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

Wimborne GM Boilers

Gas/Oil Fired Cast Iron Sectional Boilers

420kW to 1070kW

Installation, Commissioning

and Servicing Instructions

NATURAL GAS

CLASS D (35 sec fuel oil)

IMPORTANT NOTE

THESE INSTRUCTIONS MUST BE READ

AND UNDERSTOOD BEFORE INSTALLING,

I

2H

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

420kW to 1070kW

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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HAMWORTHY HEATING LTD Page 500001113/D
Wimborne GM

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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

HAMWORTHY HEATING LTD Page 500001113/D
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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).

2H

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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Wimborne GM

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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Wimborne GM

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

HAMWORTHY HEATING LTD Page 500001113/D

31

Wimborne GM

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

HAMWORTHY HEATING LTD Page 500001113/D

32

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

HAMWORTHY HEATING LTD Page 500001113/D
Wimborne GM

33

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

34

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

35

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

36

For Dimensions A, B and C refer
to figures: M and N.

APPENDIX A BOILER / BURNER WIRING DIAGRAMS

HAMWORTHY HEATING LTD Page 500001113/D
Wimborne GM

37

Notes

Poole Office

Hamworthy Heating Limited

Fleets Corner, Poole, Dorset BH17 0HH England
Main switchboard tel: [phone]

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: [phone] fax: [phone]

General enquiries 0121 360 7000

• flue components

• packaged fan dilution systems

• bespoke flue components

• bespoke flue systems

• design and installation

[e-mail]

[e-mail]

[e-mail]

[e-mail]

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: [phone] fax: [phone]

Scotland

McDowall Modular Services

14-46 Lomond Street, Glasgow, Scotland G22 6JD
tel: [phone] fax: [phone]

Southern Ireland

HEVAC Limited

Naas Road, Dublin 12, Ireland
tel: [phone] fax: [phone]

Northern Ireland

HVAC Supplies Limited

Unit 2, Antrim Line Business Park, Sentry Lane, Newtownabbey BT36 8XX
tel: [phone] fax: [phone]

North East England

Allison Heating Products

17 Beech Road, South Shields, Tyne & Wear NE33 2QH
tel: [phone] fax: [phone]