Hamworthy Spetisbury Installation, Commisioning And Maintenance Instructions

Spetisbury Boilers

Gas Fired Cast Iron Sectional Boilers

110kW to 340kW

Installation, Commissioning

and Servicing Instructions

NATURAL GAS

IMPORTANT NOTE

THESE INSTRUCTIONS MUST BE READ

AND UNDERSTOOD BEFORE INSTALLING,

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COMMISSIONING, OPERATING OR

SERVICING EQUIPMENT

Technical Enquiries 01202 662527/662528

To supplement the detailed technical brochures, technical advice on the application and use of products in the
Hamworthy Heating range is available from our technical team in Poole and our accredited agents.

Site Assembly 01202 662555

Hamworthy offer a service of site assembly for many of our products in instances where plant room area is restricted.
Using our trained staff we offer a higher quality of build and assurance of a boiler built and tested by the manufacturer.

Commissioning 01202 662555

Commissioning of equipment by our own engineers, accredited agents or specialist sub – contractors will ensure the
equipment is operating safely and efficiently.

Maintenance Agreements 01202 662555

Regular routine servicing of equipment by Hamworthy service engineers inspects the safety and integrity of the plant,
reducing the risk of failure and improving performance and efficiency. Maintenance agreements enable our customers to
plan and budget more efficiently.

Breakdown service, repair, replacement 01202 662555

Hamworthy provide a rapid response breakdown, repair or replacement service through head office at Poole and accred­ited agents throughout the UK.

Spare Parts 01202 662525

A comprehensive spare parts service is operated from our factory in Poole, providing replacement parts for both current
and discontinued products. Delivery of parts and components is normally from stock within seven days. However, a next
day delivery service is available for breakdowns and emergencies.

Customer Services

Spetisbury Boilers

Gas Fired Cast Iron Sectional Boilers

110kW to 340kW

Installation, Commissioning

and Servicing Instructions

NATURAL GAS

NOTE: THESE INSTRUCTIONS SHOULD BE READ AND UNDERSTOOD BEFORE
ATTEMPTING TO INSTALL, COMMISSION OR OPERATE THIS UNIT

THE SPETISBURY BOILER IS INTENDED FOR USE AS A COMMERCIAL APPLIANCE

THE GASED FIRED VARIANTS OF THIS BOILER ARE FOR USE ON GROUP H NATURAL

ND

GAS (2

FAMILY) I2H. PLEASE ENSURE RELEVANT INFORMATION REQUIRED WITHIN
DOCUMENT IS FOUND RELATING TO SPECIFIC FUEL TO BE FIRED BEFORE FIRING
BOILER.

THIS BOILER COMPLIES WITH ALL RELEVANT EUROPEAN DIRECTIVES.
EC TYPE CERTIFICATE No EC-87/04/038
PRODUCT IDENTIFICATION No. 87/BP/38

PUBLICATION NO. 500001118
ISSUE ‘C’
JUNE 2004

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CONTENTS

PAGE

1.0 INTRODUCTION ............................................................................................................................... 1

2.0 UNPACKAGING ............................................ ......................................... ........................................ ... 2

3.0 GENERAL REQUIREMENTS ........................................................................................................... 3

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 ........................................................................................................................................ 4

5.0 GAS SUPPLY ................................................ ..................................... ...................................... ......... 4

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

6.0 FLUE SYSTEM .................................................. ..................................... ..................................... ...... 5

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 Temperatures

6.8 Flue System Location

6.9 Condensate Discharge

7.0 AIR SUPPLY ..................................................................................................................................... 6

7.1 Air Supply By Natural Ventilation

7.2 Air Supply By Mechanical Ventilation

8.0 WATER CIRCULATION SYSTEM .................................................................................................... 7

8.1 General

8.2 Pressure Relief Valve (Safety 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 Control Schemes

8.9.1 Temperature Controls

8.9.2 Water Flow Controls

8.9.3 Frost Protection

8.10 Unvented Systems

8.11 Modular Boiler Control Schemes

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9.0 SUPPLY TO BURNER ............................................. ...................................................... ....................8

9.1 Electrical installation to Burner

9.2 Gas Train Installation to Burner

10.0 BOILER ASSEMBLY AND INSTALLATION ................................................ .....................................9

10.1 General

10.2 Preparation

10.3 Assembly of Sections

10.4 Assembly of Boiler

10.5 Casing Assembly

10.6 Burner Control and Adjustment

11.0 COMMISSIONING AND TESTING ..................................................................................................21

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 User Instructions

12.0 FAULT FINDING ..............................................................................................................................23

13.0 SERVICING ................................................... ...................................................... .............................25

14.0 REPLACEMENT OF FAILED COMPONENTS & RECOMMENDED SPARES ..............................26

15.0 TECHNICAL DATA AND GENERAL INFORMATION ....................................................................30

FIGURES PAGE

Figure 2.1 General Overview .....................................................................................................................2

Figure 7.1 Mechanical Ventilation Flow Rates ..........................................................................................6

Figure 8.3 Cold Feed and Vent Pipe Sizes ...................................................................................................7

Figure 9.1 Electrical Wiring Diagram ............................................................................................................8

Figure 10.1 Composition of Sections Within Heat Exchanger ..........................................................................9

Figure 10.2 Boiler Section Identification .......................................................................................................10

Figure 10.3 Rear Section and Cradle ...........................................................................................................11

Figure 10.4 Fitting Mastic Seal ....................................................................................................................11

Figure 10.5 Fitting Guide Ring .....................................................................................................................12

Figure 10.6 Fitting ‘O’ Ring Seal ..................................................................................................................12

Figure 10.7 Fitting the Lacing Bolts ..............................................................................................................13

Figure 10.8 Fitting Upper Tie Rods ..............................................................................................................13

Figure 10.9 Fitting Lower Tie Rods ..............................................................................................................14

Figure 10.10 Flue Gas Flow Path ..................................................................................................................14

Figure 10.11 Outflow Pipework Orientation ....................................................................................................15

Figure 10.12 Fitting Casing Support Brackets ................................................................................................15

Figure 10.13 Boiler Casing Assembly ............................................................................................................16

Figure 10.14 Boiler Casing Assembly ............................................................................................................16

Figure 10.15 Boiler Casing Assembly ............................................................................................................16

Figure 10.16 Boiler Casing Assembly ............................................................................................................17

Figure 10.17 Boiler Casing Assembly ............................................................................................................17

Figure 10.18 Boiler Casing Assembly ............................................................................................................17

Figure 10.19 Boiler Casing Assembly ............................................................................................................18

Figure 10.20 Boiler Casing Assembly ............................................................................................................18

Figure 10.21 Boiler Casing Assembly ............................................................................................................18

Figure 10.22 Burner Display Panel ................................................................................................................19

Figure 10.23 Throttle and Gas Valve Adjustment Diagram .............................................................................20

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Figure 11.2 Electrode Spark Gap Details .................................................................................................... 21

Figure 12.1 Status Display Lockout Codes .................................................................................................. 23

Figure 12.2 Fault Finding Flowchart ............................................................................................................ 24

Figure 14.1 Exploded View of Boiler ........................................................................................................... 26

Figure 14.2 Exploded View of Burner .......................................................................................................... 28

Figure 15.1 Boiler Installation Typical .................................................... ................................................... 30

Figure 15.2 Dimensions and Clearances .................................................................................................. 31

Figure 15.3 Burner Clearances ................................................................................................................... 31

Figure 15.4 Stacked Boiler Dimension ........................................................................................................ 32

Figure 15.5 Burner Mounting Plates Dimensions SP 110, 150 & 220 ............................................................ 33

Figure 15.6 SP 280 & SP 340 Burner Mounting Details ............................................................................... 33

Figure 15.7 Performance and General Data Information (Natural Gas) ................................................... 34

Figure 3.1 Water Flow Rates and Pressure Drops ................................................................................. 35

Figure 11.1 Target Appliance Readings ...................................................................................................... 35

Figure 14.3 Exploded View Return Sensor Pocket Assembly ....................................................................... 35

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1.0 INTRODUCTION

1.1 The Spetisbury boiler range consists of 5 gas

fired cast iron sectional boilers with outputs ranging
from 110kW to 340kW.

Spetisbury 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.

Stacking kits are available for pairs of Spetisbury
boilers and are assembled on site to HHL
instructions 500005091 in combination with this
manual.

Portland and Weymouth pressurisation units are
available from Hamworthy Heating Ltd for sealed
systems.

1.2 Spetisbury sectional boilers are supplied
unassembled ready for on-site assembly.

The heat exchanger consists of:

a. A front section
b. Plain intermediate sections which can be

adapted to form the 3 types of intermediate
sections.
c. A rear section

These sections are connected to each other using
guide rings and 'O' ring gaskets and are held
together by short lacing bolts. The complete
assembly is held together by four M14 threaded tie
rods running the length of the heat exchanger.

The section to section flue gas seal is made by:

d. A mastic strip around the outer perimeter of
each section.
e. A mastic strip around the perimeter of the
combustion chamber of each section.

The sections are cast with extended surface fins to
increase the heat exchange area and thus enhance
thermal efficiency in use.

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 (on front and rear), all of
which are internally lined with a ceramic fibre
insulation board. The smoke box/flue connector is
bolted to the upper part of the rear section and
sealed with a ceramic fibre gasket.

The heat exchanger is mounted on a steel cradle
which in turn stands on legs, leaving access for
cleaning beneath the heat exchanger. The flow and
return water connections are located at the rear of
the boiler. Refer to Section 8 for details of water
circulation system.

All site wiring is made direct to the burner, refer to
section 10.6 for guidance.

The boiler is housed in a powder coated sheet steel
casing which is supplied flat-packed for on-site
assembly. Refer to Section 10.5 for casing
assembly procedure.

1.3 All Spetisbury boiler sections are hydraulically
tested to 10 bar (145 psi), ensuring the Spetisbury
boiler is suitable for use on systems with maximum
working pressures of up to 5 bar (73 psi).

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2.0 UNPACKAGING

2.1 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 and insulation blankets
d. Matched burner.
e. Flue collector box
f. Burner mounting plate, drilled ready to accept burner (SP 110, 150 & 220 only. Burner mounting plate not

required on SP 280 or 340).

g. Steel cradle.

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

c. Casing Panels

e. Flue Collector Box

f. Burner Mounting
Plate (if req’d)

a. Cast Iron Sections

b. Tie Rods

d. Matched Burner

Figure 2.1 General Overview

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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, 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.5854 - Code of practice for flues and flue

structures in buildings. See para 5 (3.6).

BS.6644 - Specification for installation of gas fired
hot water boilers of rated inputs between 60kW and
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 & 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 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.

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).

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 3.1 it may be
necessary to incorporate mixing valves and shunt
pumps to ensure that the boiler will operate
satisfactorily. Figure 3.1 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.

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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 8.9.1

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

8.10 for Pressurised Water Systems.

4.0 LOCATION

4.1 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
Figure 15.2 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
BS.6644.

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 stands on a steel cradle and therefore it
requires installing 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. If a plinth
is required, it should be level, non-combustible,
50mm nominal height, and must be equal in width to
the boiler casing dimensions.

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 for details.

5.0 GAS 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 BS 6891
or IGE/UP/2. 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 BS 6891 or IGE/UP/1 and IGE/UP/1A 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.

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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, "Flues for Commercial and
Industrial Gas-Fired Boilers and Air Heaters."

The following notes are intended to give general
guidance only.

The flue passages within the Spetisbury operate
under pressurised conditions and in order to
eliminate any additional resistance, it is
recommended that the flue system shall be adapted
to its design diameter as soon as possible, after
leaving the boiler.

The boiler should be connected to a single flue
system in the case of a single boiler, or a common
flue header in the case of a multiple boiler
installation. Flue systems must be self supporting,
contain access for cleaning and contain a
maintenance joint near the boiler outlet to allow for
removal of the flue box during servicing.

Spetisbury boilers are suitable for installation in a
balanced compartment in accordance with the
requirements of BS 6644. Consult Hamworthy
Heating Technical Department for help or
assistance if in doubt.

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 15.7.

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 - 0.3mbar). It is
recommended that a draught stabiliser is fitted to the
flue system where the suction is likely to exceed

0.3mbar.

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: 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 Temperatures

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

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 at 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
of 60 kW total rated input (gross).
High Level (outlet) 270cm

2

plus 4.5cm2 per kW in excess

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
utilized providing design extraction rates comply with
Figure 7.1.

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

Forced Draught

Boilers

Inlet air

(Combustion

Ventilation)

Extract air

(Ventilation)

m3/s m3/s

Volume 0.9 0.6

Figure 7.1 Mechanical Ventilation Flow Rates

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 4” N.B. Flanged flow and return
connections located on the rear section of the boiler.
Mating flanges are supplied suitable for welding to 4”
NB pipe.

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.

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 Part 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 are detailed in
Figure 8.3.
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 15.1 for typical position.

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Boiler Output Feed Vent

60kW - 150kW 25 32

150kW – 300kW 32 38

300kW – 600kW 38 50

Figure 8.3. Cold Feed and Vent Pipe Sizes (mm)

8.5 Thermometer

See Figure 15.1 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
HHL 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 15.1 for recommended positions.

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 HHL supply) should be fitted which must
run for a minimum of 5 minutes on shut-down of the last
boiler.

8.8 Minimum Water Flow Rates

Minimum water flow rates are shown in Figure 3.1.
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 Control Schemes

8.9.1 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 DT of 20°C, care
should be taken to ensure that the return temperature
does not fall below 50°C.

8.9.2 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 3.1 is maintained.

8.9.3 Frost Protection

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

8.10 Unvented Systems

See Figure 15.1 for typical layout of a Unvented
(Pressurised) Hot Water System. For system design
refer to BS 7074 Part 2.

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

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 pressurization 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: Part 1, for
information. See also BS 6880: Part 1 for design
considerations.

8.11 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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9.1 ELECTRICAL INSTALLATION

The electrical installation should be carried out by
suitably qualified and competent personnel. Before
commencing the installation, ensure that all
electrical supplies to the burner are disconnected
and that the gas supply is turned off.

Figure 9.1 shows the electrical wiring diagram for
the burner. Connections must be made to supply
230V / 50Hz Live, Neutral, Earth and the (green/
black) NTC temperature sensor plug must be
correctly fitted.

You must always comply with the basic safety and
electrical regulations that are in force when carrying
out the electrical installation of the burner. This
includes statutory Regulations and National and
International Standards where they apply.

A means of disconnection from the supply having a
separation of at least 3mm in all poles must be
provided.

Always ensure that equipment is connected to the
earthing system and never reverse the Live and
Neutral connections.

9.2 GAS TRAIN INSTALLATION

The gas train installation should be carried out by
suitably qualified and competent personnel. Before
commencing the installation, ensure that the gas
supply is turned off and that all electrical supplies to
the burner are also disconnected.

When connecting a pipe to the Gas Valve Inlet
always use a sound taper fitting with thread
according to ISO 7-1 or a piece of new, properly
reamed pipe, free from swarf, dirt or debris.

Flanges are provided to allow for a pipe size of ¾”
for SP110, SP150, 1” for SP220 and 1¼” for SP280
and SP340 models with a threaded length of 13mm.
Do not thread or tighten the pipe or pipe fitting more
than the 13mm as this could damage or distort the
Gas Valve.

Always include a manually operated shut-off valve
and means of burner disconnection in the gas train
when carrying out the installation. This is required to
isolate the burner for maintenance and servicing
requirements, or for when the burner is taken out of
use for prolonged periods.

Figure 9.1 Electrical Wiring Diagram

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Spetisbury

SP 110 R I I I F

SP 150 R I I I I F

SP 220 R RI I I I I FI F

SP 280 R RI I I I I I FI FI F

SP 340 R RI RI I I I I I I FI FI F

Section No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14

R - REAR SECTION RI - REAR INTERMEDIATE SECTION I - INTERMEDIATE SECTION FI - FRONT INTERMEDIATE SECTION

Section Type

Figure 10.1 – Composition of Sections within Heat Exchanger

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 Boiler Sections

The heat exchanger is made up from five different
types of section, each plain section weighing around
70 kg (140kg for assembled front and rear), as
follows:-

a. One complete front section (assembled with
access doors etc.)
b. One complete rear section (assembled with
access doors etc.)
c. A number of plain intermediate sections which
are converted to the correct number of front, rear
and central intermediate sections by the addition of
flue plates.

Prior to building the boiler the flue plates and their
retaining nuts and bolts should be located and
identified in the accessory kit. Reference MUST be
made to Figures 10.1 & 10.2 . Having determined
the size of boiler to be built the numbers of each of
the three sections required (RI, I and FI) can be
read from Figure 10.1. The correct number of each
section MUST then be made up by inserting the flue
plates and locking nuts into position with nuts and
bolts. The plates MUST be inserted into the
sections in the slots provided and the number and
position of the plates MUST be in accordance with
the detail shown in Figure 10.2.

For the purposes of identification, the intermediate
sections (I) have SIX flue plates fitted into the
flueways. The front intermediate section (FI) has
TWO plates fitted across the centreline of the
flueways and the Rear Intermediate section has
FOUR plates fitted at 45

o

around the flueways.
NOTE: The assembled front and rear castings of
the boiler are already fitted with flue plates.

When fully assembled, the flue gas flow path
through one half of the boiler is as illustrated in Fig.

10.10.

IT IS MOST IMPORTANT THAT THE BOILER IS
BUILT WITH THE CORRECT NUMBER AND
TYPE OF INTERMEDIATE SECTIONS IN THE
CORRECT ORDER.

10.2 Preparation

Place boiler sections in boiler room, adjacent to
proposed site for boiler, in order of build to allow
quick and easy handling and assembly.

Clean both upper and lower ports on each section.
Thoroughly clean the machined joint faces on both
sides of each section to leave a smooth, clean,
paint-free finish.

Open fittings crate and remove lacing bolts, sealing
mastic, guide rings, and 'O'-ring sealing gaskets.
N.B. Ensure these gaskets are kept dry and free
from dirt, grit, oil and grease.

Position the steel cradle on the level surface
prepared for the boiler. Refer to Section 4 - Boiler
Location.

10.3 Assembly of Sections

Assemble the sections as follows, referring to
Figures 10.3 - 10.10 and Figure 14.1.

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Figure 10.2 – Boiler Section Identification

A Rear Intermediate section (RI)

Fitted with 4 flue plates

B Intermediate section (I)

Fitted with 6 flue plates

C Front Intermediate section (FI)

Fitted with 2 flue plates

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a. Position rear section
(Item 4) onto end of cradle
(Item 1) (Fig. 10.3) ensuring
that it is safely supported.
Sections can be lifted by
utilising suitably tested and
protected straps through the
ports or flueways.

IT IS MOST IMPORTANT
THAT THE BACK EDGES OF
THE FEET ON THE
CASTING ARE FLUSH WITH
THE REAR OF THE CRADLE
TO ALLOW FOR CORRECT
FITTING OF THE CASING.

Figure 10.3 – Rear Section and Cradle

b. Fit sealing mastic to

grooves around both
perimeter of section and
combustion chamber (Fig.

10.4). Should mastic rope
break during this operation,
the two ends MUST be
overlapped to avoid any
leakage.

N.B. Particular care should
be taken in placing a mastic
seal around both ports to
protect the 'O'-ring gaskets.

Figure 10.4 – Fitting Mastic Seal

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Figure 10.5 – Fitting Guide Ring

c. Insert guide rings (6)

into both upper and lower
ports and fix in place using a
small piece of the mastic
sealing material (Fig. 10.5).

Figure 10.6 – Fitting ‘O’-Ring Seal

d. Carefully fit 'O'-ring
gaskets (5) over guide
rings to locate into
machined recess around
perimeter of port (Fig.

10.6).

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e. Place the next correct section
(Item 3) onto the cradle and fit to
rear section, carefully locating guide
rings into ports and ensuring that 'O'­ring seals are correctly located
between the machined faces and are
not pinched or damaged.
f. Fit one of the lacing bolts (29)
provided through each of the
UPPER RIGHT and LOWER LEFT
pairs of bolt flanges on the sections
(Fig 10.7). Tighten the bolts
EVENLY to a torque of 25Nm (18 lbf.
ft.)
N.B. These bolts are intended only
to keep the sections together during
assembly. To avoid undue stress
during expansion of boiler they
should NOT be overtightened.

Figure 10.7 – Fitting Lacing Bolts

g. Repeat the above procedure

for the remaining sections in the
correct order ensuring that:
* Mastic sealer is fitted into groove
around perimeters of every
section and port.
* Guide rings and 'O'-ring seals
are correctly fitted.
* Lacing bolts are fitted and not
overtightened.
* Flue plates (19) are correctly
positioned.

Figure 10.8 – Fitting Upper Tie Rods

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h. After fitting front section (2),
fit the four tie rods (30) through
the lugs on top and bottom of front
and rear sections (Figs 10.8 &

10.9). Tighten tie rod nuts to a
torque of 45 Nm (34 lbf.ft)

Figure 10.9 – Fitting Lower Tie Rods

Figure 10.10 – Flue Gas Flow Path

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i. Fit thermostat pocket (18) in top and bottom
of front section, and ¾" BSP drain plug or cock (not
supplied) to bottom of front section (See Fig. 14.3
for fitting instruction).
j. Fit heating flow pipe elbow (28) to top of rear
section, note correct orientation.

Figure 10.11 – Outflow Pipework Orientation

k. Fit water distribution tube (11), holes

uppermost, into the return connection at bottom of
rear section. (Note: Not required on SP 110, 150
and 220.
l. 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).

10.4 Assembly of Boiler.

Further to assembly of the sections, proceed as
follows (refer to Fig. 14.1):
a. Locate and fit the flue collector box (23) to the
upper part of the rear casting using the studs, nuts
and gaskets (22) provided. The rear access doors
(25,26) will need to be loosened to allow correct
fitting of gaskets.
b. On SP 110, SP 150 and SP 220 models,
locate and fit the burner mounting plate (13)
ensuring that the pads of insulation are packed into
the burner aperture and that the fibre board gasket
(12) is in position. Carefully cut a hole through both
the fibre pads and board, large enough to accept the
burner blast tube. Note! Burner mounting plate NOT
required on SP 280 and SP 340 models.
c. Locate the foil covered insulation wrap which
comprises a front blanket, a rear blanket and
lengths of straight wrap. Position the front and rear
blankets on the boiler so that the cut outs align with
the appropriate items, i.e. burner mounting plate,
thermostat pocket, flue collector and return
connection. Mould the excess wrap backwards
around the edges of the boiler sections and tape to
secure. Position the straight wraps over the boiler
body. Where more than one wrap is used, they

should be overlapped so that the front and rear
edges fall flush with the front and rear of the boiler.
Secure wraps in position by using tape or
strapping and buckles. For further details, see
instruction sheet packed with insulation.
Note! The front and rear insulation pieces will
need to be removed for maintenance of the boiler.

d. Using a combination of M10 x 35 hex head
bolts, nuts and washers and existing tie rods fit 4
off casing support brackets as shown below.

Figure 10.12 - Fitting Casing Support Brackets

e. On SP 110, SP 150 & SP 220 models locate

burner onto mounting plate. On SP 280 and SP 340
models locate burner directly on to boiler front
casting.
f. Complete all pipework connections and fuel
lines.
g. Complete installation by fitting casing and
sensors - refer to Section 10.5, 10.6, Fig. 10.13 to

10.21 and Fig. 14.3.

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10.5 Casing Assembly

Figure 10.13

1. Using M6 nuts and washers fit
front and rear cross members to
M6 studs protruding from body of
boiler.

Figure 10.14

2. Using M6 nuts and washers
fit casing support rails to M6
studs on front and rear cross
members.

Figure 10.15

Note position of slot as
viewed from front of boiler.

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Figure 10.16

3. Snap side panels into
position on side rails locating
ball stud fasteners on base of
side panels into mating latches
on side rails.

4. Snap cross struts into
position to anchor side panels
in position.

5. Attach casing support strut to
front edges of side panels and
secure with M5 x 10 pozi
screws and washers.

Figure 10.17

Note: On assemblies with two side panels,
secure panels together with M8 x 16 hex head
screw, nut and washer utilising the 9mm
diameter hole towards the top of the side panel.

Figure 10.18

6. Snap top panel(s) into
position, locating on pre-fitted
latch and strikers. Note that top
panel should overlap to the
front.

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Figure 10.19

7. Position and fit rear cover to rear
of casing using M5 x 10 posi screws
and washers.

Figure 10.20

Note: Ensure that rear cover is
located in correct position as
indicated below.

8. After mounting burner on burner mounting plate, fit plastic strikers and
latches to upper and lower covers and side covers then snap covers into place.
Note: Attach edging to bare edges of upper top panel.

Figure 10.21

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10.6 BURNER CONTROL AND ADJUSTMENT

10.6.1 Fan Speeds

The fan speeds for the Spetisbury range of burner
are pre-set and should not require adjustment.
Although max/min speeds can be adjusted if
required, adjustment of the ignition speed is not
recommended as this may affect the reliability of
operation.

10.6.2 Starting Up

AS WITH ALL FORCED DRAUGHT BURNER
SYSTEMS THE SPETISBURY SP PREMIX
BURNER MUST BE SET UP CORRECTLY TO
ENSURE SATISFACTORY AND RELIABLE
OPERATION

Note: The air pressure switch on this burner is
factory set and should not require adjustment.

Before attempting to light the burner for the first
time, suitably competent personnel should inspect
the installation to ensure the following;

a) That all electrical safety circuits are made and

the electrical installation has been carried out
according to the instructions in this manual.

b) There must be an adequate ground to the

burner and the Live and Neutral should be
correctly connected.

c) The gas pipe work is of a suitable size for the

burner requirements and the installation has
been checked for leaks and fully purged.

On turning on the burner the display should be as
show in Fig 10.22 below.

Press the start button and after a few seconds the
burner should start to pre-purge. Ignition will
commence and the fan will stay at ignition speed for
10 seconds. The burner is pre-programmed with a
step-control, so it will not reach maximum fan speed
for approximately 90 seconds.

Once the burner has reached maximum fan speed
check the CO
shown in the table below:

levels. These should be the same as

2

CO CO2

<10ppm 9.4%±0.2

Drive the fan speed manually to the minimum
setting. This is done by pressing and holding down
for 3 seconds the hidden button below the ‘STATUS’
figure at the same time as the ‘-’ (minus) button. See
Fig. 10.22 below. The ‘STATUS’ figure will now
show;

STATUS

Check for adequate flue gas temperature and CO2
levels. The CO
table below.

should now be as shown in the

2

CO CO2

<10ppm 9.3%±0.2

Fig 10.22 Burner Display Panel

HAMWORTHY HEATING LTD

Hidden button for fan speed
adjustment.

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10.6.3 Burner Adjustment

If adjustments are required to obtain the correct flue
gas temperature and CO

levels, do this by carrying

2

out the following steps;

a. Manually drive the fan speed to maximum by

pressing the hidden button as before, but this
time at the same time as the ‘+’ (plus) button.
Hold them both down for 3 seconds.

b. To increase the CO

levels at the maximum

2

fan speed, first remove the black plastic
throttle security cover. Below this is the 3mm
Allen key screw for throttle adjustment. To
increase the CO

, turn the throttle screw anti-

2

clockwise a quarter turn at a time, checking
the levels constantly until the desired level is
reached.

c. To decrease CO

levels at the maximum fan

2

speed, turn the throttle screw clockwise a
quarter turn at a time.

d. Manually drive the fan speed back to

minimum by pressing the hidden button at the
same time as the ‘-’ (minus) button. Again,
hold them both down for 3 seconds.

e. Recheck the flue gas temperature and CO

2

levels

f. To increase CO

levels at the minimum fan

2

speed, first remove the dust cover from the
regulator on the gas valve. Below this is the
white plastic torx offset adjustment screw.
Turn the screw clockwise a quarter turn at a
time, checking the levels constantly until the
desired level is reached.

g. To decrease the CO

levels at the minimum

2

fan speed, turn the screw anti-clockwise a
quarter turn at a time, checking the levels
constantly until the desired level is reached.

h. Replace the gas valve security cover.

i. Manually drive the fan speed back to

maximum by pressing the hidden button at
the same time as the ‘+’ (plus) button. Once
again, hold them both down for 3 seconds.
Check CO

j. Recheck the flue gas temperature and CO

/ rating.

2

2

at
minimum rate to make sure that they are still
correct. If required the flue gas temperature
should be adjusted by altering the minimum
fan speed.

k. When finished, replace both security dust

covers over the adjustment screws.

10.6.4 Starting Up and Running

Press the On/Off button on the Burner Display Panel
(see Fig. 10.22). After a few seconds the burner
should start to pre-purge. Ignition will commence
and the fan will stay at ignition speed for a short
period. The burner is pre-programmed with a step­control, so it will not reach maximum fan speed for
at least 90 seconds after this. The burner should
then run normally.

If a lock out condition occurs, refer to the Status
Display Lock Out Code Table in the Fault Finding
Section of this manual (Section 12.0) to identify the
cause. If other faults occur, refer to the Fault Finding
Flowchart in Section 12.0. If repairs are deemed
necessary ring Hamworthy Heating Technical
Department for assistance.

10.6.5 Shutting Down

To switch off the burner, press the On/Off switch on
the Burner Display Panel. The burner should shut
down immediately.

If required, an external timing device can be
attached to the burner to switch it off remotely.

THROTTLE ADJUSTMENT

POSITION OF

POSITION OF

VENTURI

GAS VALVE

Figure 10.23 - Throttle and Gas Valve Adjustment

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SPETISBURY

SCREW

20

GAS VALVE

SECURITY

COVER

OFFSET

ADJUST MENT

SCREW

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11.0 COMMISSIONING AND TESTING

11.1 Electrical Installation

Wiring MUST be checked by a suitably competent
person. An isolator correctly fused should be sited close
to the boiler. Refer to section 9 and 10 of this manual.

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 pressurization unit should
not be utilized 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 pressurization 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) Flueway passages to chimney are clear.

2) Adequate ventilation as per Section 7: AIR SUPPLY

exists in the boilerhouse.

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

3.1.

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.

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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 plates are correctly
located in sections, then replace and reseal.
e. Check all thermostat bulbs are correctly inserted
in the appropriate pockets on the upper and lower
faces of the front casing.
f. Check for water leaks and ensure that both boiler
and heating system is full of water and properly
vented. On SP 280 and 340 models check
distribution tube is fitted.
g. Check that all drain cocks are closed, and that all
isolating valves in flow and return pipework are
open.
h. Check soundness of gas installation and that
pipework is purged of air, as detailed in I. Gas. E.
Publications IGE/UP/1 or IGE/UP/1A respectively.
Check that gas meter is operational and has been
checked by the local region of British Gas.
j. Check that gas meter and supply pipework is of
sufficient size to meet the input rating of the burner/
boiler. Refer to Figure 15.2.
k. Check that burner output is correct for size of
boiler in question, referring to Figure 15.7

Note: -
Refer to the firing procedure of the burner in
Section 10.6 of this manual 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 Gas fired Boilers

a. Check that ignition electrode and rectification

probe are correctly positioned. See Fig. 11.2 below;

Figure 11.2 - Spark Gap and Electrode Positions

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b. Check burner seats correctly onto burner
mounting plate and is securely fastened in place.
c. Open main isolating valve in gas supply to boiler.
Check for leaks throughout gas train and pipework
to boiler.
d. 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.
e. Close main isolating valve in gas supply 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 after three failed ignition attempts.
f. Open main isolating valve in gas supply. Reset
the burner control and restart the burner, the main
flame should light at the ignition rate and stabilise
for 90 seconds before running up to full rate. Note:
the fan speed for start, max/min run is factory set
and does not need adjustment (refer to fig 15.7).
g. After allowing burner to reach stable firing
conditions for approximately 15 minutes, carry out
combustion gas check.
Measure gas pressure at the burner inlet CO

, CO,

2

flue gas temperature, and circulating water
temperature rise across the boiler. The readings
obtained for the appropriate gas should be as
indicated in figure 11.1, target appliance readings.
Readings should be taken at max and min firing
rates. Check and adjust parameters to comply with
target figures nominated in section 10.6 of this
manual.

IF BURNER REPEATEDLY FAILS TO LIGHT, A
FULL INVESTIGATION TO FIND CAUSE SHOULD
BE MADE.

h. Check gas flow rate at meter. Ensure that all

other appliances served by the meter are isolated
whilst flow rate is checked.
j. 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.
k. Set boiler control thermostat to required setting,
and check operation of heating control system.
l. 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 15.1. 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 should then be handed over and kept
in a safe place for easy reference.

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12.0 FAULT FINDING

If the equipment still cannot be operated satisfactorily after following these instructions, consult Hamworthy
Heating Technical Department for assistance.

Figure 12.1 - Status Display Lock Out Codes

Parameter

Code

0

Interrupted or short-circuited boiler FLOW

1 1CA

1CB

1CC

2 1CG

1CD, 1CF

1CE, 1CH

Lock Out Condition

temperature sensor (NTC1)

Interrupted or short-circuited boiler RETURN
temperature sensor (NTC2)

Boiler FLOW temperature sensor (NTC1) higher
than lock out temperature.
Boiler RETURN temperature sensor (NTC2) higher
than lock out temperature.
Hot water tank temperature sensor (NTC3 - if
fitted) higher than lock out temperature.

Boiler FLOW (NTC1) and RETURN (NTC2)
temperature sensors have been exchanged.
Boiler FLOW (NTC1) and RETURN (NTC2)
temperature sensors are not equal in rest position.
Boiler FLOW (NTC1) and RETURN (NTC2)
temperature sensors are too high while running.

3 2BH, 2BI,

2BJ, 2BK

4

5

6

7

No flame signal after all ignition attempts.

Flame error in operation.

Flame on in rest position.

Parameters programmed incorrectly.

8 1AH, 1AK

9 1AI

A 1AI

B

C

D

E

F

Parameters programmed incorrectly.

Gas valve not connected or defective.

Gas valve circuit test incorrect.

Mains voltage control problem.

Software fault/EMC interference.

Too many gradient interventions at boiler FLOW
(NTC1) temperature sensor per heat demand.

Fan not switched off when in stand-by.

Speed control is activated when in operation.

Fan does not start to run.

H

HAMWORTHY HEATING LTD

Electronics module out of order.

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Figure 12.2 - Fault Finding Flowchart

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13.0 SERVICING & MAINTENANCE

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 TWELVE months. In the case of
continuous operation, the maintenance operations
should be carried out every SIX months.

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 or
unusual noise from burner.
b. After allowing burner to reach stable firing
conditions for approximately 15 minutes, carry out
combustion gas check.
Measure CO

, CO, flue gas temperature and water

2

temperature rise across the boiler. The readings
obtained should be noted for reference upon
completion of the servicing procedure.
c. Measure gas pressure at inlet to burner gas
train.
d. Check operation of both boiler and heating
system controls, then set burner to OFF.
Allow the boiler/burner to cool.

13.2 Burner Service Procedure.

SWITCH OFF ELECTRICAL SUPPLY AND FUEL
SUPPLY TO BOILER.

a. Disconnect electrical and fuel connections to
burner.
b. Disconnect burner from mounting flange and
remove from front of boiler (taking care to remove
thermostat bulbs).
c. Check the burner head for any signs of
damage or degrading of the material. Cleaning
should only be done using a soft bristle brush and
vacuum cleaner.
d. Examine the condition of the electrodes and
check that they are clean, undamaged, and not
loose. If necessary, remove, clean using a very fine
emery paper and then refit. For the correct spark
gap and position of the electrodes, refer to Fig. 11.2
In this manual.
e. Examine all gasket material and check for any
signs of damage or degrading. If necessary, replace
them, but always use the correct type.
f. Check all electrical connections and cables to
ensure that they are all sound, undamaged and

have not worked loose.
g. Remove and clean the flexible tube to the air
pressure switch and check that this is functioning
correctly.
h. If required, clean the combustion air fan.
i. Refit all parts and reconnect the electricity
and gas supplies.
j. Check for gas soundness and electrical safety
before switching on.
k. Switch on the burner and check for correct
operation.
l. Check combustion CO and CO

, levels at

2

both the minimum and maximum fan speeds as
described in Section 10.6 and adjust if necessary.

IF IT IS NECESSARY TO REPLACE ANY PARTS,
REFER TO SECTION 14.2 OF THIS MANUAL FOR
CORRECT PART NUMBERS.

13.3 Boiler Service Procedure

a. After removing burner, remove boiler casing

and front insulation to gain access to front section of
boiler.
b. Remove heat exchanger access plates (11,
12 and 15 referring to Fig. 14.1), and corresponding
insulation panels, from boiler front section.
Boiler combustion chamber and heat exchanger
flueways are now accessible for cleaning with
suitable brushes and a vacuum cleaner.
c. Access to rear of heat exchanger flueways
and combustion chamber can be obtained by
removing rear insulation wrap, flue box (Fig. 14.1
item 31), cover plate (Fig 14.1 item 32), insulation
and fire brick (Fig. 14.1 item 28) from rear of boiler.
The refractory fire brick (Fig. 14.1 item 28), located
at the rear of the boiler, should be checked at least
once every two years and replaced if necessary.
N.B. Removal of flue box requires disconnection of
flue.
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 and casing. For
guidance, refer to Section 10.
f. Refit burner. Reconnect fuel and electrical
supplies. Refit and ensure thermostat bulbs are
correctly located in pocket.
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

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14.0 REPLACEMENT OF PARTS

There are a number of components listed in Fig 14.1 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 burner and turn off the gas supply before removing covers and
commencing any servicing or component exchange procedure.

Figure 14.1 – Exploded View of Boiler

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SPARE PARTS LIST

14.1 Boiler Spares (refer to Fig. 14.1)

ITEM DESCRIPTION PART NO.

1 Boiler Cradle

Spetisbury 110 ........................................................................ 573405511

Spetisbury 150 ........................................................................ 573405512

Spetisbury 220 ........................................................................ 573405514

Spetisbury 280 ........................................................................ 573405165

Spetisbury 340 ........................................................................ 573405167

2 Front Section ……………………………………………………………………….573405170

3 Intermediate Section .......................................................................................... 573405172

4 Rear Section ……………………………………………………………………….573405174
5 'O-Ring' Seal ……………………………………………………………………….573405175
6 Guide Ring ……………………………………………………………………….573405176

7 Front Access Plate Insulation Panel ................................................................... 573405177

8 Front Access Plate - Right Hand ........................................................................ 573405179

9 Front Access Plate - Left hand ........................................................................... 573405178

10 Cast Iron Hand Nut ............................................................................................. 573405180

11 Water Distribution Tube ...................................................................................... 573405181

(Not Required on SP 110, SP 150 or SP 220 Models)

12 Burner Plate Insulation Panel ............................................................................. 573405182

(Not Required on SP 280 or SP 340 Models)

13 Burner Mounting Plate ........................................................................................ 530805065

(Not Required on SP 280 or SP 340 Models)

14 Sight Glass Insulation Gasket ............................................................................ 573405184

15 Sight Glass Assembly ........................................................................................ 573405185

16 Gasket 135 Dia X 100 X 4 .................................................................................. 573405186

17 Cast Iron Plate ¾" BSP ...................................................................................... 573405187

18 Thermostat Pocket ¾" BSP ............................................................................... 573405049

19 Intermediate Section Flueway Plate .................................... ............................... 573405188

19A Front Section Flueway Plate .............................................................................. 573405189

20 Fire Brick ……………………………………………………………………….573405190

21 Combustion Chamber Rear Cover Plate ............................................................ 573405191

22 Flue Box Gasket ................................................................................................. 573405192

23 Flue Box ……………………………………………………………………….573405193

24 Rear Access Plate Insulation Panel ................................................................... 573405194

25 Rear Access Plate - Left Hand ........................................................................... 573405195

26 Rear Access Plate - Right Hand ......................................................................... 573405196

27 Return Pipe Flange ............................................................................................ 573405197

28 Flow Pipe Elbow ................................................................................................. 573405198

29 Lacing Bolt M10 X 150 ....................................................................................... 573405199

30 Tie Rod Set (M14)

Spetisbury 110 ......................................................................... 573405521

Spetisbury 150 ......................................................................... 573405522

Spetisbury 220 ......................................................................... 573405524

Spetisbury 280 ......................................................................... 573405200

Spetisbury 340 ......................................................................... 573405202

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14.2 – Burner Spares (Refer to Figure 14.2)

Air Pressure
Switch

Control

Control Box

Gas Valve

Fan Gasket

Fan

Electrodes

Burner Head

Burner Head
Gasket

Mounting Plate
Gasket

Electrode Gasket

Fan Gasket

Relay

Temperature Limiter

Figure 14.2 – Exploded View of Burner

Parts Common To All Models

Relay 533306054

Control Display 533306055
Temperature Limiter 533306056
Electrode Gasket 533306057
Electrode Assembly 533306058
Air Pressure Switch 533306073

Spetisbury SP 110

Control Box 533306065
Gas Valve 533306066
Fan Unit 533306067
Mounting Plate Gasket 533306068
Burner Head Gasket 533306069
Fan Gasket 533306070
Burner Head 533306071
Inlet Gas Flange kit 533306072
Gasket Kit 563605284
Service Kit 563605285

Not shown in exploded view

Display PCB 533306059
Lock-out PCB 533306060
Volt Free Relay 533306061
Relay housing 533306062
NTC Sensor 1.5m 533306063

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Spetisbury SP 150

Control Box 533306075
Gas Valve 533306066
Fan Unit 533306067
Mounting Plate Gasket 533306068
Burner Head Gasket 533306069
Fan Gasket 533306070
Burner Head 533306071
Inlet Gas Flange kit 533306076
Gasket Kit 563605284
Service Kit 563605285

Spetisbury SP 220

Control Box 533306077
Gas Valve 533306078
Fan Unit 533306067
Mounting Plate Gasket 533306068
Burner Head Gasket 533306069
Fan Gasket 533306070
Burner Head 533306071
Inlet Gas Flange kit 533306076
Gasket Kit 563605284
Service Kit 563605285

Spetisbury SP 280

Control Box 533306079
Gas Valve 533306080
Fan Unit 533306081
Mounting Plate Gasket 533306082
Burner Head Gasket 533306083
Fan Gasket 533306084
Burner Head 533306085
Inlet Gas Flange kit 533306086
Gasket Kit 563605286
Service Kit 563605287

Spetisbury SP 340

Control Box 533306089
Gas Valve 533306080
Fan Unit 533306081
Mounting Plate Gasket 533306082
Burner Head Gasket 533306083
Fan Gasket 533306084
Burner Head 533306085
Inlet Gas Flange kit 533306086
Gasket Kit 563605286
Service Kit 563605287

Note:

The Gasket Kit contains all the gaskets used in the burner assembly.

The Service Kit contains all the parts needed during a service.

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15.0 TECHNICAL DAT A

Figure 15.1 Boiler Installation Typical

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900 214

FLOW CONNECTION
4” NB FLANGE

1030

550

286

L 840 960 1200 1440 1680

350

350

157

L

500**

RETURN CONNECTION
4” NB FLANGE

C

D

670

250

Figure 15.2 Dimensions and Clearances

Note ** - this dimension is a minimum recommendation permitting access to the rear of the boiler for maintenance

(800mm for stacked boilers). It may not however be adequate for the installation of flue bends within the boiler
house. Where necessary, the dimension must be increased accordingly.

Figure 15.3 Burner Clearances

Boiler / Burner Model C mm D mm

SP 110 310 480
SP 150 310 480
SP 220 310 600
SP 280 505 560
SP 340 505 560

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STACKED BOILER DIMENSIONS

Front View

Figure 15.4 - Stacked Boiler Dimensions.

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BURNER MOUNTING PLATE DIMENSIONS

When installing a Spetisbury SP 110, SP 150 or SP 220 a burner mounting plate is supplied, the dimensions of
which are shown below.

Figure 15.5 - SP 110, 150, 220 Burner Mounting Plate Dimensions

When installing a Spetisbury SP 280 or SP 340 a burner mounting plate is not required as the burner fits directly
to the boiler casting. The dimensions of the SP 280 / 340 burner fixings are shown below.

Figure 15.6 - SP 280 / 340 Burner Fixings

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GENERAL INFORMATION

BOILER MODEL - Spetisbury

GENERAL DATA

No. OF SECTIONS

BOILER INPUT - maximum kW

(nett) 34.06 MJ/m3

BOILER INPUT - maximum kW

(gross) 37.8 MJ/m3

BOILER OUTPUT - maximum kW

FLUE DATA

NOMINAL FLUE DIA. mm

FLUE DRAUGHT REQUIRED

AT BOILER OUTLET

COMBUSTION CHAMBER

RESISTANCE (maximum)

APPROX. FLUE GAS TEMP (gross)

APPROX. FLUE GAS VOLUME

@ NTP (wet)

GAS DATA

NOMINAL GAS INLET PRESSURE mbar

MAXIMUM GAS INLET PRESSURE

GAS FLOW RATE

5 6 8 10 12

Btu/hr x 1000

Btu/hr x 1000

Btu/hr x 1000

in

mbar

in.wg.

mbar

in.wg.

°C

m3/h

ft3/h

mbar

m3/h 13.3 18.2 26.5 32.8 39.9

ft3/h

110 150 220 280 340

125.5 171.2 250.5 309.9 377.9

428.2 584.1 854.7 1057 1289

139.37 190.1 278.2 344.0 419.4

475.5 648.6 949.2 1174 1431

110 150 220 280 340

375 511 751 955 1160

180

7

0.1 - 0.3

0.04 - 0.12

2.8 5.0 5.9 3.9 5.5

1.1 1.96 2.32 1.54 2.17

225

174 236 294 383 467

6144 8333 10381 13532 16501

20

25

469.5 642.5 935.5 1157 1410

GAS INLET CONNECTION

WATER DATA

WATER CONNECTIONS - FLOW &
RETURN

MAXIMUM WATER bar g.

PRESSURE

WATER CONTENT litres

BOILER WEIGHT (FULL) kg

WITHOUT BURNER

BURNER WEIGHT kg
(including packaging)

PRESSURE SWITCH SETTING mbar

MAX WATER TEMP.
(TEMP LIMITER SET AT °C)

ELECTRICAL SUPPLY

4 in N.B.

psi g

UK gal.

lb

lb

Rc ¾” Rc 1” Rc 1¼”

5.0

73.0

78 92 120 148 176

17.2 20.3 26.4 32.6 38.8

508 592 755 923 1106

1118 1302 1661 2031 2433

27.6 27.6 27.6 47.6 47.6
61 61 61 105 105

0.3 0.2 0.4 1.3 1.4

100°C

230V 1ph ~ 50Hz

Figure 15.7 – Performance and General Data Information (Natural Gas)

Note: For matched burner/boiler combinations, refer to Figure 15.7

For combustion target figures, refer to Figure 11.1

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Lower front section flange
refer item 17 figure 14.1

3/4” Nipple

3/4” Equal Tee

3/4” Nipple

Thermostat Pocket
and Spring

Thermostat pocket

Reducing bush

Figure 14.3 – Exploded View return sensor pocket assembly

Connection for drain
cock, non HHL supply

BOILER
MODEL

Spetisbury

SP 110 158.5 34.8 3.5 1.4 80 17.6 1.0 0.4
SP 150 206.7 45.4 6.5 2.6 108 23.8 1.8 0.7
SP 220 286.7 63.1 11.5 4.5 157.7 34.7 3.7 1.5
SP 280 357.5 78.6 16.5 6.6 196.3 43.2 5.0 2.0
SP 340 435.0 95.7 21.0 8.4 240.0 52.8 6.4 2.6

FLOW RATE PRESS. DROP FLOW RATE PRESS. DROP

l/min UK gal/min mbar in. wg l/min UK gal/min mbar in. wg

DESIGN FLOW RATE

(11 ° C. ∆T)

MINIMUM FLOW RATE

(20 ° C. ∆T)

Figure 3.1 - Water Flow Rates and Pressure Drops

Fuel

Type

BOILER MODEL

CO2 (DRY) 9.6% ±0.2

SP 110 SP 150 SP 220 SP 280 SP 340

9.4% ±0.2

CO Less than 100 ppm (air free)

Natural Gas

G20

Flue Gas
Temp Rise

O

Temp Rise
Across Boiler

C

225 OC

Less than 20OC

Figure 11.1 – Target Appliance Readings.

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

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

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NOTES:

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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

[email protected]

[email protected]

[email protected]

[email protected]

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]