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MELBURY HE 3800-10000 - 

Installation, Use and Maintenance 

 

Page 30 / 36 

410821-V11 

 

 

 

5.  OPERATING CONDITIONS 

 

5.1.  Fuels 

 

The  Melbury HE  boilers are designed for operation 

with fuel oil EL and natural gas. Models Melbury HE 

3800-10000 can also be operated on heavy fuel. 

 

CAUTION: 

The use of other fuels such as for example biogas is only permitted with the express 

approval of the manufacturer. 

 

 

5.2.  Combustion air 

 

The combustion air must not have high dust 

concentrations. 

 

 

 

 

CAUTION: 

Furthermore, it must be  free  of  halogens  (chlorine  and  fluorine  compounds).  

An excessive presence of halogen in the combustion air leads to great corrosion 

damage. Make sure that no paints, thinners, cleaning agents, degreasing agents, 

solvents, chlorine containers, etc. are stored in the boiler room! 

 

 

 

 

5.3.  Filling the installation and water quality 

 

The installation must be thoroughly rinsed before it is 

finally filled. 
When filling for the first time and refilling, check the 

quality of the water in accordance with the values 

recommended in chapter "Water quality", page 

5.  Poor water quality leads to damage in heating 

installations from calcification and corrosion. On the 

other  hand,  the  service  life,  functional  reliability  and 

efficiency can be increased using appropriately treated 

water. 
During the filling process, the circulation pumps should 

be switched off and all ventilating valves opened, so 

that the air in the system can completely escape. The 

filling process is finished when the operating pressure 

has been reached. 

 

5.4.  Protection against corrosion 

Normally, no corrosion problems arise if systems are 

properly designed and installed and are run according 

to these instructions; consequently there is no need  

to use chemical additives. However, if water is of poor 

quality or if oxygen seeps from the air into the heating 

system (expansion chambers open, expansion/supply 

chambers too small, plastic tubes without diffusion 

blocking in floor heating) damages are something 

which cannot be completely excluded. If you happen to 

 

 

use chemical additives in your system, make sure that 

they are effective, harmless and above all appropriate 

for the materials your system is made of. Enquire with 

your chemical additive supplier. 
In this case, you will need to arrange for a specialist 

water company to carry out annual quality checks on 

the water used in the heating system in order to avoid 

any damage to the system. 

 

5.5.  Requirements for operation 

 

The maximum operating pressure and the maximum 

temperature to be observed are listed on the type plate. 

The minimum temperatures to be observed are given 

in chapter 2.1. 
It is strictly recommended to maintain the boiler in 

operation during several hours after a cold start-up    

in order to evaporate condensates that are inevitably 

formed in any boiler during cold start-up. 

! 

! 

Содержание Melbury HE 10000

Страница 1: ...MELBURY HE 3800 TO 10000 Document No 410821 V11 18 12 2020 FR DE EN ES IT NL Installation use and maintenance instructions CAUROIR SITE Route de Solesmes FR 59400 CAUROIR L ...

Страница 2: ...MELBURY HE 3800 10000 Installation Use and Maintenance Page 2 36 410821 V11 ...

Страница 3: ...ntilate the affected rooms thoroughly by opening doors and windows Do not use any electronic devices mobile phone etc Do not activate any electrical contacts light motor lift doorbell etc Do not ignite matches or lighters and do not smoke Call the gas board or heating engineer The boiler The boiler room must be lockable and it s external air openings must conform to the norms prevailing locally Wh...

Страница 4: ...disposed of appropriately at the end of their life cycle Local regulations must be observed Installation and settings The installation and calibration of the unit must be performed exclusively by qualified personnel in conformity with existing regulations and the indications provided in this Manual INFORMATION For hot water installation o Maximal operating temperature 95 C when the boiler is manag...

Страница 5: ...is more than three times the water capacity of the heating system requires a full cleaning to remove sludge and scaling to be performed Additional precautions are required for operation When the unit has a water softener the equipment must be inspected on a regular basis in order to ensure that it is not outputting chloride rich water into the system The concentration of chlorides must always rema...

Страница 6: ...chapter 2 5 1 2 5 2 Unit monitoring If the recommendations listed above new installation or renovation have been followed the unit monitoring is limited to Checking the amount of make up water fill water volume make up water volume 3 times the unit volume Checking the pH level stable or slightly increasing Checking the total hardness stable or slightly decreasing We recommend monitoring these para...

Страница 7: ...d for efficiency by qualified personnel when in doubt Never confuse neutral wires with phase wires The unit must be hooked up to the electrical network with a plug socket connection that is such as to boiler from undesirable effects prevent inversion of phase and neutral Install a master switch for the heating plant as requested by existing legislation The entire electrical system and all cable se...

Страница 8: ... DATA 11 2 1 Main data 11 2 2 Minimum operating pressure 11 2 3 Dimensions Melbury HE 12 2 4 Dimensions of custom made models for Melbury HE 14 2 5 Technical data Melbury HE 16 2 6 Correction values for different operating conditions 20 3 BOILER CONTROL PANEL 21 3 1 Description 21 3 2 Basic equipment NAVISTEM B1000 and B2000 21 3 3 Additional equipment 21 3 4 Heating regulators 22 3 5 Burner cable...

Страница 9: ...ling the installation and water quality 30 5 4 Protection against corrosion 30 5 5 Requirements for operation 30 6 OPERATION 31 6 1 Commission 31 6 2 Decommission 31 6 3 First steps to take in case of failure 32 7 MAINTENANCE 33 7 1 Periodical checks and maintenance operations 33 7 2 Boiler cleaning 33 7 3 Burner maintenance 33 8 SPARE PARTS 33 ...

Страница 10: ... material are the low thermal conductivity and the low specific thermal capacity This leads to a further reduction of the stand by losses On the larger boilers a special concretewith similar characteristics is used as thermal insulation of the boiler door The revolving door gives easy access to parts of the boiler that are in contact with combustion gases This allows cleaning of combustion chamber...

Страница 11: ...heavy fuel Melbury HE 75 C Min return temperature with fuel oil 50 C 60 C 60 C 60 C with natural gas with propane with heavy fuel Melbury HE Max CO2 content with fuel oil 15 5 dry flue gas with natural gas 11 7 with propane 13 7 Min flue gas temperature with fuel oil S content 50 ppm 100 C 0 05 110 C 0 1 115 C 0 2 120 C 0 5 125 C with natural gas S content 10 mg nm3 95 C 150 mg nm3 110 C with heav...

Страница 12: ...MELBURY HE 3800 10000 Installation Use and Maintenance Page 12 36 410821 V11 22297 B 2 3 Dimensions Melbury HE figure 2 Melbury HE 3800 10000 ...

Страница 13: ...ection PN16 g2 DN 80 80 100 100 100 125 125 Distance supply safety valve m mm 1751 1855 2024 2190 2370 2590 2850 Discharge position k mm DN 167 2 182 2 187 2 135 65 140 65 150 65 127 80 Height flue collector discharge k1 mm DN 264 11 4 279 11 4 284 11 4 335 2 340 2 350 2 360 2 Distance front feet l1 mm 600 640 650 Catwalk width b2 mm 700 700 700 750 800 850 850 Catwalk length n2 mm 4340 4577 4977 ...

Страница 14: ...tical flue connection CAUTION The vertical smoke nozzles are not made on the Melbury HE figure 3 Melbury HE 3800 1000 Melbury HE 3800 4500 5400 6300 7400 8600 10000 Flue outside diameter e mm 550 600 650 700 750 850 900 Flue position n1 mm 4235 4477 4872 5277 5722 6254 6849 Overall length L1 mm 4695 4960 5380 5850 6320 6900 7520 Catwalk length n mm 3940 4157 4527 4905 5325 5807 6377 The other dime...

Страница 15: ...E 3800 4500 5400 6300 7400 8600 10000 a mm 3915 4132 4502 4882 5302 5784 6354 a1 mm 30 30 30 30 30 30 30 a2 mm 100 100 100 100 100 100 100 b mm 1970 2170 2280 2560 2710 2810 2900 c1 mm 1110 1263 1285 1295 1530 1760 1572 c2 mm 1005 1105 1160 1485 1375 1351 1623 d1 mm 1960 2160 2270 2250 2700 2800 2890 d2 mm 1750 1950 2060 2300 2450 2550 2640 e mm 588 608 638 678 708 768 798 f mm 1820 2020 2130 2430...

Страница 16: ...tions of the 8 and 10 bar versions are PN16 Melbury HE 3800 4500 5400 6300 7400 8600 10000 4 bar G kg 6332 7891 9566 12116 14717 17295 20358 8 bar G kg 7521 9258 11184 14458 17181 20174 23220 10 bar G kg 8225 9907 11923 16022 18574 21378 24754 2 5 Technical data Melbury HE CAUTION The power indicated is the maximum power that the corresponding heating body model can deliver The selected burner and...

Страница 17: ...low max 1 kg h 351 1 415 4 496 8 578 2 679 1 786 4 910 1 min 1 2 143 9 178 6 223 6 260 2 305 6 369 6 455 1 Exhaust gas mass flow max wet kg s 1 79 2 12 2 54 2 95 3 47 4 01 4 64 min wet 1 2 0 73 0 91 1 14 1 33 1 56 1 89 2 32 EXHAUST GAS DATA LOSSES Overpressurecombustionchamber max mbar 10 80 9 99 10 71 12 22 14 13 15 73 17 16 Exhaust gas temperature at 80 60 C max C 198 196 190 185 185 178 169 min...

Страница 18: ... h 418 0 494 6 591 4 689 0 808 0 936 0 1083 0 min 1 2 92 0 121 2 153 8 165 0 202 0 243 0 303 0 Exhaust gas mass flow max wet kg s 1 74 2 06 2 46 2 87 3 36 3 89 4 51 min wet 1 3 0 38 0 50 0 64 0 69 0 84 1 01 1 26 EXHAUST GAS DATA LOSSES Overpressurecombustionchamber max mbar 11 01 10 18 10 91 12 46 14 4 16 03 17 48 Exhaust gas temperature at 80 60 C max C 199 197 191 186 185 179 170 min 3 95 Exhaus...

Страница 19: ...eavy fuel Melbury HE 3800 4500 5400 6300 7400 8600 10000 POWER Boiler nominal power qN 80 60 C max kW 3300 4000 4700 5600 6700 8100 9700 Calorific power qF max 1 kW 3579 4336 5075 6047 7243 8751 10443 1 LCV 11 53 kWh kg 970 kg m3 1 S Respect the operating conditions according to chapter 2 1 Further data on request ...

Страница 20: ... 70 C Since the minimum power of the boiler is limited by the minimum allowable flue gas temperature the modulation range increases when the average boiler temperature increases This is exemplary illustrated in the figure below example for oil operation with a minimum flue temperature of 120 C figure 7 Flue gas temperature Boiler power diagram example for two average boiler water temperatures 2 6 ...

Страница 21: ...he flow andtemperature of return water by acting on the three way valves of the heating circuits or three way valve for heating the boiler return temperature The control panels are supplied ready to be connected The regulators must be set according to the recommendations in the instructions provided in the control panel to protect the boiler against condensation Settings must also be adapted to co...

Страница 22: ...circuits 3 4 2 RVS 63 regulator included as standard with NAVISTEM B2000 control panel Regulator enabling A burner to be run at one speed two speeds or modulating Running a direct heating circuit Running two heating circuits or one heating circuit and a mixer valve protecting the heater in return temperature Running domestic hot water preparation Achieve a tile effect with one or more other boiler...

Страница 23: ...bustion air is 5 ppm Halogen compounds are found in spray cans thinners cleaning agents degreasing agents and solvents among others In addition halogen emissions are strongly suspected in the vicinity of dry cleaners hair dressing salons swimming pools printing offices and washing machines installed in the same room In the case of doubt the perfect quality of the combustion air must be ensured wit...

Страница 24: ...00 1000 1000 1000 1000 1000 Boiler feet length I mm 2700 2850 3200 4110 4510 4912 5412 Boiler feet width b mm 1150 1290 1350 1520 1610 1670 1730 Measure d mm 15 15 15 42 42 42 42 Silent block length e mm 706 562 706 634 634 634 670 670 Silent block width S mm 50 50 60 75 75 85 85 Number of silent blocks 6 2 8 10 12 14 14 16 U girder width S1 mm 60 60 65 80 80 90 90 The dimension can be reduced to ...

Страница 25: ...nd the maximum operating temperature are given in chapter 2 1 page 11 No minimum level of the amount of circulating water is required Damage can occur from corrosion when oxygen continuously enters the heating water through open installations expansion tanks that are too small floor heaters with pipe material that is not oxygen tight etc If this cannot be prevented additional measures are necessar...

Страница 26: ...ed in the smoke tubes the combustion gas temperature can be controlled All smoke tubes in the third pass must equally be provided with turbulators These smoke tubes are those that are open on the rear part in the direction of the combustion gas collector The mounting instructions can be found in the separate assembly guide Melbury HE 3800 4500 5400 6300 7400 8600 10000 Number of turbulators 54 63 ...

Страница 27: ...0 Burner mini tube max qN max length max qN low NOx P mm 290 350 370 390 440 390 430 500 590 540 580 600 Screw hole centre diameter Lk mm 580 640 680 680 700 8xM12 15 4xM16 20 4xM12 20 Maximum door load from burner weight kg x m 370 440 500 745 850 915 980 BURNER ORIENTATION Max swivel radius R mm 1365 1505 1615 1780 1895 1985 2065 Distance boiler axle pivot D1 mm 860 960 1015 1150 1225 1275 1320 ...

Страница 28: ...nect the fuel supply to the burner in such a way that the supply line has to be disconnected in order to be able to open the boiler door Another possibility is to attach the burner cables with glands in such a way that the connectors on the burner have to be pulled to open the door CAUTION Customer installations oil tubes etc must not be attached to the boilercladding Gas burner Observe the separa...

Страница 29: ...ight are all important elements in determining sizes 4 7 2 Flue gas tubes We recommend the use of flue gas tubes made from acid resistant non corrosive materials The tube must be laid and introduced in the chimney to an inclination of 30 45 to minimize pressure loss The tube will have to be inserted in such a way as to prevent any condensation reversal from the chimney down into the boiler To avoi...

Страница 30: ...ation pumpsshould be switched off and all ventilating valves opened so that the air in the system can completely escape The filling process is finished when the operating pressure has been reached 5 4 Protection against corrosion Normally no corrosion problems arise if systems are properly designed and installed and are run according to these instructions consequently there is no need to use chemi...

Страница 31: ...er andburner have been opened Whether the circulation pumps work Whether the air supply is ensured and the flue outlet is free The inside of the burner door is built using insulating refractory concrete The residual humidity present in the concrete resulting from the manufacturing process may during the initial operating phase release steam and form water droplets on the door The steam must be all...

Страница 32: ...er LED is on Press burner reset button No oil Add oil Gas pressure insufficient Call the gas board Overheat temperature LED is on Safety thermostat has come into operation Fix the cause wait until temperature has dropped below overheat setpoint then reset the safety thermostat by pushing the pin External default LED is on Fix the cause No heat release to consumers Incorrect operation type setting ...

Страница 33: ... burner manual Check fuel oil level Clean boiler and chimney 7 2 Boiler cleaning Boiler should be cleaned by your chimney sweeper and engineer The cylindrical type construction of the boilers makes cleaning much easier to perform However we recommend that heating surfaces in fuel oil boilers be cleaned with appropriate chemical products Your installation contractor as an engineer will know how to ...

Страница 34: ...x House New Fields Business Park Stonsford Road Poole Dorset H17 ONF Tel 01202662500 Fax 01202 662522 seNice hamworthy heating com www hamworthy heating corn CAUROIR SITE 1 route de Solesmes FR 59400 CAUROIR ...

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