Hamworthy Milborne 500 Series Design Installation, Commissioning And Operating Instructions Download

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IMPORTANT NOTE

THESE INSTRUCTIONS MUST BE READ

AND UNDERSTOOD BEFORE INSTALLING,

COMMISSIONING, OPERATING OR

SERVICING EQUIPMENT

MILBORNE 500 SERIES

BOILERS

Wall Hung, Pre-Mix, Condensing,

Modular Boilers

Design Installation, Commissioning

and Operating Instructions

NATURAL GAS

LPG - PROPANE

Summary of Contents for Milborne 500 Series

Page 1: ...D AND UNDERSTOOD BEFORE INSTALLING COMMISSIONING OPERATING OR SERVICING EQUIPMENT MILBORNE 500 SERIES BOILERS Wall Hung Pre Mix Condensing Modular Boilers Design Installation Commissioning and Operating Instructions NATURAL GAS I2H LPG PROPANE I3p ...

Page 2: ...rating 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...

Page 3: ...ng Pre Mix Condensing Modular Boilers 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 A JUNE 2005 ...

Page 4: ... 7 8 0 FLUE SYSTEM 11 9 0 VENTILATION 16 10 0 GAS SUPPLY 18 11 0 POWER SUPPLY AND WIRING 18 12 0 EMERGENCY MODE 23 13 0 SET UP FOR MODULAR MILBORNE INSTALLATIONS 24 14 0 PROGRAMMABLE ROOM THERMOSTAT 27 15 0 COMMISSIONING 29 16 0 MASTER CONTROL PANEL ERROR MESSAGES 33 17 0 MASTER CONTROL PANEL DESCRIPTION 37 18 0 USER S PARAMETER MODIFICATION 38 19 0 PROGRAMMING MODE 41 20 0 PROPANE LPG 51 21 0 CON...

Page 5: ...Enable 23 Figure 12 3 Master Card Emergency Enable 23 Figure 13 1 Milborne Multiple Installation 24 Figure 13 2 Setting Jumpers Typical Example 25 Figure 13 3 Example of Boiler Installation 7 boiler Modules in same Cascade Sequence 26 Figure 13 4 Setting Up Positioning of Room Thermostats 27 Figure 15 1 Gas Valve Adjustment Points 29 Figure 15 2 Gas Inlet Pressure Test Point 30 Figure 15 3 1 Analy...

Page 6: ...ING LTD MILBORNE 500 SERIES 500001130 A iv TABLES Table 9 1 Air Flow Table for Restricted Space Installations 16 Table 9 2 Air Flow Table for Restricted Space Installations 16 Table 20 1 Technical Table LPG Firing 51 ...

Page 7: ... 6700 Design installation testing and maintenance of services supplying water for domestic use BS 6880 1 2 3 Code of practice for low temperature hot water heating systems of output greater than 45kW BS 7074 1 2 Application selection and installation of expansion vessels and ancilliary equipment for sealed water systems Code of practice for low and medium temperature hot water systems I Gas E Publ...

Page 8: ...rotation by means of a variable load factor so that when the first unit reaches a certain power percentage e g 30 the following units starts unison control all with the same load factor This makes it possible to divide supplied power onto several heat exchangers with a power heat exchanger surface ratio which is particularly useful to exploit latent condensation heat The Milborne boiler offers the...

Page 9: ... internal coil Water side Copper Flue gas side stainless steel The micro flame burner is located high at the centre of the exchanger and is a grid type with one combined ignition electrode and flame probe 2 Pre mixing unit consisting of a modulating gas valve integrated with a high head fan The system ensures a constant mixing ratio in all operating conditions and flue gas discharge through a plas...

Page 10: ...ontrol All 3 circuits can be set in the parameters to operate at different temperatures The low temperature heating and DHW circuits have additional optional sensors for control of water temperature DHW can be set in the parameters to operate with traditional calorifiers or plate heat exchangers using voltage free switching thermostats Where the heating circuits are controlled from the Master boil...

Page 11: ...l type Should the product not match with the order immediately contact customer services at Hamworthy Heating Ltd Location Milborne series 500 Boiler assemblies shall be installed in accordance with the most recent applicable standards and technical regulations on boiler installations and condensing boilers as with any other boiler installation Wall mounting The boiler must be installed on a solid...

Page 12: ...astic polypropylene pipes should be used to create the condensate discharge system as the acidity in the condensate will rapidly corrode metal pipes Never use copper pipes Flue system condensate discharge piping Should it be necessary to extend the vertical or the horizontal section of the discharge piping to over 4 metres create a U bend at the foot of the pipe The siphon s useful length must be ...

Page 13: ...ystem operate with the circulating pump for approximately 7 days Discharge the system s dirty water and wash once or several times using clean water If the system is very dirty repeat the last procedure until clean Figure 7 1 Pipework Schematic No 1 Pump the water additive through the system for approximately 7 days and perform a final wash as described in the previous paragraph At the end of clea...

Page 14: ...ne boiler has the facility to start and control 3 pumps It is therefore important when designing the heating system to allow pump number 3 to be assigned as the boiler primary pump where required see pipework schematic 1 In all other installations pump 3 will be assigned as the low temperature heating circuit pump see pipework schematic 2 Therefore where a primary system pump is required the contr...

Page 15: ...each boiler is made using isolating valves and for the flow connections a 3 port isolation vent valve Optional wall support brackets as shown Kit for two Milborne 502 boilers installed in series up to 600 kW Hamworthy kit ref PKD502 HHL Part No 573407125 Fig 7 4 1 x gas header diameter 3 PN6 1 x flow header diameter 3 PN6 1 x return header diameter 3 PN6 Each header is fitted with a 4 x 25 mm bran...

Page 16: ...dual motorised isolating valves close flow rates for the remaining modules are maintained Alternatively a fixed speed pump with flat curve characteristics may be used Maximum Operating Pressure The boiler s maximum operating pressure is 6 bar its minimum operating pressure is 0 5 bar Boiler Filling and Draining The boiler should be filled using the system quick fill connection This connection must...

Page 17: ... and multiple boiler installations Flue Maximum Length Each 50 mm flue pipe maximum equivalent length is 30 metres with a maximum 4 metre flow resistance for each 90 bend and 3 metres for a 45 bend Open Flue Installations type B23 Figure 8 1 shows the configuration of a single Milborne 501 boiler installation using the B23 open flue arrangement In this application combustion air is taken directly ...

Page 18: ...the installation of several Milborne 500 Series boilers will be easier if a 125 mm diameter polypropylene flue gas header with male female connections is used The header is designed to collect the flue gas from the two 50 mm flue pipes of a Milborne 502 each of which contains a flue gas non return valve When using the flue gas header for up to three 3 boiler assemblies connected in series the mini...

Page 19: ...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 20: ...pe ø50 mm x 500mm Polypropylene pipe ø50 mm x 1000mm Polypropylene pipe ø50 mm x 1500mm 573407111 573407112 573407113 573407114 Cravat for flat room ø50 mm 573407115 Cravat for pitched roof ø50 mm 573407116 Stainless steel horizontal wall terminals ø50 mm 573407117 Twin duct horizontal flue discharge air intake kit Consisting of 2 x 90 bends 2 x ø50 mm x 500mm pipe 2 x ø50 mm x 250mm pipe 2 x Stai...

Page 21: ...o terminal Equivalent lengths for 90 bends is 4 metres with 3 metres equivalent length for a 45 bend Pictorial View Description HHL Part No Polypropylene 45 bend ø125 mm Polypropylene 90 bend ø125 mm 573407143 573407044 Polypropylene pipe ø125 mm x 250mm Polypropylene pipe ø125 mm x 500mm Polypropylene pipe ø125 mm x 1000mm Polypropylene pipe ø125 mm x 1500mm 573407136 573407137 573407138 57340713...

Page 22: ...ernal space In addition to the above requirements the vents between rooms or internal spaces must be increased to no less than 323 cm2 The final vent to outside will remain at 215 cm2 Where the boiler is to be installed in a cupboard or compartment permanent high and low level air vents are required for cooling purposes in the cupboard or compartment Both vents must communicate directly with outsi...

Page 23: ...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 At floor lev...

Page 24: ... boiler s power supply Warnings Always check the effectiveness of the earthing of the electrical system to which the boiler assembly is going to be connected Indeed should the earthing be inefficient the correct operation of the ignition detection electrode might be affected Warning 230 V cables must be separated from the 24 V ones using independent PVC conduits Warning Before connecting external ...

Page 25: ...HAMWORTHY HEATING LTD MILBORNE 500 SERIES 500001130 A 19 Figure 11 1 ...

Page 26: ...he alarm device must be connected to terminals no 18 and 19 figure 11 3 Connection of a Remote Control Outside Air Sensor Connection If outside temperature compensation is to be used the outside air sensor needs to be connected to terminals no 7 and 8 figure 11 1 The outside air sensor shall be installed on an outside wall North or North East aspect at a minimum height of 2 5 metres away from wind...

Page 27: ...rlocks should be joined in series and wired to a multiple contactor located across each time clock circuit figure 11 4 The installation within the external time clock circuits will allow correct shutdown of the boiler when the circuit is broken Note The interlock circuit should never be used to isolate the boiler power supply Isolating the boiler electrically during normal operation may lead to ov...

Page 28: ...HAMWORTHY HEATING LTD MILBORNE 500 SERIES 500001130 A 22 Figure 11 6 Milborne 502 Slave Wiring Schematic ...

Page 29: ...e 4 pole connector J14 from the Master card see figure 12 1 Master Figure 12 2 12 2 Set all four J17 switches located on each Slave of the boiler installation to the OFF position Figure 12 3 Slave Master 12 3 Supply all system circulators with mains current using the appropriate switches see figure 11 2 12 4 Terminal X1 or Terminal X2 which are part of the cabling of the J14 connector disconnected...

Page 30: ... Milborne 502 Master with n 2 Milborne 502 Slave Milborne 502 Slave Milborne 502 Master Milborne 502 Slave Each slave one for each burner needs to be properly configured so that the Master controller can identify their position in the sequence First the Slave boards need to be divided into 15 blocks The Master control system can manage a maximum of 15 blocks each made up of 4 Slave boards each Eg ...

Page 31: ...e Slave Address Jumpers 1 2 3 4 OFF OFF OFF OFF Emergency Code OFF OFF OFF ON Block 1 OFF OFF ON OFF 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 Bl...

Page 32: ...ence Block 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 33: ...emperature switching hysteresis 0 2 0 8 C Contacts rating Max 250V 5A Internal frost protection 6 C Minimum setting period 1 Hour 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 locate...

Page 34: ... at the Master control receives the switch live return and should be wired to terminal 2 at the thermostat For low temperature heating circuit terminal 11 at the Master control provides the live and should be wired to terminal 1 at the thermostat Terminal 12 at the Master control receives the switch live return and should be wired to terminal 2 at the thermostat For programming details please refe...

Page 35: ...g the boiler with a LPG Gas supply or equivalent flue lengths greater than 15 metres parameter 36 must first be modified in accordance with the table below Instructions detailing the procedure for modifying parameters are given in Section 19 0 of this manual 15 1 3 Check that the heating system has been flushed and refilled and that air has been purged from all high points 15 1 4 Ensure that the s...

Page 36: ...ommissioning the Boiler Once the preliminary checks have been completed and the gas inlet pressure has been verified as correct commissioning of the boiler modules may begin 15 3 1 Insert the combustion analyser probe in the flue at the analysis point shown in figure 15 3 1 Fig 15 3 1 Analysis Point Fig 15 3 2 LPG Flow Adjustment Starting the boiler Ensure that all external time clock and thermost...

Page 37: ... The operating 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 pre purge Rd Gn Fig 15 3 6 15 3 7 Run the burner to maximum power To achieve this p...

Page 38: ...a condition of the flue gas analysis rather than a fixed pressure Check the CO2 values in accordance with table 15 1 If the CO2 values are incorrect then adjustment must be made by adjusting the gas valve offset adjustment screw See figure 15 3 11 Turning the offset screw anticlockwise increases the gas flow and increases the CO2 value Turning the offset clockwise decreases the gas flow and decrea...

Page 39: ...ts relevance 1 The display starts flashing to signal one or more faults 1b Press S4 the display will alternate between the address of the first unit boiler module and the first error code Press S4 again to display all the errors for this unit boiler module The error of the successive unit boiler module will be visualized one after the other press S4 Press S5 to display the errors in the opposite w...

Page 40: ... stack 16 4 Master Panel Blocking Errors E errors automatic reset The following blocking error numbers are possible Display Nr PC Nr Error Description E25 0 E2PROM_READ_ERROR E2prom isn t readable E23 28 REFHI_TOO_LO_ERROR Temperature measurement is incorrect E24 29 REFHI_TOO_HI_ERROR Temperature measurement is incorrect E25 30 REFLO_TOO_LO_ERROR Temperature measurement is incorrect E26 31 REFLO_T...

Page 41: ... 5 sec ignition A02 Too many failed ignitions A04 GK relay open error A05 GK relay not open error or Phase neuter are inverted A06 Safety relay does not close A07 Safety relay does not open A08 Safety relay open while closed expected A09 RAM error A10 E2prom error A11 Fan error A12 Wrong e2prog signature A13 Stack error A14 Internal control error A15 Internal control error A16 Safety relay closed ...

Page 42: ...w sensor E43 Flow sensor with open contact E44 Short circuit return sensor E45 Return sensor with open contact E46 Flow sensor error when limit temp is exceeded see option selected E47 Return sensor error E48 Flue sensor error The following blocking error numbers are possible Fig 17 1 Control Panel Overview Master S1 S2 S3 S6 S4 S5 U2 U3 U4 D4 D5 S1 Reset S2 Set Esc S3 Set Values S4 Increase S5 De...

Page 43: ...manent lock out of one boiler module Reset either the Master or the relevant boiler module to restore normal operation The D4 green LED displays the presence of communication between the Master and individual boiler modules The 3 display LED s U2 U3 and U4 display the following SYSTEM STATUS DISPLAY No demand of heat and water the right digits display the flow temperature T1 e g T1 30 C Request fr...

Page 44: ... flashing and the display will be restored to the mode display S6 18 1 Changing Operating Temperature Set Points e g To change the Setpoint value of the low heating circuit T6 from 50 to 40 C 1 Mode display is reading high temperature circuits at 80 C e g high circuit real value 80 C fig 1 2 Press S3 to enter into the setting display press it again and set 6 on the first digit to display the requi...

Page 45: ...high circuit real value 80 C 2 Press S2 SET ESC for 5 sec The display shows that it is possible to read the values or the functioning mode of boiler module 1 3 Press S4 or S5 to scroll the desired boiler module e g for boiler module 19 4 Press S3 to display the 1st value for the selected boiler module Press the same button S3 to display the following values e g 1st value flow temperature reading 5...

Page 46: ...efault Value Note Specification 1 Setpoint_T _CH_High 10 C utente T_CH High_Limit 70 For the 1st circuit or unique Setpoint_T_CH_High Required flow temperature for high temperature heating circuit when CH_tpye_High is 0 parameter 14 Max required flow temperature for high temperature heating circuit when in other modes 2 Set value for DHW 10 C utente T_DHW_Li mit 50 For DHW Circuit T3 set DWH Requi...

Page 47: ...the second figure of the password 5 Use 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 7a Use S4 and S5 to scroll all password protected parameter addresses See parameter list for address and range settings 7b Press S2 Set Esc to select the parameters...

Page 48: ..._ch_hyst 2 Only sanitary circuit DHW 10 T_tank _extra 0 C S 50 C 30 Temperature of the primary circuit during DHW production This value has to be added to the DHW set point parameter 2 to obtain the set point for primary circuit Ex 50 C 30 C 80 C DHW 11 T_tank _hyst_ up 0 C S 20 C 1 Upper offset setting for stored DHW off temperature Ex 50 C 1 C 51 C DHW 12 T_tank _hyst_ down 0 C S 20 C 5 Lower of...

Page 49: ...d_ Hyst_on 0 C Rh 20 C 7 Burner is switched on when T_flow_high Setpoint_CH_High CH_high_mod_hyst_on Ex 80 C 7 C 73 C CH_ high 20 CH_high _mod_ Hyst_off 0 C Rh 20 C 3 Burner is switched off when T_flow_high Setpoint_CH_High CH_high_mod_hyst_off Ex 80 C 1 C 81 C CH_ high 21 Attenuation _high 0 C Rh 70 C 0 Attenuation of the compensat ed heating curve after the 1st circuit room thermostat opening Th...

Page 50: ..._ch_low CH_low_mod_hyst_on CH_ low 27 CH_low_ Mod_hyst_ off 0 C Rb 20 C 3 Burner is switched off when T_flow_low Setpoint_ch_low CH_low_mod_hyst_off CH_ low 28 Mixing_ Valve_step _open _period 0 sec Rb 255 sec 5 Time period for mixing_valve to open from completely closed position CH_ low 29 Mixing_ Valve_step _closed _period 0 sec Rb 255 sec 7 Time period for mixing_valve to close from completely ...

Page 51: ...e 37 T_out _min 20 C G 30 C 0 Climatic curve regulation Outside temperature at which maximum flow temperature is required High limited by T_out_max CH_ high 38 T_out _max 0 C G 30 C 18 Climatic curve regulation Outside temperature at which minimum flow temperature is required Low limited by T_out_min Above this value the heating system will be turned off Summer shutdown CH_ high 39 T_out _correct ...

Page 52: ...ioning 5 Pump over run high temp circuit This is the post pump time after the high temperature heating circuit room thermostat opens CH_ high 50 T_high correctio n 20 C 30 C Rh 30 C 0 Calibration correction of the high temp sensor lower limit at 20 C CH_ high 51 T_high correctio n 85 C 30 C Rh 30 C 1 Calibration correction of the high temp sensor upper limit at 85 C CH_ high 52 Blocking time DHW C...

Page 53: ...ctor for PI control in DHW mode DHW 60 I factor DhW_ instantaneo us 0 S 255 70 I factor for PI control in DHW mode DHW 61 D factor_Dhw instantaneo us 0 S 255 128 D factor for PI control in DHW mode DHW 62 P factor Dhw_ storage 0 S 255 30 P factor for PI control in DHW mode DHW 63 I factor Dhw_ storage 0 S 255 70 I factor for PI control in DHW mode DHW 64 D_factor_ Dhw_ storage 0 S 255 128 D factor...

Page 54: ... stop 0 P 255 60 Power 79 Cycle_ Limit_ Inc 0 P 50 10 Power 80 Burners rotation 0 never P 255 hours 24 Lead boiler rotation After this number of hours the burners ignition order is changed Power 81 Flow switch present on the slaves 0 SL 1 0 No flow switch on Milborne Boilers 0 0 The slave will not check for the flow switch function Slave 82 Return sensor present on the slaves 0 SL 1 1 0 No slave c...

Page 55: ...Temp_ Max_ slave 10 SL 117 80 Safety option slave If flue_gas_temp flue_gas_temp_max for 5 secs error Slave 90 Flue gas sensor slave 0 blocki ng 1 lock out SL 0 Safety option slave If there is an error on flue_gas_sensor the burner has to be turned off for 10 minutes and the fan has to be activated at the maximum speed for the same time Slave 91 Flow temp and return temp slave max temp 0 blocki ng...

Page 56: ...the I_reduce_value will be subtracted from the high byte of the sum of the errors This causing the calculated power to reduce faster than on a normal I action Power 98 Low_load waiting 0 sec P 255 sec 60 When the master detects that a slave is at low load the master waits this period to check if another slave is also at low load condition Slave low load 99 Low_load_ period slave 0 sec SL 255 sec 6...

Page 57: ...dditional LPG conversion kits please contact Hamworthy Heating Ltd to order the required number of kits quoting part number 573407132 One kit will be required for each 50kW module ie Milborne 501 1 kits Milborne 502 2 kits Full details for fitting the LPG kit to the boiler are provided in the operation and commissioning manual During commissioning the parameters must be set for propane firing to e...

Page 58: ... from the gas valve the rubber seal will be clearly visible see fig 21 5 All Milborne s are supplied Natural Gas as standard so there will be no orifice fitted to the gas valve air inlet passage 21 6 Fitting the LPG Orifice The LPG orifice consists of a precisely drilled washer of 6 5mm internal diameter This orifice is to be fitted in the gas valve air inlet port There is no need to remove the ru...

Page 59: ...If after commissioning the larger orifice has to be installed then the full commissioning procedure as detailed in Section 15 0 must again be completed Figure 21 8 21 8 Reassembly Procedure Ensure that all the components that have been removed and modified are clean Position the venturi to the gas valve and refit 3 screws that were previously removed in step 21 4 Ensure the 3 screws are securely t...

Page 60: ...HAMWORTHY HEATING LTD MILBORNE 500 SERIES 500001130 A 22 0 TECHNICAL DATA Milborne 500 Series Performance and General Data Information 54 ...

Page 61: ...24 Hour programmable room thermostat for low and high temperature heating circuits TAat TAbt 573407127 7 Day programmable room thermostat for low and high temperature heating circuits TAat TAbt 573407126 Hot water cylinder temperature sensor for secondary storage temperature SB 573407124 Pipework header kit PKS502 c w valves for single 502 models XKIT0351 573407125 Pipework header kit PKD502 c w v...

Page 62: ...HAMWORTHY HEATING LTD MILBORNE 500 SERIES 500001130 A 56 INSTALLER SITE ADDRESS BOILER TYPE BOILER SIZE S UNIT NO S SERIAL NO S FLUE NOTES ...

Page 63: ...Notes ...

Page 64: ...hy 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 B...

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