturer's technical information supplied with the burner.
h. Fit a pressure gauge on burner oil pump to check pump pressure is correctly set.
i. Check that overheat thermostat manual reset is set, and that boiler control thermostat and control system are set to call for heat. Switch the boiler on and start the burner.
j. The burner control will first operate the fan to pre­purge the boiler, then produce an ignition spark and finally open the oil solenoid valve and the flame should ignite.
k. Purge air from oil pump through pressure gauge port.
IF BURNER LOCKS OUT WAIT 45 SECONDS BEFORE PRESSING RESET BUTTON ON BURNER CONTROL BOX.
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l. 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.
m. After allowing burner to reach stable firing conditions for approximately 15 minutes, carry out combustion gas check.
Measure CO
, CO, smoke number, flue gas
2
temperature and circulating water temperature rise across the boiler. The readings obtained should be as indicated in Figure O, target appliance readings.
Readings should be taken at both High and Low settings. A link 20-22 is provided in the control panel terminals, the removal of which, will hold the burner on low fire.
n. Switch off boiler. Remove oil pressure gauge and replace sealing plug complete with gasket.
o. 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.
p. Set boiler control thermostat to required setting, and check operation of heating control system.
q. 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.
11.4.3 Gas fired Boilers
a. Check that ignition electrode and rectification
probe are correctly positioned. Refer to manufacturer's technical information supplied with the burner.
b. Check that ignition electrode and rectification probe leads are connected.
c. Check blast tube is correctly located, and securely fastened in place.
d. Check burner seats correctly onto burner mounting plate and is securely fastened in place.
e. With firing head separate from burner adjust air and gas settings, as specified in the manufacturer's technical information supplied with the burner.
f. 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 Figure D for the boiler in question, to obtain gas pressure value to be measured at burner test point.
g. Open main isolating valve in gas supply to boiler. Check for leaks throughout gas train and pipework to burner.
h. 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.
i. Adjust start and main output gas rates as detailed in the manufacturer's technical information supplied with the gas burner.
j. Check that overheat thermostat manual reset is set, and that boiler control thermostat and control system are set to call for heat.
k. 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.
l. 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 pre­purge, 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.
m. 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.
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n. After allowing burner to reach stable firing conditions for approximately 15 minutes, carry out combustion gas check.
Measure CO
, CO, flue gas temperature, and
2
circulating water temperature rise across the boiler. The readings obtained for the appropriate gas should be as indicated in Figure O, target appliance readings.
Readings should be taken at both High and Low settings. A link 20-22 is provided in the control panel terminals, the removal of which, will hold the burner on low fire.
o. After all other adjustments have been made, set burner air pressure switch as instructed in manufacturer's technical information supplied with burner.
p. Check gas pressure at burner head corresponds with value determined from burner manufacturer's technical information - as detailed in (f) above.
q. Check gas flow rate at meter. Ensure that all other appliances served by the meter are isolated whilst flow rate is checked.
r. 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.
s. Set boiler control thermostat to required setting, and check operation of heating control system.
t. 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.
11.5 External Controls
The external controls used in typical boiler installations, for both vented and unvented systems, are shown in Figure A. 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.
11.6 Installation Noise
In order to avoid the possibility of noise from the installation, care should be taken to follow the manufacturer’s instructions. Particular attention should be paid to minimum water flow rates. 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.
11.7 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 should then be handed over and kept in a safe place for easy reference.
12.0 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.
13.0 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.
13.1 Initial Inspection
a. 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
2
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.
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13.2 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.
a. Disconnect electrical and fuel connections to burner, as necessary.
b. Disconnect burner from the fuel supply and open the hinged door, with the burner attached.
13.3 Boiler Service Procedure
a. After hinging the burner, remove boiler casing,
control panel (taking care to remove thermostat bulbs) and front insulation to gain access to front section of boiler. The power supply to the control panel and additional control cables, if used, must be disconnected.
b. Boiler combustion chamber and heat exchanger flueways are now accessible for cleaning with the brush and a vacuum cleaner once the flue inserts have been removed.
c. Access to rear of heat exchanger flueways and combustion chamber can be obtained by removing the access covers from rear of boiler.
d. Replace all access/cover plates, ensuring that all gaskets and insulation panels are correctly fitted. Refit securing studs/nuts and tighten evenly.
e. Refit boiler insulation, casing and control panel (ensure thermostat bulbs are correctly located in pocket). For guidance, refer to Section 10.
f. Refit burner. 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 11.0: Commissioning & Testing.
14.0 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. See Section 11.0: Commissioning & Testing..
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:- For replacement of burner components refer
to the burner manufacturers instructions.
14.1 Control and High/Low Thermostat/s
Record the existing temperature setting of the thermostat for reference before removal.
NOTE:- Before removing the control panel top, the thermostat knobs must be pulled off and the temperature limiter (high limit) cover knob unscrewed and removed.
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.
14.2 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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Figure L - Exploded view of boiler
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15.0 SPARE PARTS LIST
No. Off Req’d Per Assembly
Ref Description HHL Pt
No
Distance Bolt M6 x 45 5111480817 1 1 1 1 1 1
47 Silicone Primer 5017150100 2 2 2 3 3 3
45 Boiler Cement 5017400100 5 5 6 8 9 10
60 Inspection Window Bolt M10 x 35 5200649712 2 2 2 2 2 2
Screw M12 x 30 5202453642 4 4 4 4 4 4
28 Pin M10 x 45 5204036011 6 6 6 6 6 6
Screw M6 x 8 5206236211 10 12 10 10 12 10
Washer 14 x 28 x 2 5280161911 28 28 28 28 28 28
Washer M6 x 14 x 1.5 5281621101 12 12 12 12 12 12
Gasket 90 x 120 dia. x 6 thk 5034110205 4 4 4 4 4 4
Tubing 5036470100 1 1 1 1 1 1
65 Flue Hood Screw M8 x 30 5039210123 4 4 4 4 4 4
Screw M10 x 16 5039210136 3 3 3 3 3 3
43 Screw M10 x 30 for Flue Spigot 5039210138 4 4 4 6 6 6
59 Door Panel Bolt M10 x 65 5039210139 4 4 4 4 4 4
64 Screw M12 x 30 for Door Hinge 5039210149 12 12 12 12 12 12
38 M12 x 40 bolts (for 3” Flanges) 5039210150 24 24 24 24 24 24
Screw M6 x 16 5039270116 2 2 2 2 2 2
Torx Screw 4.8 x 16 5039360121 70 110 110 130 150 150
Bits torx 867-4Z TX-25 5039360999 1 1 1 1 1 1
63 Door Lock-nut M24 5039370120 4 4 4 4 4 4
62 M10 Nut for Door Panel Bolt 5039370160 4 4 4 4 4 4
Nut M12 5039370166 52 60 68/76 84/92 100/112 116
Washer M8 16 x 1.5 5039820107 4 4 4 4 4 4
44 Washer M10 for Flue Spigot 5039820127 4 4 4 4 4 4
Circuit Breaker 5045620003 1 1 1 1 1 1
Fitting 5033490100 1 1 1 1 1 1
Fitting 5033490103 1 1 1 1 1 1
Limit Switch 5033510138 1 1 1 1 1 1
Screw M4 x 20 5039270108 2 2 2 2 2 2
M4 Nut 5039370150 2 2 2 2 2 2
M4 Serrated Lock Washer 5039800101 2 2 2 2 2 2
Circuit Breaker Bracket 5045620002 1 1 1 1 1 1
Tubing 0.4m 5721017904 1 1 1 1 1 1
Tubing 18.6 5033350102 0.4m 0.4m 0.4m 0.4m 0.4m 0.4m
Nut for Tubing 5763011503 2 2 2 2 2 2
30 4” Flange, painted (Table D) 5701016201 2 2 2 2 2 2
34 Drain Flange 3/4” 5701016202 1 1 1 1 1 1
37 Gasket 90 x 120 5701068103 2 2 2 2 2 2
29 Extension 5701414701 1 1 - - - -
29 Extension 5701414801 - - 1 - - -
29 Extension 5701414805 - - - 2 3 -
Extension c/w threaded hole 5701414721 1 1 - - - -
Extension c/w threaded hole 5701414821 - - 1 - - 1
Insulation 1.2m wide x 7250 x 80mm thk 5701576401 1 1 1 1 1 2
GM6 GM7 GM8
GM9
GM10 GM11
GM12 GM13
GM14 GM15
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15.0 SPARE PARTS LIST (Continued)
No. Off Req’d Per Assembly
Ref Description HHL Pt
No
Rear Isolation 5702003701 2 2 2 2 2 2
36 Flange - plain 5701016203 1 1 1 1 1 1
35 Flange 3” 5702005602 1 1 1 1 1 1
56 Section Bolts, M12 x 230 5702004301 20 24 28/32 36/40 44/48 52/56
57 Flue Gas Plate Bolts M12 x 140 5702004302 4 4 4 4 4 4
49 Applicator 5702005001 1 1 1 1 1 1
46 Silicone Sealant 5702005301 a/r a/r a/r a/r a/r a/r
Plug 3/8” 5711059605 1 1 1 1 1 1
Plug 1/2” 5711059607 1 1 1 1 1 1
Plug 3/4” 5711059610 1 1 1 1 1 1
52 Flue Pipe Brush Extension 5702005701 1 1 - - - 1
53 Flue Pipe Brush Extension 5702005702 - - 1 1/0 - 1
54 Flue Pipe Brush Extension 5702005703 - - - 0/1 1 -
39 Smoke Outlet Pipe 250mm 5702008201 1 1 1 - - -
7 ‘O’ Ring 5702010603 10 12 14/16 18/20 22/24 26/28
Burner Sealing Compound (2kg) 5702012701 1 1 1 1 1 1
4 Flue Gas Plate 250mm 5702015501 1 1 1 - - -
5 Flue Gas Plate 350mm 5702015502 - - - 1 1 1
3 Rear Section 5702020411 1 1 1 1 1 1
8 Front Door 5702020507 1 1 1 1 1 1
Front Door Gasket 5111427302 12 12 12 12 12 12
Glass Fibre Braid 3/4” 5017310122 3.1m 3.1m 3.1m 3.1m 3.1m 3.1m
Screw M6 x 12 5200636612 2 2 2 2 2 2
Screw M8 x 70 5039210132 12 12 12 12 12 12
M8 Nut 5039370155 12 12 12 12 12 12
Washer M8 5039840101 12 12 12 12 12 12
Insulation (Rockwool) 5702042801 3 3 3 3 3 3
Plug KR 1/4” 5711059604 1 1 1 1 1 1
15 Hinge Bracket 5702020601 4 4 4 4 4 4
26 Cleaning Door 5721003101 1 1 1 1 1 1
48 Primer Applicator 5702023401 1 1 1 1 1 1
6 Guide Ring 5702024901 10 12 14/16 18/20 22/24 26/28
61 Spacer Bolt 5702026201 4 4 4 4 4 4
9 Inspection Window 5702028001 1 1 1 1 1 1
Inspection Window Gasket 5702027601 2 2 2 2 2 2
Inspection Window, fire resisting 5721005901 1 1 1 1 1 1
Flue Gas Pipe 5702029401 - - - 1 1 1
Sealing Cover 5702029701 - - - 1 1 1
50 Flue Pipe Brush 5702030701 1 1 1 1 1 1
1 Front Section 5702040011 1 1 1 1 1 1
2 Intermediate Section 5702040111 4 5 6/7 8/9 10/11 12/13
Insulation 5702042501 2 2 2 2 2 2
Insulation PS 51252 5702042601 2 2 2 2 2 2
27 Lock Handle 5711105611 6 6 6 6 6 6
Locking Nut 5702045901 2 2 2 2 2 2
GM6 GM7 GM8
GM9
GM10 GM11
GM12 GM13
GM14 GM15
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15.0 SPARE PARTS LIST (Continued)
No. Off Req’d Per Assembly
Ref Description HHL Pt
No
88 Flue Tube x 945 lg, 6 Section 5702041106 22 - - - - -
88 Flue Tube x 1125 lg, 7 Section 5702041101 - 22 - - - -
88 Flue Tube x 1315 lg, 8 / 9 Section 5702041102 - - 22 - - -
88 Flue Tube x 1665 lg, 10 / 11 Section 5702041103 - - - 22 - -
88 Flue Tube x 2025 lg, 12 / 13 Section 5702041104 - - - - 22 -
88 Flue Tube x 2385 lg, 14 / 15 Section 5702041105 - - - - - 22
Flue Tube Extraction Tool 5702042101 1 1 1 1 1 1
F Front Right Hand Side Casing Panel 5702043001 1 1 1 1 1 1
E Front Left Hand Side Casing Panel 5702043101 1 1 1 1 1 1
J Right Hand Rear Panel (6-9 Section) 5702043201 1 1 1 - - -
J Right Hand Rear Panel (10-15 Section) 5702043202 - - - 1 1 1
H Left Hand Rear Panel (6-9 Section) 5702043301 1 1 1 - - -
H Left Hand Rear Panel (10-15 Section) 5702043302 - - - 1 1 1
Q Top Rear End Panel 5702043501 1 1 1 1 1 1
K Bottom Rear Left Hand Panel 5702043601 1 1 1 1 1 1
L Bottom Rear Right Hand Panel 5702043701 1 1 1 1 1 1
X Support Rail 1057mm 5702043801 - 4 8 8/0 - -
X Support Rail 1520mm 5702043802 - - - 0/8 8 8
G Side Panel 556mm 5702043901 - 4 2/2 6/4 4/8 6
G Side Panel 736mm 5702043902 - - 2/0 0/2 - 2
G Side Panel 916mm 5702043903 2 - 0/2 - 2/0 0
P Top Rear Intermediate Panel - 439mm 5702044001 - 1 - 1/0 0/1 0
P Top Rear Intermediate Panel - 619mm 5702044002 - - 1/0 0/1 - 1
P Top Rear Intermediate Panel - 799mm 5702044003 1 - 0/1 - 1/0 0
P Top Intermediate Panel 5702044101 - 1 1 1 1 1
N Top Front Panel 5702044201 1 1 1 1 1 1
M Top Front End Panel 5702044401 1 1 1 1 1 1
B Front Door Casing 5702044701 1 1 1 1 1 1
A Front Door Side Plates 5702044801 2 2 2 2 2 2
Rivet 3.2 x 5 5111438206 4 4 4 4 4 4
Isol. Plate 5702044501 1 1 1 1 1 1
Plastic Plug 5711231702 8 8 8 8 8 8
Sensor Tube 5702070401 1 1 1 1 1 1
10 Inspection Window Flange 5721003301 1 1 1 1 1 1
Screw M6 x 30 5200637412 4 4 4 4 4 4
41 Gasket for 250mm Spigot 5721006002 1 1 1 1 1 1
51 Handle for Flue Pipe Brush 5721009305 1 1 1 1 1 1
17 Hinge Pin 5721010501 4 4 4 4 4 4
16 Hinge Bolt 5721010601 4 4 4 4 4 4
Burner Gasket 5721015901 1 1 1 1 1 1
Burner Gasket 5721015904 1 1 1 1 1 1
Insulation 5721023202 1 1 1 1 1 1
Key (Din894) 5000907732 1 1 1 1 1 1
GM6 GM7 GM8
GM9
GM10 GM11
GM12 GM13
GM14 GM15
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15.0 CONTROL PANEL / SPARES
No. Off Req’d Per Assembly
Ref Description HHL Pt
No
Control Panel Complete (inc. instruments) 563902223 1 1 1 1 1 1
Control Panel Support Bracket (LH) 530101024 1 1 1 1 1 1
Control Panel Support Bracket (RH) 530101025 1 1 1 1 1 1
Control Panel Cover 533902031 1 1 1 1 1 1
Control Thermostat 533901178 2 2 2 2 2 2
Temperature Limiter 533901179 1 1 1 1 1 1
Temperature Gauge 557002005 1 1 1 1 1 1
Hours Run Meter 533901067 2 2 2 2 2 2
On/Off Switch (Illuminated) 533901212 1 1 1 1 1 1
Fuse Holder 747224779 1 1 1 1 1 1
Anti-Surge Fuses 5A & 6.3A (20mm) 500005033 1 1 1 1 1 1
Green Neon 533901031 2 2 2 2 2 2
Red Neon 533901029 1 1 1 1 1 1
GM6 GM7 GM8
GM9
GM10 GM11
GM12 GM13
GM14 GM15
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Wimborne GM
chamber chamber (mm)
diameter length
216
240
250
240
250
240
250
240
250
328
250
328
250
328
250
328
280
240
280
240
242.0 25.61
(Nett) Gas Rate (Nett) Gas Rate
(kW) (kW) m³/h (kW) m³/h dim (B) mm dim (A) mm dim (C) mm
Output
420.0 465.9 49.3
Burner Details Boiler Details Combustion Combustion Comb head
266.0 28.15
306.0 32.38
350.0 37.04
400.0 42.33
444.0 46.98
488.0 51.64
522.0 55.24
565.0 59.79
594.0 62.86
56.3
480.0 532.0
550.0 610.5 64.6
630.0 698.4 73.9
720.0 798.5 84.5
800.0 887.4 93.9
880.0 976.2 103.3
950.0 1043.7 111.5
1020.0 1131.2 119.7
1070.0 1186.9 125.6
Make Model Mode Heat Max Heat Input Min Heat Input
GM6 Riello RS50 Hi / Lo
GM6 Riello RS50 / M Modul'n 85.0 8.99 635 920 216
GM6 Nu Way XGN 650 Hi / Lo 353 37.3
GM7 Riello RS70 Hi / Lo
GM7 Riello RS70 / M Modul'n 135.0 14.29 635 1100 250
GM7 Nu Way XGN 650 Hi / Lo 389 41.1
GM8 Riello RS70 Hi / Lo
GM8 Riello RS70 / M Modul'n 135.0 14.29 635 1280 250
GM8 Nu Way XGN 1000 Hi / Lo 389 41.1
GM9 Riello RS100 Hi / Lo
GM9 Riello RS100 / M Modul'n 150.0 15.87 635 1460 250
Boiler
model
GM9 Nu Way XGN 1000 Hi / Lo 247 26.1
GM10 Riello RS100 Hi / Lo
GM10 Riello RS100 / M Modul'n 150.0 15.87 635 1640 250
GM10 Nu Way BG 700 Hi / Lo 247 26.1
GM11 Riello RS100 Hi / Lo
GM11 Riello RS100 / M Modul'n 154.0 16.3 635 1820 250
GM11 Nu Way BG 700 Hi / Lo 247 26.1
GM12 Riello RS100 Hi / Lo
GM12 Riello RS100 / M Modul'n 169.0 17.88 635 2000 250
GM12 Nu Way BG 700 Hi / Lo 423.5 44.8
GM13 Riello RS100 Hi / Lo
GM13 Riello RS100 / M Modul'n 183.2 19.39 635 2180 250
GM13 Nu Way BG 700 Hi / Lo 423.5 44.8
GM14 Riello RS130 Hi / Lo
GM14 Riello RS130 / M Modul'n 196.0 20.74 635 2360 280
GM14 Nu Way XGN 2100 Hi / Lo 423.5 44.8
GM15 Riello RS130 Hi / Lo
GM15 Riello RS130 / M Modul'n 214.7 22.72 635 2540 280
Figure M - Matched Burner Boiler Combinations for Natural Gas
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GM15 Nu Way XGN 2100 Hi / Lo 423.5 44.8
Comb head
Combustion
Combustion
(mm) dim
chamber
chamber
250
150
250
150
250
150
250
150
250
240
250
240
250
240
250
240
250
240
250
(C) mm
(A) mm
length dim
635 920
635 1100
635 1280
635 1460
635 1640
635 1820
635 2000
635 2180
240
635 2360
635 2540
(B) mm
diameter dim
2nd
nozzle
nozzle
Max Heat Input Min Heat Input
Fuel rate
(Nett)
Fuel rate
(Nett)
(kW)
Output
l/h
(kW)
l/h
(kW)
4.50
5.00
4.50
5.50
5.50
5.00
6.00
6.00
7.00
6.00
7.00
7.00
8.00
7.50
9.00
8.00
9.00
9.00
10.00
10.00
5.00
5.00
7.00
5.50
7.50
5.00
8.50
6.00
7.00
7.50
8.00
8.50
9.00
14.00
15.00
10.00
1000 1113.4 113.0 556.7 56.5
1070 1191.2 120.9 595.6 60.45
1130 1258.2 127.7 629.1 63.85
440 489.7 49.7 244.9 24.86
10.00
11.00
12.00
13.00
510 567.5 57.6 283.8 28.8
580 645.4 65.5 322.7 32.75
670 745.9 75.7 373.0 37.86
760 846.4 85.9 423.2 42.95
840 935.0 94.9 467.5 47.45
925 1029.7 104.5 514.9 52.26
Hi / Lo
Hi / Lo
Hi / Lo
Hi / Lo
Hi / Lo
Hi / Lo
Hi / Lo
Hi / Lo
Hi / Lo
Hi / Lo
Hi / Lo
Hi / Lo
Hi / Lo
Hi / Lo
Hi / Lo
Hi / Lo
Hi / Lo
Hi / Lo
Hi / Lo
Hi / Lo
RL50
RL50
RL70
RL70
RL100
RL100
RL100
RL100
RL130
NOL 25T
NOL 25T
NOL 30
NOL 30
NOL 50
NOL 50
NOL 50
NOL 50
RL130
NOL 50
NOL 50
Burner Details Boiler Heat Inputs / Outputs 1st
Make Model Mode Max
Boiler
model
Nu Way
GM6 Riello
Nu Way
Nu Way
Nu Way
Nu Way
Nu Way
Nu Way
Nu Way
Nu Way
Nu Way
GM7 Riello
GM8 Riello
GM9 Riello
GM10 Riello
GM11 Riello
GM12 Riello
GM13 Riello
GM14 Riello
GM15 Riello
Figure N - Matched Burner Boiler Combinations for Class D Oil
HAMWORTHY HEATING LTD Page 500001113/D Wimborne GM
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MAKE (type) MODEL MODE QUANTITY PART No. DESCRIPTION
RIELLO
(Danfoss/
Delavan)
GM6 HI/LO 1 532904015 5.0 x 60° - (Low)
1 532904009 4.5 x 60° -(High)
GM7 HI/LO 1 532904020 7.0 x 60°-(Low)
1 532904009 4.5 x 60°-(High)
GM8 HI/LO 1 532904022 7.5 x 60°-(Low)
1 532904016 5.5 x 60°-(High)
GM9 HI/LO 1 532904050 8.5 x 60°-(Low)
1 532904017 6.0 x 60°-(High)
GM10 HI/LO 1 532904024 10.0 x 60°-(Low)
1 532904020 7.0 x 60°-(High)
GM11 HI/LO 1 532904026 11.0 x 60° - (Low)
1 532904020 7.0 x 60° - (High)
GM12 HI/LO 1 532904027 12.0 x 60° - (Low)
1 532904049 8.0 x 60° - (High)
GM13 HI/LO 1 532904066 13.0 x 60° - (Low)
1 532904023 9.0 x 60° - (High)
GM14 HI/LO 1 532904051 14.0 x 60° - (Low)
1 532904023 9.0 x 60° - (High)
GM15 HI/LO 1 532904067 15.0 x 60° - (Low)
1 532904024 10.0 x 60° - (High)
Figure O.1 - Riello Oil Nozzle selection
MAKE (type) MODEL MODE QUANTITY PART No. DESCRIPTION
Nu-Way
(Monarch)
GM6 HI/LO 1 532904034 5.0 x 60° - (Low)
1 532904034 5.0 x 60° -(High)
GM7 HI/LO 1 532904040 5.5 x 60°-(Low)
1 532904040 5.5 x 60°-(High)
GM8 HI/LO 1 532904034 5.0 x 60°-(Low)
1 532904034 5.0 x 60°-(High)
GM9 HI/LO 1 532904042 6.0 x 60°-(Low)
1 532904042 6.0 x 60°-(High)
GM10 HI/LO 1 532904043 7.0 x 60°-(Low)
1 532904042 6.0 x 60°-(High)
GM11 HI/LO 1 532904044 7.5 x 60° - (Low)
1 532904043 7.0 x 60° - (High)
GM12 HI/LO 1 532904072 8.0 x 60° - (Low)
1 532904044 7.5 x 60° - (High)
GM13 HI/LO 1 532904045 8.5 x 60° - (Low)
1 532904072 8.0 x 60° - (High)
GM14 HI/LO 1 532904070 9.0 x 60° - (Low)
1 532904070 9.0 x 60° - (High)
GM15 HI/LO 1 532904071 10.0 x 60° - (Low)
1 532904071 10.0 x 60° - (High)
Figure O.2 - Nu-Way Oil Nozzle selection
HAMWORTHY HEATING LTD Page 500001113/D Wimborne GM
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BOILER MODEL
FUEL TYPE
NATURAL
GAS
G20
CLASS D
FUEL OIL
Figure P - Combustion target figures
CO2 (DRY)
CO
FLUE GAS TEMP. °C gross
TEMP RISE ACROSS BOILER 0C
CO2 (DRY)
CO
FLUE GAS TEMP. °C gross
TEMP RISE ACROSS BOILER 0C
SMOKE No.
GM6 GM7 GM8 GM9 GM10 GM11 GM12 GM13 GM14 GM15
10.0 - 10.5%
Less than 100 ppm (air free)
200—210
Less than 20
10.5 – 11%
Less than 85 ppm (air free)
220 - 230
Less than 20
0 - 1
Burner Model
Volume - m3
Surface Area - m2
GM6 GM7 GM8 GM9 GM10 GM11 GM12 GM13 GM14 GM15
0.291 0.349 0.407 0.465 0.522 0.581 0.639 0.697 0.754 0.811
2.15 2.51 2.86 3.22 3.58 3.94 4.3 4.65 5.01 5.38
150
A
B
C
Figure Q - Combustion chamber data
HAMWORTHY HEATING LTD Page 500001113/D Wimborne GM
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For Dimensions A, B and C refer to figures: M and N.
APPENDIX A BOILER / BURNER WIRING DIAGRAMS
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Notes
Poole Office
Hamworthy Heating Limited
Fleets Corner, Poole, Dorset BH17 0HH England Main switchboard tel: 01202 662500
Technical enquiries 01202 662527/662528 01202 665111 Spare parts 01202 662525 01202 665111 Service department 01202 662555 01202 662522
Birmingham Office
Hamworthy Heating Limited
Shady Lane, Great Barr, Birmingham B44 9ER Main switchboard tel: 0121 360 7000 fax: 0121 325 2309
General enquiries 0121 360 7000
• flue components
• packaged fan dilution systems
• bespoke flue components
• bespoke flue systems
• design and installation
spares@hamworthy-heating.com
service@hamworthy-heating.com
technical@hamworthy-heating.com
sales.flues@hamworthy-heating.com
Customer Services
Associate Companies, Offices and Agents throughout the World.
Hamworthy reserves the right to make changes and improvements which may necessitate alteration to the specification without prior notice.
Connect direct
Direct Dial Telephone and Fax Numbers
Direct Email Addresses
Hamworthy Heating Accredited Agents
Website
www.hamworthy-heating.com
• boilers
• controllers
• water heaters
• pressurisation sets
North West England
Gillies Modular Services
210-218 New Chester Road, Birkenhead, Merseyside L41 9BG tel: 0151 666 1030 fax: 0151 647 8101
Scotland
McDowall Modular Services
14-46 Lomond Street, Glasgow, Scotland G22 6JD tel: 0141 336 8795 fax: 0141 336 8954
Southern Ireland
HEVAC Limited
Naas Road, Dublin 12, Ireland tel: 00 3531 141 91919 fax: 00 3531 145 84806
Northern Ireland
HVAC Supplies Limited
Unit 2, Antrim Line Business Park, Sentry Lane, Newtownabbey BT36 8XX tel: 02890 849826 fax: 02890 847443
North East England
Allison Heating Products
17 Beech Road, South Shields, Tyne & Wear NE33 2QH tel: 0191 455 7898 fax: 0191 455 7899
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