Hamworthy Shaftesbury HE Series Installation, Commisioning And Maintenance Instructions Download

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HAMWORTHY HEATING LTD

SHAFTESBURY HE

500001049/N

CONTENTS

PAGE

1.0 INTRODUCTION

...............................................................................................................................

2.0 UNPACKAGING

................................................................................................................................

3.0 GENERAL

REQUIREMENTS

...........................................................................................................

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

........................................................................................................................................

5.0 GAS/OIL

SUPPLY

.............................................................................................................................

5.1 Service

Pipes

5.2 Meters
5.3 Gas

Supply

Pipes

5.4 Boosted

Supplies

5.5

Boiler House Control Valve

5.6

Boiler Gas System Leak Check

6.0 FLUE

SYSTEM

..................................................................................................................................

6.1

Flue System 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

.....................................................................................................................................

7.1

Air Supply By Natural Ventilation

7.2

Air Supply By Mechanical Ventilation

8.0 WATER

CIRCULATION

SYSTEM

....................................................................................................

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

8.10 Unvented

Systems

8.11

Modular Boiler Control Schemes

Summary of Contents for Shaftesbury HE Series

Page 1: ...BEFORE INSTALLING COMMISSIONING OPERATING OR SERVICING EQUIPMENT Shaftesbury HE Series Boilers Gas Oil Fired Cast Iron Sectional Boilers 110kW to 400kW Installation Commissioning and Servicing Instruc...

Page 2: ...ating 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...

Page 3: ...HE OIL FIRED VARIANTS ARE FOR USE ON CLASS D 35sec FUEL OIL PLEASE ENSURE RELEVANT INFORMATION REQUIRED WITHIN DOCUMENT IS FOUND RELATING TO SPECIFIC FUEL TO BE FIRED BEFORE FIRING BOILER THIS BOILER...

Page 4: ...STEM 5 6 1 Flue System 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...

Page 5: ...IX A INFORMATION RELATING TO PROPANE FIRING 38 APPENDIX B INFORMATION RELATING TO OIL FIRING 38 APPENDIX C BOILER BURNER WIRING DIAGRAMS 39 FIGURES PAGE Figure 2 1 General Overview 2 Figure 7 1 Mechan...

Page 6: ...s Class D Fuel Oil 27 Figure 11 4 Oil Nozzle Selection 28 Figure 11 5 Target Appliance Readings 28 Figure 11 6 Combustion Chamber and Burner Data 29 Figure 15 1 Exploded View of Boiler 31 Figure 15 2...

Page 7: ...ncy of over 80 based on gross CV The heat exchanger assembly is completed by cast iron front and rear combustion chamber plates and access plates for the cleaning and inspection of the heat exchanger...

Page 8: ...lankets d Control panel e Matched burner fuel oil or gas f Flue collector box g Burner mounting plate drilled ready to accept burner h Steel cradle i Oil burner nozzle s where applicable Remove all pa...

Page 9: ...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...

Page 10: ...hen 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...

Page 11: ...S 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 Shaftesbury HE operat...

Page 12: ...PPLY 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...

Page 13: ...e 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 pipew...

Page 14: ...to 8 stages For further information contact Hamworthy Heating for details 9 0 ELECTRICAL SUPPLY WARNING THIS APPLIANCE MUST BE EARTHED 9 1 Site Wiring Wiring external to the boiler must be installed i...

Page 15: ...N BURNER CONNECTIONS 7 7 PLUG MALE 7 PIN L BLACK 9 14 6 GN YE COMMISSIONING REMOTE LINKS LOW HIGH OVERHEAT LOCKOUT NORMAL RUN SUPPLY IN GN YE GN YE BOILER ON OFF VOLT FREE CONTACTS if fitted LOCKOUT 2...

Page 16: ...LACK BLACK 8 7 HIGH FIRE LOW FIRE METER HOURS RUN METER HOURS RUN BURNER CONNECTIONS 8 7 8 7 PLUG MALE 4 PIN PLUG MALE 7 PIN L BLACK 9 14 6 GN YE COMMISSIONING REMOTE LINKS LOW HIGH OVERHEAT LOCKOUT N...

Page 17: ...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 th...

Page 18: ...ESBURY HE 500001049 N Figure 10 2 Boiler Section Identification A Rear Intermediate section RI Fitted with 4 flue plates C Front Intermediate section FI Fitted with 2 flue plates B Intermediate sectio...

Page 19: ...traps 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 b Fit sealing m...

Page 20: ...g Figure 10 6 Fitting O Ring Seal 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 d Carefully fit O ring gaskets 5 o...

Page 21: ...h 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 togethe...

Page 22: ...Figure 10 10 Flue Gas Flow Path 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 o...

Page 23: ...nto 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 c Locate the foil cove...

Page 24: ...nuts and washers fit front and rear cross members to M6 studs protruding from body of boiler Figure 10 13 2 Using M6 nuts and washers fit casing support rails to M6 studs on front and rear cross memb...

Page 25: ...ss struts into position to anchor side panels in position 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 towa...

Page 26: ...Ensure that rear cover is located in correct position as indicated below Figure 10 19 Figure 10 20 Figure 10 21 7 After fitting control panel snap lower front cover into place locating pre fitted latc...

Page 27: ...ew Replace thermostat knobs and front casing panel allowing cabling to exit from the cut out It should be noted that if a 3 phase burner be supplied the 3 phase supply should be wired direct to the bu...

Page 28: ...the fuel supply upwards from a low position to ensure that a fuel rich mixture is not achieved 11 4 2Oil fired Boilers a Check flexible oil lines are tightly jointed and are not twisted or kinked to f...

Page 29: ...ating Technical Department for advice Check for oil water and flue gas leakage Tighten all access flue box and burner mounting bolts and nuts p Set boiler control thermostat to required setting and ch...

Page 30: ...oted for reference upon completion of the servicing procedure c Measure either gas pressure at burner head or oil pressure at burner pump as applicable and check value is correct for size of boiler in...

Page 31: ...R40GS20 M HI LO MODULATING 110 125 5 13 3 77 77 8 1 8 1 440 455 120 125 70 70 HE150 RIELLO RIELLO RS28 RS28 M HI LO MODULATING 150 171 2 18 2 81 52 8 6 8 6 440 575 216 155 130 70 HE190 RIELLO RIELLO R...

Page 32: ...S28 RS28 M HI LO MODULATING 190 216 3 8 9 81 52 3 3 440 695 216 130 HE220 RIELLO RIELLO RS38 RS38 M HI LO MODULATING 220 250 5 10 2 105 70 4 75 440 815 216 130 HE250 RIELLO RIELLO RS38 RS38 M HI LO MO...

Page 33: ...0 168 5 17 4 81 8 2 440 575 216 130 HE190 RIELLO RL28 HI LO 190 211 8 21 9 81 8 2 440 695 216 130 HE220 RIELLO RL38 HI LO 220 246 6 25 4 116 11 8 440 815 216 130 HE250 RIELLO RL38 HI LO 250 281 2 28 9...

Page 34: ...2904057 3 0 x 45 High HE400 HI LO 1 532904069 5 0 x 45 Low 1 532904063 4 0 x 45 High Figure 11 4 Oil Nozzle Selection Fuel Type BOILER MODEL HE 110 HE 150 HE 190 HE 220 HE 250 HE 280 HE 310 HE 340 HE...

Page 35: ...high limit cover knob unscrewed and removed Remove the upper front casing panel Turn the two latches a quarter turn using a screwdriver or coin and lift off The fascia can then be hinged downwards by...

Page 36: ...ls 12 Burner Plate Insulation Panel 573405182 13 Burner Plate Blank 573405216 14 Sight Glass Insulation Gasket 573405184 15 Sight Glass Assembly 573405185 16 Gasket 135 Dia X 100 X 4 573405186 17 Cast...

Page 37: ...HAMWORTHY HEATING LTD 31 SHAFTESBURY HE 500001049 N Figure 15 1 Exploded View of Boiler...

Page 38: ...l Fascia C1 C2 C3 C4 9 11 12 13 14 15 16 L N E H 2 L B5 B4 N N N B4 B5 L1 E N T1 T2 S3 B4 B5 T6 T7 T8 BLACK WHITE WHITE YELLOW YELLOW VIOLET VIOLET A1 A2 14 12 11 A1 A2 14 12 11 A1 A2 14 12 11 R1 R2 R...

Page 39: ...RIPTION PART NO 1 Control Thermostat 533901178 2 Temperature Limiter High Limit 533901179 3 Temperature Gauge 557002005 4 Hours Run Meter 533901067 5 On off Switch illuminated 533901212 6 Fuse Holder...

Page 40: ...HAMWORTHY HEATING LTD 34 SHAFTESBURY HE 500001049 N 16 0 TECHNICAL DATA Figure 16 1 Boiler Installation Typical...

Page 41: ...gly MODEL C mm Gas Firing Oil Firing Dual Fuel RIELLO NUWAY RIELLO NUWAY RIELLO NUWAY 110 356 N A 261 N A N A N A 150 356 N A 434 N A N A N A 190 546 N A 434 N A N A N A 220 546 N A 434 N A N A N A 25...

Page 42: ...9 9 42 7 45 4 ft3 h 469 5 642 5 808 4 935 5 1062 1157 1281 1410 1509 1605 GAS INLET CONNECTION Rc 1 WATER DATA WATER CONNECTIONS FLOW RETURN 4 in N B MAXIMUM WATER bar g 5 0 PRESSURE psi g 73 0 WATER...

Page 43: ...1025 900 2 1 25 2 6 5 1 0 75 R E T U R N 8 6 5 1 07 5 F LO W L B A Model Dim A Dim B Dim L HE 110 490 n a 840 HE150 610 n a 960 HE190 730 n a 1080 HE220 850 n a 1200 HE250 970 n a 1320 HE280 1090 545...

Page 44: ...7 37 37 37 37 37 37 37 37 Max Gas Inlet Pressure mBar 45 45 45 45 45 45 45 45 45 45 Gas Flow Rate m hr 5 7 7 8 8 9 10 2 11 6 12 9 14 3 15 7 16 8 17 9 ft hr 201 275 314 360 410 455 504 555 594 632 APPE...

Page 45: ...7 T 8 NOTES THIS DIAGRAM SHOWS THE CONTROL PANEL WIRING 230V 50Hz SUPPLY THE ELECTRICAL SUPPLY TO THE BURNER IS DEPENDANT UPON THE MODEL SELECTED REFER TO BURNER MANUFACTURERS INSTRUCTIONS TWO FUSES...

Page 46: ...P TO 230V ENLARGED DETAIL OF BOILER PANEL WIRING TERMINAL NOTE REMOVE EXISTING LINKS IF REMOTE CONTROL IS REQUIRED C2 C4 C1 C3 REMOTE TIME CLOCK ON OFF SEQUENCER SAFETY INTERLOCK CONTROLS REMOTE CONTR...

Page 47: ...Notes...

Page 48: ...y 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 Addre...

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