Hamworthy WESSEX-HE 200 Installation, Commissioning And Servicing Instructions Download Page 4

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HAMWORTHY HEATING LTD

WESSEX-HE 200 BOILER

500001008/K

CONTENTS

PAGE

Front Page

......................................................................................................................... i

Contents

.........................................................................................................................ii

1.0 INTRODUCTION

............................................................................................................ 1

2.0 TECHNICAL

DATA

........................................................................................................ 1

2.1 Overall

Dimensions

2.2

Technical Data Table

3.0 GENERAL

REQUIREMENTS

........................................................................................ 2

3.1 Related

Documents

4.0 LOCATION

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

5.0 GAS

SUPPLY

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

5.1 Service

Pipes

5.2 Gas

Supply

Pipes

5.3

Boilerhouse Control Valve

5.4

Boiler Gas System Leak check

6.0 FLUE

SYSTEM

............................................................................................................... 5

6.1 Suction

6.2

Design Waste Gas Volume and Temperature

6.3 Flue

Condensation

6.4 Surface

Temperature

6.5

Flue Pipe Location

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

8.3

Open Vent Pipe and Cold Feed Pipe

8.4

Altitude Gauge (Water Pressure Gauge)

8.5 Thermometer
8.6 Drain

Taps

8.7 Circulating

Pump

8.8 Minimum

Water

Flow

Rates

8.9

Waterside Pressure Drop

8.10

Control

Schemes

8.11

Minimum Water System Pressure

8.12

Unvented Pressurised Systems

Summary of Contents for WESSEX-HE 200

Page 1: ...BE READ AND UNDERSTOOD BEFORE INSTALLING COMMISSIONING OPERATING OR SERVICING EQUIPMENT WESSEX HE 200 WESSEX HE COUNTY HOT WATER BOILER FOR HEATING AND DOMESTIC HOT WATER INSTALLATIONS INSTALLATION CO...

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: ...PPLIANCE INSTALLED IN A SEPARATE BOILERHOUSE WITH ADEQUATE VENTILATION AND IS NOT CERTIFIED FOR USE IN DOMESTIC APPLICATIONS THIS BOILER IS FOR USE ON GROUP H NATURAL GAS 2ND FAMILY I2H AND LPG PROPAN...

Page 4: ...SYSTEM 5 6 1 Suction 6 2 Design Waste Gas Volume and Temperature 6 3 Flue Condensation 6 4 Surface Temperature 6 5 Flue Pipe Location 7 0 AIR SUPPLY 6 7 1 Air Supply by Natural Ventilation 7 2 Air Su...

Page 5: ...ernal Controls 2 Installation Noise 11 7 User s Instructions 12 0 FAULT FINDING 13 12 1 Summary of Safety Features 12 2 Fault Finding 12 3 Causes of Lockouts 13 0 SERVICING 14 14 0 REPLACEMENT OF FAIL...

Page 6: ...HAMWORTHY HEATING LTD WESSEX HE 200 BOILER 500001008 K iv...

Page 7: ...he Wessex HE has a low water content and water flow rates MUST be maintained at or above the mini mum levels shown in Section 8 and Fig 3 1 2 This boiler must be installed and serviced by a competent...

Page 8: ...6 0 Water Content not including headers litres 20 40 System Design Flow Rate 11 C DT Rise l s 4 28 8 56 Minimum Flow Rate 15 C DT Rise l s 3 42 6 83 Shipping Weight kg 257 515 ELECTRICAL DATA Power Co...

Page 9: ...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 A...

Page 10: ...Supply pipes must be fitted in accordance with BS 6891or UP 2 as appropriate Pipework from the meter to the boiler must be of adequate size Do not use pipes of a smaller size than the boiler gas conne...

Page 11: ...the flue exceeds 4metres 6 2 Exhaust Gas Volume and Temperatures The volumes etc relating to Propane firing can be found in Appendix A It is recommended that the volume and temperature of the waste g...

Page 12: ...ombustion and general ventilation in addition to that required for any other appliance 7 1 Air Supply by Natural Ventilation The purpose provided space housing the boiler must have or be provided with...

Page 13: ...t connection A vent pipe and cold feed pipe must be fitted to the water system between the boiler and the first isolating valve in the water system The sizes of these pipes are shown below The vent pi...

Page 14: ...water flow rate shown in Figure No 3 is maintained It is recommended that a water flow switch is fitted to the system The switch should be connected such that the boiler cannot fire unless the water f...

Page 15: ...s for all boilers The method of connection to the mains electricity supply must facilitate complete electrical isolation of the boiler module with a contact separation of at least 3mm in all poles A m...

Page 16: ...o connecting the boilers to the flue system Care must be taken to prevent damage to the casings prior to contract completion NOTE Fit the top insulation panel to the boiler prior to installing the flu...

Page 17: ...ion 7 iii The system is fully charged with water ready to receive heat all necessary valves are open and the pump is running and circulating the water iv The pipework and valve arrangement is installe...

Page 18: ...e test point and for reference CO2 measurements should be between 9 and 10 or 3 5 to 5 0 O2 Normal CO levels should not exceed 200 ppm NOTE All the above measurements refer to dry flue gas samples 11...

Page 19: ...uit if fitted is made A 230 Volt supply on the Programmer Terminal No 1 will determine this c Check that the remote stop start circuit loop across terminals C5 and C6 is made Check Fascia mounted swit...

Page 20: ...filter if fitted pressure gauge etc are in a serviceable and working condition and still comply with the relevant and aforementioned standards and Codes of Practice 13 2 1 Remove controls cover by un...

Page 21: ...e differential pressure switch Bundy pipes to check that they are clear when they have been detached from the pressure switch to prevent damage to the diaphragm d Gently brush both sides of swirler lo...

Page 22: ...system This is best carried out by specialists using suitable chemicals Follow the chemical manufacturer s recommendations and instructions regarding method solution strength and safety and handling...

Page 23: ...recautions 13 4 9 Clean up mating surfaces and re assemble covers to tube plates with new gaskets lightly greased before assembly Torque the M12 bolts down evenly to 81Nm 13 4 10 a Re assemble baffles...

Page 24: ...nd 5 pin Wieland plug fitted and that there is a replacement rubber gasket packed loose Un plug fan assembly from main controller wiring loom Remove the four M5 Pozidrive screws holding the controls b...

Page 25: ...rked 3 COM c Green Yellow wire to earthing terminal Tighten cable gland Check switch is set to 1 2 mbar and replace cover plate Start the boiler several times to check for reliability 14 6 Control The...

Page 26: ...eads to the appropriate item spade connectors Release switch or lamp from mounting fascia by pressing in the plastic retaining lugs at the top and bottom Pull components out frontwards Push in new com...

Page 27: ...noid Valve 533903030 Pilot Solenoid Coil 533903031 Differential Pressure Switch 533901394 Control Thermostat Landis Gyr 339009345 IMIT 533901178 Temperature Limiter Landis Gyr 339011044 IMIT 533901179...

Page 28: ...HAMWORTHY HEATING LTD WESSEX HE 200 BOILER 500001008 K 22 Figure No 2 Typical Boiler Installation...

Page 29: ...HAMWORTHY HEATING LTD WESSEX HE 200 BOILER 500001008 K 23 Figure No 3 Wessex HE 200 Module Waterside Pressure Loss...

Page 30: ...4 FN FN L N E 24 Figure No 4 Terminal and Mains Cable Layout KEY I BOILER CASING II CABLE CLAMP III SUGGESTED CABLE ROUTE IV CABLE GUIDE V TERMINAL BLOCK VI CONTROL THERMOSTAT VII WIRING DETAIL VIII E...

Page 31: ...I Power ON Lamp Red II Temperature Limiter III Control Thermostat IV EMC Filter V 2A Fuse VI Sequence Controller inc Layout VII Gas Pressure Switch if fitted VIII Probe Test Link Terminal IX Flame Pro...

Page 32: ...BOILER CASING III PROGRAMMER IV GAS VALVE WIRING PLUG V PILOT BURNER VI BY PASS GAS VALVE VII MAIN GAS VALVE VIII GAS ORIFICE IX Rp1 GAS CONNECTION X PRESSURE TEST POINTS XI DIFFERENTIAL PRESSURE SWIT...

Page 33: ...nition Circuit Off Pilot Proving Period Starts YELLOW RED Position E Main Gas Valve opens RED YELLOW Position F Pilot Gas Valve Closes YELLOW GREEN Position G Burner Normal Run GREEN WHITE Position H...

Page 34: ...HY HEATING LTD WESSEX HE 200 BOILER 500001008 K 28 1755 1190 400 600 377 BS 4504 PN6 80 DIA 344 I DIA 320 215 102 300 OUTLET 884 320 300 INLET Rp 1 GAS 540 22 DIA 640 Figure No 9 Boiler Dimensions Cle...

Page 35: ...essex Pilot Burner Assembly Key I ELECTRODE PROBE SCREW 748132146 II SPARK ELECTRODE 333801440 III FLAME PROBE 533805006 IV JET CARRIER 333310871 V IGNITER BLOCK 333311465 VI PILOT INJECTOR 331101959...

Page 36: ...HAMWORTHY HEATING LTD WESSEX HE 200 BOILER 500001008 K 30 BS 4504 PN6 80 DIA Rp 1 GAS 600 358 I DIA 775 711 775 221 775 141 1345 1031 45 Rc Rc Figure 11 Arrangement Drawing Wessex HE County...

Page 37: ...al Gas is increased to 17 5mbar for Propane f Relevant labels are replaced to indicate the appropriate gas for which the boiler module is set up to fire The following tables paragraphs and figures usi...

Page 38: ...r across the orifice NOTE The above is a first order check Final setting must be made using a gas meter 11 5 2 Combustion Checks A flue gas sampling point is provided in the front boiler casing see Fi...

Page 39: ...OILER CASING III PROGRAMMER IV GAS VALVE WIRING PLUG V PILOT BURNER VI NOT USED VII MAIN GAS VALVES 2 OFF VIII GAS ORIFICE IX Rp1 GAS CONNECTION X PRESSURE TEST POINTS XI DIFFERENTIAL PRESSURE SWITCH...

Page 40: ...o 8 Burner Flow System Schematic Propane KEY I Manual Gas Valve Ball Type II Control Gas Valves III Not Used IV Pilot Gas Valve V Pilot Burner VI Main Burner VII Differential Pressure Switch VIII Burn...

Page 41: ...HAMWORTHY HEATING LTD WESSEX HE 200 BOILER 500001008 K 35 NOTES...

Page 42: ...HAMWORTHY HEATING LTD WESSEX HE 200 BOILER 500001008 K 36 NOTES...

Page 43: ...Notes...

Page 44: ...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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