Hamworthy MILBORNE381 Series Design Installation, Commissioning And Operating Instructions Download

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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

LPG - PROPANE

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 MILBORNE381 Series

Page 1: ...ng 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...

Page 2: ...NDIX 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 Boi...

Page 3: ...7 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...

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...

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 sys...

Page 6: ...ng 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...

Page 7: ...he 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...

Page 8: ...ure 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 pu...

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: ...ge 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 s...

Page 11: ...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...

Page 12: ...proof 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 Su...

Page 13: ...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 occ...

Page 14: ...ve 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 por...

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...

Page 16: ...d 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 straigh...

Page 17: ...ocations 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 change...

Page 18: ...rne 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 co...

Page 19: ...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 us...

Page 20: ...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 C...

Page 21: ...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...

Page 22: ...kit for 502 boiler 160 mm Polypropylene header kit for 501 boiler 160 mm 573407292 573407295 573407290 573407294 Condensate trap tee piece kit 125 mm Condensate trap tee piece kit 160 mm Flue pipe wa...

Page 23: ...e 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 sudde...

Page 24: ...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 arrangeme...

Page 25: ...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 PR...

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 c...

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...

Page 28: ...ting 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 St...

Page 29: ...ith 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...

Page 30: ...ed 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 faul...

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 Cont...

Page 32: ...tem 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...

Page 33: ...tivated 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 Discon...

Page 34: ...mum 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...

Page 35: ...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...

Page 36: ...ck 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...

Page 37: ...erature 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...

Page 38: ...ing 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...

Page 39: ...o 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 e...

Page 40: ...rs 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 cle...

Page 41: ...o 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 restor...

Page 42: ...alue 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 mod...

Page 43: ...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 temperat...

Page 44: ...4 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...

Page 45: ...ted 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...

Page 46: ...it 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 Do...

Page 47: ...and 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 with...

Page 48: ...ir 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...

Page 49: ...e 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 maximu...

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...

Page 51: ...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 L...

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...

Page 53: ...own 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 o...

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 Combu...

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 servi...

Page 56: ...omplete 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 Num...

Page 57: ...32 33 34 35 37 38 39 40 41 Figure 11 4 sensor resistance values T C R T C R T C R T C R 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...

Page 58: ...8 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 sens...

Page 59: ...hould 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 installation...

Page 60: ...ssioned 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 ori...

Page 61: ...turi 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 o...

Page 62: ...nnection 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 a...

Page 63: ...eter 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 term...

Page 64: ...ion 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 fa...

Page 65: ...ical 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 c...

Page 66: ...ilation 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...

Page 67: ...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...

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 lo...

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 Considera...

Page 70: ...o 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...

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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