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Hamworthy MILBORNE 381 Series, Design Installation, Commissioning And Operating Instructions, Page: 1 / 72

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Hamworthy MILBORNE 381 Series Design Installation, Commissioning And Operating Instructions Download Page 1

 
HAMWORTHY HEATING LTD 

 

MILBORNE 

 

500001130/J 

 

 

MILBORNE BOILERS 

 

Wall Hung, Pre-Mix, Condensing, 

Modular Boilers 

 

381 & 501 Series 

 

Design Installation, Commissioning 

and Operating Instructions 

NATURAL GAS   

I

2H 

LPG - PROPANE   

I

3p

 

i 

  

NOTE:

 

THESE INSTRUCTIONS SHOULD BE READ AND UNDERSTOOD BEFORE 

ATTEMPTING TO INSTALL, COMMISSION OR OPERATE THIS UNIT 
 

 

 
 
 
 
 
 
 
 
 
 
 
 
 

 
 
 
 
 
 
 
 
 
 

PUBLICATION NO. 500001130 
ISSUE  ‘J’ 
JULY 2009

 

Summary of Contents for MILBORNE 381 Series

Page 1: ...ing Modular Boilers 381 501 Series Design Installation Commissioning and Operating Instructions NATURAL GAS I2H LPG PROPANE I3p i NOTE THESE INSTRUCTIONS SHOULD BE READ AND UNDERSTOOD BEFORE ATTEMPTING TO INSTALL COMMISSION OR OPERATE THIS UNIT PUBLICATION NO 500001130 ISSUE J JULY 2009 ...

Page 2: ...ENDIX A GAS DATA 55 APPENDIX B ELECTRICAL CONNECTIONS CONTROLS 58 APPENDIX C FLUE DATA 60 APPENDIX D VENTILATION 62 APPENDIX E WATER DATA 64 PICTORIAL AND DIAGRAMATICAL DATA FIGURES PAGE Figure 2 1 Boiler Packaging 2 Figure 2 2 Boiler Packaged Dimensions 3 Figure 2 3 Single Boiler Arrangement 3 Figure 2 4 Two Boiler Arrangement 4 Figure 2 5 Three Boiler Arrangement 4 Figure 2 6 Two Boiler Back to ...

Page 3: ...27 Figure 8 1 2 System Overview 27 Figure 8 2 6 1 Load Control Graph 28 Figure 8 2 6 2 Temperatue Control Graph 28 Figure 8 3 1 Jumper J14 Connection on PCB 29 Figure 8 3 2 Jumper J17 Connection on PCB 29 Figure 8 3 3 PCB Set up for Multiple Boiler Installations 29 Figure 8 4 1 Milborne Multiple Installation 30 Figure 8 4 2 Jumper Settings 31 Figure 8 4 3 Example Installation Consisting 7 Boiler M...

Page 4: ...2 Removal of Ignition Electrode from Heat Exchanger 51 Figure 10 6 3 Ignition Electrode Recommended Spark Gap Dimension 51 Figure 10 6 4 Ignition Electrode Recommended Spark Gap Dimension 51 Figure 10 8 Flue Sample Point Sealing Plug 51 Figure 11 1 Replacement Casing Panels 52 Figure 11 2 Recommended Replacement Parts 52 Figure 11 3 Recommended Replacement Parts 53 Figure 11 4 Sensor resistance va...

Page 5: ... that the primary pump MUST be controlled from the Master boiler to ensure synchronised operation refer to fig 4 6 1 4 The boiler is only suitable for connection to an un vented pressurised heating system care must be taken to ensure all extra safety requirements are satisfied and that the relevant interlocks will shut the boiler s off should a high or low pressure fault occur The pressurisation u...

Page 6: ...ing handling Care must be exercised to avoid toppling the boiler as this will result in damage Warranty Full warranty assistance will be covered when the appliance is commissioned by Hamworthy Heating Ltd see Terms Conditions for full details Hamworthy Heating Ltd will not accept any liability resulting from damage due to tampering improper use handling installation errors operation and maintenanc...

Page 7: ...the missing item Frame Set and Pipework Header Kits Where pipework kits are supplied these are packaged separately from the boilers Additionally ancillary items such as isolation valves and boiler make up connectors are packaged in a cardboard box on the same pallet The whole is shrink wrapped for security and basic protection Figure 2 3 Single boiler arrangement showing frame flue header water pi...

Page 8: ...gure 2 4 Two boiler arrangement showing frame flue header water pipework and primary circuit pump kit Figure 2 5 Three boiler arrangement showing frame flue header water pipework and primary circuit pump kit Open flue with air drawn from plant room ...

Page 9: ...HAMWORTHY HEATING LTD 5 MILBORNE 500001130 J Figure 2 6 Two boiler back to back arrangement showing frame flue headers water pipework and primary circuit pump kit ...

Page 10: ...nge has been designed to utilise minimum wall space therefore it is important that the plantroom has sufficient ceiling height to allow for installation and connection to the flue system allowing for sufficient access at sides and below boiler for pipework connections See Figure 3 1 Figure 3 1 Dimensions ...

Page 11: ...E HEADER 160mm DIAMETER FLOW DN50 PN6 RETURN DN50 PN6 1980 NOM WALL DUCT 3 2 The Hamworthy Heating Ltd frame set and pipework kit is designed to provide a compact solution for connecting the boilers to the gas supply and flow and return water connections Figure 3 2 1 Single boiler installation dimensions room sealed Figure 3 2 2 Two boiler installation dimensions ...

Page 12: ...eproof in accordance with BS 6644 The plantroom must have sufficient space for installation of boilers pipework pumps controls flues ventilation access and servicing and other items of plant 4 2 Gas Supply Gas supply pipes must be in accordance with BS 6891 or IGE UP 2 Gas supply connections to the boiler must not be smaller than the connection on the boiler G 3 4 Gas installation must be soundnes...

Page 13: ...r open flue type B23 installation drawing combustion air from the plantroom or room sealed twin duct type C53 installation see section 5 2 Due to the low flue gas temperature 50 C condensation will occur in the flue flue materials must be non corrosive and utilise fully sealing joints Adequate facilities must be provided for draining the flue condensation Any horizontal runs of flue must provide c...

Page 14: ...ove an opening air brick opening window etc 300 C Horizontally to an opening air brick opening window etc 300 D Below gutters soil pipes or drain pipes 75 E Below eaves 200 F Below balconies or car port roof 200 G From a vertical drain pipe or soil pipe 150 H From an internal or external corner 300 I Above ground roof or balcony level 300 J From a surface facing the terminal 600 K From a terminal ...

Page 15: ... boiler to ensure synchronised operation refer to fig 4 6 Where twin head pumps are installed a changeover control not HHL supply external to the boiler is required Pressurised system to comply with BS 7074 Each module is supplied with a safety valve set at 6barg It is strongly recommended that the system pipework is flushed at least twice before adding water treatment and before installing the bo...

Page 16: ...rd drain subject to National or Local regulations Location of condense pipework should prevent freezing within tundishes traps and pipework The connection to the boiler condense drain accepts a straight push fit coupling for 18mm i d plastic waste pipe Maximum condensate production 5 1l hr per 37 5kW 7 2 l hr per 50 kW module Figure 4 5 1 Boiler Condensate Connection Figure 4 5 2 Flue Condensate C...

Page 17: ...locations Electrical supplies to boiler modules should only serve the boiler Any pump controlled by the boiler must be installed using an adequate contactor Where twin head pumps are installed a changeover control not HHL supplied external to the boiler is required Where an external alarm is required a 230v signal is provided from the boiler Time clock control should be via the boiler modules stop...

Page 18: ...Milborne Horizontal Flue 5 2 2 1 Flue Maximum Length Each 50 mm flue pipe maximum equivalent length is defined in Appendix C figure C1 1 5 2 2 2 Open Flue Installations type B23 Figure 5 2 2 1 shows the configuration of a single Milborne 381 501 boiler installation using the B23 open flue arrangement Note Consideration must be made for the prevention of condensate from freezing within the condensa...

Page 19: ...s 150 mm see figure 5 2 3 1 Note the 80mm connecting pipes must be so arranged so as to provide the necessary 3 slope on the header to ensure the drainage of condensate to a suitable point Note When using the 125 mm diameter flue header the maximum number of modules acceptable in a single flue system is six 6 or 3 x 382 502 models Larger cascade capacities must use the 160mm diameter header For eq...

Page 20: ...C 1 A 12 11 10 9 8 7 6 5 4 3 2 1 J11 1 2 3 4 5 6 7 8 HT LT J12 ROOM STATS 1 2 3 4 5 6 7 8 9 27 28 26 24 25 23 21 22 20 18 19 J8 J9 J10 1 2 1 2 3 1 2 3 4 5 6 ALARM VALVE MIX ON OFF D PUMP PRIMARY PUMP CIRC 1 DHW PUMP L N L L N L N L N L N DHW CIRCUIT OR NTC SENSOR CYLINDER STAT 80 C 60 C HEATING CIRC 1 HIGH TEMP ROOM STAT STAT ROOM PUMP CIRCUIT 1 PUMP DHW CIRCUIT 2 NTC SENSOR MIXING VALVE LOW TEMP ...

Page 21: ...d flow sensor 5 2 FLUE SYSTEM 5 2 1 Room Sealed Flue Installations Type C63 Twin Ducts Figure 5 2 1 shows the twin pipe flue connection for a Milborne 502 boiler This allows the air supply and the flue to be piped using separate ducts for room sealed applications It is important that horizontal flue terminals discharges are positioned in accordance with the requirements detailed in Figure 4 3 Air ...

Page 22: ... kit for 502 boiler ø160 mm Polypropylene header kit for 501 boiler ø160 mm 573407292 573407295 573407290 573407294 Condensate trap tee piece kit ø125 mm Condensate trap tee piece kit ø160 mm Flue pipe wall bracket ø125 mm Flue pipe hanger bracket ø125mm Flue pipe wall bracket ø160 mm Flue pipe hanger bracket ø160mm 573407296 573407297 573407247 573407355 573407328 573407329 Horizontal Discharge T...

Page 23: ...he boiler controls will modulate the burner to maintain 20 C T As a safety precaution a differential pressure switch is fitted to the boiler heat exchanger to shut the system down in the event of sudden adverse flow conditions Where using Hamworthy Heating Ltd frame set and pipework kits assembly of these is detailed in Operation and Maintenance manual 500001156 supplied with kit 5 3 Water Connect...

Page 24: ...d purge certificates should be available for viewing 6 2 Ventilation Ensure that ventilation and air supply to plantroom is correct 6 3 Pipework Valves and Pump Ensure that Pipework and valve arrangement is installed to Hamworthy Heating recommendations Circulating system is full of water vented and pressurised appropriately Circulation pump is fitted working and interlocked where required Pipewor...

Page 25: ...e each 2 minute check period Following soundness tests close valve B and remove manometer connections and tighten test points 7 0 CHECKS PRIOR TO LIGHTING IMPORTANT BEFORE PROCEEDING ENSURE THAT THE PRE COMMISSIONING CHECKS ON PAGE 20 HAVE BEEN CARRIED OUT AND THE RESULTS SATISFACTORY 7 1 Boiler Gas System Leak Check Ensure that the appliance manual gas service valve is in the OFF position Althoug...

Page 26: ... purged from all high points 5 Ensure that the system isolating valves are in the open position and that the water pressure within the heating system is correct Minimum pressure 0 5barg 6 Ensure that circulating pumps have been installed correctly and that the pumps are available for operation 7 Ensure that the flue ducts are correctly fitted and that they are free from obstruction Check that the ...

Page 27: ... is firing as the heat exchanger components can achieve temperatures which could cause injury if touched Fig 7 4 3 Starting the Boiler 1 Ensure that all external controls are in demand and that the gas supply to the module is isolated 2 Switch the main boiler on off switch located on the underside of the boiler to the on position as indicated in figure 7 4 3 3 Start the individual boiler module us...

Page 28: ...ating sequence for the display is as follows No Demand for heat Heat Demand for domestic hot water circuit or from heating circuits 1 and 2 Slow flashing LED Standby Fast Flashing LED Ignition phase Steady LED Flame is present Note The ignition sequence is as follows 1 5 Seconds of pre purge 2 4 Seconds of post purge Rd Gn Fig 7 4 6 7 Run the burner to maximum power To achieve this press and hold ...

Page 29: ...with table 7 1 If the CO2 values are incorrect then adjustment must be made by adjusting the gas valve offset adjustment screw See figure 7 4 11 Turning the offset screw anticlockwise decreases the gas flow and decreases the CO2 value Turning the offset clockwise increases the gas flow and increases the CO2 value See fig 7 4 11 Note To increase the gas flow turn the offset screw clockwise to decre...

Page 30: ...sed on outside air temperature and a common curve Each circuit can be offset from this curve by setting the maximum and minimum water temperatures in the parameters A comprehensive self diagnostic fault identification system is incorporated within the Master control allowing visibility of all boilers in the installation 8 2 System Design Hamworthy Heating strongly recommend the use of a primary ci...

Page 31: ... S4 S5 U2 U3 U4 D4 D5 S1 Reset S2 Set Esc S3 Set Values S4 Increase S5 Decrease S6 Prog Ok U2 LED Display U3 LED Display U4 LED Display D4 Power on green LED D5 Faults display red LED Figure 8 1 1 Control Panel Master Figure 8 1 2 System overview illustration ...

Page 32: ...stem and facilitate load sharing via lead boiler rotation All ancillary plant primary pump and secondary circuit pumps valves must be controlled via the BMS The BMS must ensure operation of the primary pump using flow switches before initiating boiler operation All plant interlocks pumps pressurisation units fire alarms etc must be configured to prevent boiler operation via the 0 10Volt analog sig...

Page 33: ...ctivated in the case of a mal function of the Master control Emergency Mode Once enabled this ensures that the system will operate at a default delivery temperature set by the Manufacturer 8 3 1 Disconnect the 4 pole connector J14 from the Master pcb see figure 8 3 1 8 3 2 Set all four J17 switches located on each Slave to the OFF position see figure 8 3 2 8 3 3 Supply all system pumps with mains ...

Page 34: ...imum of 15 blocks each made up of 4 Slaves Eg If 5 Slave controllers are connected to one Master controller then 2 blocks are required The first containing 4 Slave controllers and the second just 1 To configure the addresses follow the next procedure 1 Identify the block that each Slave is to be assigned eg block 1 2 3 etc 2 Identify the position that each Slave is to be assigned in its chosen blo...

Page 35: ...F Block 2 OFF OFF ON ON Block 3 OFF ON OFF OFF Block 4 OFF ON OFF ON Block 5 OFF ON ON OFF Block 6 OFF ON ON ON Block 7 ON OFF OFF OFF Block 8 ON OFF OFF ON Block 9 ON OFF ON OFF Block 10 OFF OFF ON ON Block 11 ON ON OFF OFF Block 12 ON ON OFF ON Block 13 ON ON ON OFF Block 14 ON ON ON ON Block 15 Block Settings Block Address Slave Address Block Address 4 Boiler modules to each block Figure 8 4 2 ...

Page 36: ...ock 1 1 2 ON OFF 1 2 3 4 ON OFF Boiler module 1 1 2 ON Block 1 1 2 3 4 ON OFF Boiler module 2 Block 1 1 2 ON OFF 1 2 3 4 ON OFF Boiler module 3 1 2 ON OFF Boiler module 4 1 2 3 4 ON OFF Block 1 Block 2 1 2 3 4 OFF 2 ON OFF ON Boiler module 1 1 Block 2 1 2 3 4 OFF 1 2 ON OFF ON Boiler module 2 Block 2 1 2 3 4 OFF 1 2 ON ON Boiler module 3 ...

Page 37: ...perature switching hysteresis 0 2 0 8 C Contacts rating Max 250V 5A Internal frost protection 6 C Minimum setting period 1 Hour 8 5 1 Locating the thermostat The thermostat should be positioned in the area of the building most critical for comfort Within this area the thermostat must be positioned away from heat sources such as radiators sun rays and kitchens Additionally the thermostat must be lo...

Page 38: ...ting Ltd for a copy of instruction manual 8 6 Master control panel error codes The following tables display the Master control errors messages These messages relate to faults that can occur within the Master control panel or from the sensors and circuits connected to the Master control panel Errors can be divided into two groups lock out errors which can be automatically reset E errors and permane...

Page 39: ...to the first unit boiler module e g unit boiler module 2 error code E 05 Fault can be either E codes or A codes If errors derive from the Master they will be displayed before the other errors as U 00 error code The Master controller always has addresses U 00 See error list for codes and re lated faults Procedures Display Button Required 3 Press S2 SET ESC to exit errors and go back to display mode...

Page 40: ...ors A manual reset A01 1 5 failed attempts of starting up Check the gas cock Check for spark and condition of ht lead Check and replace Slave board A02 2 Too many failed ignition attempts Check and clean or replace the spark elec trode Check and clean or replace the ht lead A04 4 Intervention of limit stat 90 C Check and correct boiler flow rate Check and replace limit thermostat A05 5 Failed gas ...

Page 41: ...to the mode display If the value needs to be modified press S4 and S5 until the desired value is displayed Press S6 to store the value The chosen value will stop flashing and the display will be restored to the mode display Display Nr PC Nr Fault Action E33 33 Polarity reversed L N Check and correct E34 34 Reset key error pressed more than 7 times in 30 mins If after 40 mins the error has not clea...

Page 42: ...value corresponds with the set value the display will be restored to the mode display If after pressing and at step 4 no operation is carried out after 1 minute the display shall be restored to the mode display The new selected value shall not be restored 8 9 Monitor Mode Press S2 to enter into the Monitor mode and display the running status of each single boiler module from address 1 to 60 see fi...

Page 43: ...f no operations are carried out for 5 minutes the display shall be restored to the mode display Figure 8 8 1 procedure for accessing the Monitor Mode Pos Value Display 1 High temp circuit flow temperature T1 70 C 2 Domestic hot water storage temperature T3 50 C 3 External temperature T4 60 C 4 2nd circuit or low temp circuit flow temperature T6 50 C 5 1st circuit or high temp circuit room thermost...

Page 44: ...S4 and S5 to enter the first figure of the password on the central digit e g password 22 6 Press S6 Prog OK to store the password If the password is wrong the display will return to mode position 7 Use S4 and S5 to scroll all password protected parameter addresses Press S2 Set Esc to select the parameters for modification Parameter address and its respective value will alternate on the display See...

Page 45: ...ated All combustion fans will be activated If a module or slave is electrically isolated by the On Off switch see figure 7 4 3 all other fans will run To access the combustion test display screen Step Procedures Button Required Display 1 Press S2 SET ESC and S4 for 5 seconds All system fans will operate at the selected speed 2 The maximum and minimum speeds can be selected by pressing S4 for maxim...

Page 46: ...uit type Set to 0 for DHW disabled Set to 1 for plate h ex with NTC sensor Set to 2 for calorifier with NTC sensor Set to 5 for Plate h ex with thermostat Set to 6 for calorifier with thermostat P 8 Domestic hot water circuit upper limit Limits the end users set point adjustment available at parameter 2 Max 70 C P 9 Domestic hot water circuit priority Set to 0 or 1 for shared priority with heating...

Page 47: ...mand The priority method may reduce the power available to other circuits if there is a high demand in the prioritised circuit and the boiler sizing is lean If all circuits are required to operate without interruption the priority should be set to shared ie setting 0 8 10 4 Setting low temperature heating circuit functions for constant temperature End user adjustable parameters P 3 Low temperature...

Page 48: ...air temperature limits for low temperature heating circuit P 38 Compensation curve max external air temp setting Set for external air temperature at which the minimum flow temperature set in parameter 18 is required Eg 18 C Also sets external air temperature limits for low temperature heating circuit Circuit priority Parameter P 16 Prioritising one heating circuit over the other allows the boiler ...

Page 49: ...ve static period Set time mixing valve is to remain static after moving Eg 5 secs Max 255 secs P 37 Compensation curve min external air temp setting Set for external air temperature at which the maximum flow temperature set in parameter 23 is required Eg 1 C Also sets external air temperature limits for high temperature heating circuit P 38 Compensation curve max external air temp setting Set for ...

Page 50: ... be made to ascertain the cause refer to section 9 3 9 2 Fault Finding Procedures General error codes are detailed in section 8 5 to assist with general fault finding If the boiler still cannot operate satisfactorily after following the instructions consult Hamworthy Heating for assistance 9 3 Possilbe Causes of Boiler Lockout 1 Ignition failure due to faulty igniter 2 Ignition failure due to faul...

Page 51: ...M STAT 9 10 HT ROOM STAT LPB BUS CONNECTION TO ADDITIONAL BOILERS IN MODULAR APPLICATIONS 6 5 4 3 2 1 5 4 3 2 1 9 10 11 12 13 1 2 3 4 5 6 7 NEUTRAL LIVE EARTH SLAVE MODULE No 1 14 MAIN EARTHING BLOCK LIVE 230V A C NEUTRAL 230V A C NEUTRAL LIVE GV 230V 50Hz BOILER ISOLATION SWITCH N L GV N L GV Ground Neutral Live GV GV 6 5 4 3 2 1 3 2 1 2 1 1 2 3 4 5 6 7 8 28 27 26 25 24 23 22 21 20 19 18 1 2 3 4 ...

Page 52: ... ral Fan 10 11 9 Flow Tem p Sens or Sens or Return Tem p Return Tem p Sens or WD Slave Mod ul e N o 1 T3 PC J5 J10 J17 Main J9 J16 1 2 BUS1 Modul e ON OFF Switch Input Sens Hall 1 1 PC J5 J1 7 J1 0 J11 J9 BUS1 Mai n J16 T3 1 2 Neutral 2 9 3 4 J4 5 10 11 Li ve Sens H a l l Sens H a l l 1 2 3 4 Main Module Earth J12 WD T1 Slav e Module No 2 3 2 4 5 Flame Probe 1 3 J7 J8 F1 Fuse 4A J2 6 J1 2 3 4 5 7 ...

Page 53: ...hown in figure 10 3 1 Upper panel fixing screws Figure 10 3 1 Figure 10 3 2 Disconnect the power supply connector of the fan as shown in figure 10 3 2 Fan power supply connector Figure 10 3 3 Removal of venturi securing screws Unfasten the three screws on the Venturi pipe to disconnect it from the fan as shown in figure 10 3 3 Figure 10 3 4 Unscrew the 4 nuts locking the flange onto the burner hea...

Page 54: ... brush it clean see figure 10 4 2 Remove any debris from the combustion chamber with a vacuum cleaner Finally wash with water Caution After cleaning the exchanger new sealing gaskets must be used Combustion chamber Figure 10 5 1 Figure 10 5 2 Figure 10 5 3 10 5 Cleaning the condense drain The condense drain must be cleaned once per year as follows Disconnect the condensate drain device by removing...

Page 55: ... the electrode wires see figure 10 6 3 10 6 4 NOTE Two types of electrode have been used and both are interchangeable The distance should be 3 5 mm 10 7 Reassembly having carried out the detailed servicing procedure re assemble all components having fitted replacement gaskets where required Check all gas connections are tightened securely before opening the gas service cock Re connect Distance bet...

Page 56: ...complete Boiler Module Control Panel Serial Numbers are given The Boiler and Module Serial Numbers are located on the Data Plates affixed to the combustion chamber front panel The Electrical Serial Number is located inside the Control panel on the maximum power rating label These numbers MUST be quoted when ordering spare parts Figure 11 1 1 2 3 4 5 6 7 8 9 10 11 12 13 Figure 11 2 ...

Page 57: ... 33 34 35 37 38 39 40 41 Figure 11 4 sensor resistance values T C R Ώ T C R Ώ T C R Ώ T C R Ώ 20 67799 15 14694 50 4161 85 1451 15 53452 20 12090 55 3538 90 1266 10 42449 25 9999 60 3021 95 1108 5 33925 30 8313 65 2589 100 973 0 27279 35 6944 70 2229 105 857 5 22069 40 5828 75 1925 110 757 10 17959 45 4913 80 1669 ...

Page 58: ...18 Burner 501 502 573407076 18 Burner 381 382 573407259 19 Ignition flame electrode 501 502 573407077 19 Ignition flame electrode 381 382 573407021 19a Ignition cable 573407067 20 Flow temperature sensor 573407085 21 High limit thermostat 573407087 22 Automatic air vent 573407001 23 Electrode gasket 573407079 24 Flow pipe assembly 573407102 25 Return pipe assembly 501 502 573407101 25 Return pipe ...

Page 59: ...should be positioned near the boiler and at low level It is important that the space housing the boiler is adequately ventilated at high and low level refer to Appendix D For single module installations ie 1 x Milborne 381 501 the boiler must not be installed in a room or compartment located below ground level BS6798 For multiple module installations ie 1 x Milborne 382 502 or greater the boiler m...

Page 60: ...issioned by our engineers This will ensure that the boiler is operating correctly and efficiently LPG Conversion Kit HHL Part No 573407132 The LPG kit is supplied with 2 sizes of orifice The 6 50mm orifice is used for the majority of installations However the 6 75mm orifice is occasionally used in special circumstances see Section A2 3 point 7 A2 3 Procedure for Converting boiler from Natural Gas ...

Page 61: ...nturi to gas valve joint 9 Modifying the Boiler Parameter Master Boiler Only It is essential to modify the boiler parameter number 36 to identfy the type of gas being used This must also take account of the flue length as indicated in the table below To modify the parameter it is necessary to reinstate the gas and electrical supplies WARNING As the boiler MUST NOT fire before the parameter is modi...

Page 62: ...onnection to the mains electricity supply must facilitate complete electrical isolation of the single boiler battery with a separation of at least 3mm in all poles 3 A mains isolator must be provided adjacent to the boiler in a readily accessible position The supply should only serve the boiler 4 Multiple modules It is highly recommended that each boiler is connected via its own mains isolator to ...

Page 63: ...meter during commissioning The pumps shall be installed using an adequate contactor as shown in Figure B 1 2 Figure B 1 2 BMS Connections For 0 10v connection the input signal must be connected to terminals 13 14 see figure B 1 3 Note any safety interlocks MUST be wired across the 0 10v circuit using suitable low voltage contact ratings For connection of an external alarm device use terminals 18 1...

Page 64: ...tion is directed back down the slope to an open drain connection in the flue The drain pipe must be manufactured from a corrosion resistant material and be at least 15mm diameter It must also have a fall of at least 2 3 approx 30 50mm per meter and connect to a drain via a waste trap c Boiler flue outlet sizes A flue system designed with the same diameter as the boiler flue outlet may not provide ...

Page 65: ...nical Department for help or assistance if in doubt C1 9 Condensate Discharge Due to the high thermal efficiency of the boiler condensation will occur within the boiler casing during firing from cold conditions A drain with an integral trap is fitted to each module suitable for connection to a 20mm plastic waste pipe not Hamworthy Heating Ltd supply which must be connected to a tundish not Hamwort...

Page 66: ...tilation is required which must communicate direct to outside for cooling purposes Low level inlet 10cm per kW of total rated input Net High level output 5cm per kW of total rated input Net D1 2 2 Air Supply by Natural Ventilation Room Sealed Installations Where the boiler s are to be installed in a boiler room or internal space the room or internal space must have permanent air vents directly to ...

Page 67: ...s follows At floor level or 100mm above floor level 25 C At mid level 1 5m above floor level 32 C At ceiling level or 100mm below ceiling level 40 C D 1 5 General Requirements The air supply should be free from contamination such as building dust and insulation fibres from lagging To avoid unnecessary cleaning and servicing of the boiler modules the boilers should not be fired whilst building work...

Page 68: ... has G1 male flow and return connections Boilers should be connected by flow and return headers Hamworthy strongly recommend that boilers are connected in a primary circuit configuration utilising a low loss header arrangement to enable secondary circuits to be connected to the header Figure E1 1 1 on the following page show typical layouts 5 Ideally individual valves should be fitted to each modu...

Page 69: ... As a precaution the Milborne boiler is fitted with a flow switch The flow switch is designed to operate such that the boiler will shut down if insufficient flow occurs E1 10 Frost Protection Consideration should be given to fitting an optional outside air sensor to provide the necessary frost protection E1 11 Unvented Systems Refer to Figure E1 1 1 on opposite page for typical layout of an unvent...

Page 70: ...Do uble check valve vessel Ex pansion valve Loc kshield Ma ins water valve Drain valve Lockshield System Circulation pump Primary loo p Circulation pump Circ ulatio npum p Hamworthy Modular Boilers Mo dule Drain UNVENTED SYSTEM Single pipe header 1 Circulation pump Module 2 Module 3 Temperature gauges Pressure Safety valve P T He ating load Automatic Air Vent Valve System Valv e Primary loop Locks...

Page 71: ...HAMWORTHY HEATING LTD 67 MILBORNE 500001130 J NOTES ...

Page 72: ...HAMWORTHY HEATING LTD 68 MILBORNE 500001130 J INSTALLER SITE ADDRESS BOILER TYPE BOILER SIZE S UNIT NO S SERIAL NO S FLUE USEFUL USER INFORMATION ...

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