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HAMWORTHY HEATING LTD 

 

LILLIPUT HE 

 

500001047/F 

3. 0    

INSTALLATION REQUIREMENTS

 

 
3.1 Gas 

Safety 

 
It is the law that all gas appliances are installed by a 
competent person, i.e. a CORGI registered gas 
installer, in accordance with the requirements of all 
relevant current legislation and codes of practice - 
see below. 
 

3.2 

Legislation and Codes of Practice 

 

Lilliput HE boilers should be installed in accordance 
with all relevant legislation, codes of practice and 
British Standards, including the following: 
 

a. Legislation 

Regulations 

 

 

 

The Gas Safety (Installation and Use) 

Regulations 1984 . 
 

 

The Gas Safety (Installation & Use) 

(Amendment) Regulations 1990. 
   

The Health & Safety at Work Act. 

   

Health & Safety Executive Guidance Note 

PM5. 
   

The Building Regulations. 

 

 

 

The IEE Wiring Regulations for Electrical 

Installations. 
   

The Byelaws of the Local Water Undertaking. 

   

Local Authority Regulations. 

   

Local Gas Region Regulations. 

   

Local Fire Authority Regulations. 

   

Insurance Company Requirements. 

 

b. 

British Standards Codes of Practice 

 
BS.CP342

 - Code of practice for centralised hot 

water supply.  

Part 2

: Buildings other than individual 

dwellings. 

BS.5410

 - Code of practice for oil firing.  

Part 1

:  

Installations up to 44 kW, and

 Part 2

: Installations of 

44 kW and above capacity for space heating, hot 
water and steam supply purposes. 

BS.5440

 - Code of practice for flues and air supply 

for gas appliances of rated input not exceeding 
60kW 

Part 1

: Flues

; Part 2

: Air supply. 

BS.6644

 - Specification for installation of gas fired 

hot water boilers of rated inputs between 60kW and 
2MW. 

BS.6798

 - Specification for installation of gas fired 

hot water boilers of rated input not exceeding 60kW. 

BS.6891

 - Installation of low pressure gas pipework 

of up to 28mm in Domestic Premises. 

BS.6700

 - Design, Installation, testing and 

maintenance of services supplying water for 
domestic use. 

BS.6880

 - Code of practice for low temperature hot 

water heating systems of output greater than 45kW.  

Part 1

: Fundamentals & design considerations.  

Part 2

:  Selection of equipment.  

Part 3

:  

Installation, commissioning and maintenance. 

c. British 

Gas 

Publications 

 
IM/2

 Purging procedures for non-domestic gas 

installations. 

IM/5

  Soundness testing procedures for industrial 

and commercial gas installations. 

IM/11

 Flues for commercial and industrial gas fired 

boilers and air heaters. 

IM/16

 Guidance notes on the installation of gas 

pipework, boosters and compressors in customers 
premises (excluding domestic installations of 25mm 
and below). 
 

3.3 Boiler 

Location 

 

The boiler location must permit the provision of a 
satisfactory flue system, and provide adequate 
space around the boiler for servicing and air 
circulation. 
 
Sufficient space must be provided at the front of the 
boiler to allow the removal of the burner assembly 
for servicing/replacement, and at the rear for 
installation of pipes, valves and flue. 
 
Sufficient clearance above the boiler must also be 
provided to allow access for servicing.  Refer to 
Section 2.2 for recommended clearances. 
 
The boiler room, or compartment, housing the boiler
(s) - whether specifically constructed for the 
purpose, or a modification of an existing space - 
should be in accordance with the requirements of 
either BS.6644,  BS.5410 Part 1, or BS.5410 Part 2, 
as appropriate. 
 
Where a separate purpose built boiler room is not 
available, measures should be taken to protect the 
boiler or boilers from damage, and the boiler should 
be sited such that extraneous material cannot be 
stored next to, or against it. 
 
The boiler should be installed on a non-combustible, 
level plinth of 50mm nominal height, capable of 
withstanding temperatures of 65 deg. C, and able to 
support the weight of the boiler (including pipework 
and ancillary equipment) when filled with water. 
 
The plinth should end flush with the boiler casing 
front to prevent interference with the burner oil 
pipework or gas train and should be at least the 
width and length of the casing dimensions. 
 
The compartment housing the boiler must have 
permanent air vents communicating directly with the 
outside air at both high and low level.  Refer to 
Section 3.7 for details. 
 

3.4 Gas 

Supply 

 

The Gas Safety (Installation and Use) Regulations 
require that only competent persons,  i.e. CORGI 
Registered gas installers, should install gas 

Summary of Contents for LILIPUT HE

Page 1: ...SE INSTRUCTIONS MUST BE READ AND UNDERSTOOD BEFORE INSTALLING COMMISSIONING OPERATING OR SERVICING EQUIPMENT LILLIPUT HE GAS OIL FIRED CAST IRON SECTIONAL BOILERS INSTALLATION COMMISSIONING AND MAINTE...

Page 2: ......

Page 3: ...ISSION OPERATE OR MAINTAIN THIS UNIT THE LILLIPUT BOILER IS INTENDED FOR USE AS A COMMERCIAL APPLIANCE AND IS NOT CERTIFIED FOR USE IN DOMESTIC APPLICATIONS GAS FIRED VARIANTS OF THE LILLIPUT BOILER R...

Page 4: ...il Supply 3 6 Flue System 3 7 Ventilation and Air Supply 3 7 1 Natural Ventilation 3 7 2 Mechanical Ventilation 4 0 WATER SYSTEM 7 4 1 Pipework 4 2 Pumps 4 3 Vent Pipe 4 4 Safety Valve 4 5 Pressure Ga...

Page 5: ...ater Flow Rates and Pressure Drops 7 Table 4 Composition of Sections within Heat Exchanger 10 FIGURES Figure 1 Overall Dimensions and Clearances 3 Figure 2 Boiler Control Panel Wiring Diagram 9 Figure...

Page 6: ...be used individually or in a multiple boiler configuration and are suitable for use on either open vented or sealed low temperature hot water heating systems For hot water production they can be used...

Page 7: ...AS VOLUME AT NTP NAT GAS m3 h ft3 h 90 0 3178 118 2 4174 APPROX FLUE GAS TEMP NAT GAS deg C 190 FLUE DRAUGHT REQUIRED AT BOILER OUTLET mbar in wg 0 1 0 25 0 04 0 10 WEIGHT FILLED WITHOUT BURNER kg lb...

Page 8: ...Dimensions and Clearances Fig 1 Overall Dimensions and Clearances BOILER MODEL Lmm Hmm Amm Gas Amm Oil Bmm Cmm Dmm min LILLIPUT HE 65 800 530 347 261 400 500 400 LILLIPUT HE 90 960 530 389 261 400 500...

Page 9: ...allation commissioning and maintenance c British Gas Publications IM 2 Purging procedures for non domestic gas installations IM 5 Soundness testing procedures for industrial and commercial gas install...

Page 10: ...sh Standards and Local Authority Regulations Oil Supply Lines The oil supply line s between storage tank and burner should be run in copper steel or aluminium pipe Galvanised pipes and fittings should...

Page 11: ...output and above The following notes are given as general guidance 3 7 1 Air Supply by Natural Ventilation The boiler room must have or be provided with permanent air vents directly to the outside ai...

Page 12: ...d be taken into account when selecting the circulating pump for the system In the case of open vented systems it is essential that the pump does not pump over i e push water out of the open vent pipe...

Page 13: ...ief safety valve of approved manufacture and sized to match the boiler s rating in accordance with BS 6644 should be installed in the flow pipe between the boiler s and open vent pipe connection The s...

Page 14: ...The boiler control panel includes a terminal block for all electrical connections to the boiler Refer to Fig 2 below Wiring diagrams showing the electrical connection of burner to boiler are given in...

Page 15: ...One front section F Intermediate sections I Special intermediate sections SI For the purposes of identification the Intermediate sections have a joint face between the middle and upper part of the se...

Page 16: ...oiler sections Check that the cut outs A are positioned around the rear spacers and secure in position with duct tape A Fit the rear insulation jacket over the flue outlet Secure the top and side edge...

Page 17: ...cable entry hole A is at the front of the boiler Se cure the top cover to the rear cover using the 4x10 self tapping screws B A B B Remove the cable entry blanking plate A from the control con sole a...

Page 18: ...r as detailed in British Gas Publications IM 5 and IM 2 respectively Check that gas meter is operational and has been checked by the local region of British Gas Check that gas meter and supply pipewor...

Page 19: ...aximum pressure of gas train governor is not exceeded i Adjust start and main output gas rates as detailed in the manufacturer s technical information supplied with the gas train j Check that overheat...

Page 20: ...ISOLATOR AND SHUT OFF FUEL SUPPLY TO BOILER a a For oil installations Desludge oil storage tank and examine for leaks and signs of deterioration b Examine contents gauge for visibility and clean or r...

Page 21: ...LLIPUT HE 500001047 F 16 i h Check all flue joints for integrity j i Check ventilation ducts grilles to boiler room and ensure they are clear k j Re commission boiler as detailed in relevant parts of...

Page 22: ...Hexagonal bush 1 BSP 573405119 9 Thermostat pocket 573405228 10 Plug BSP 573405121 11 Door hinge 573405229 12 Insulation front door 573405230 13 Insulation front 573405231 14 Front door 573405232 15...

Page 23: ...HAMWORTHY HEATING LTD LILLIPUT HE 500001047 F 18 Fig 4 Exploded View of Boiler 26 Item 26 insulation to be placed between refractory brick and door casting...

Page 24: ...LIGHT L N 3 WIRE BURNER CONNECTION FOR REMOTE LOCKOUT LAMP OR VOLT FREE SIGNAL FOR OVER TEM PERATURE LOCKOUT FOR BURNER WORKING SIGNAL FOR EXTERNAL THERMOSTAT OR PRESSURE SWITCH FOR EXTERNAL PUMP SWI...

Page 25: ...mm 616 776 Combustion Chamber Type Reversed BURNER TYPE FOR GAS INSTALLATIONS Burner Manufacturer RIELLO BURNER MODEL 40 GS10 40 GS10 Blast Tube Penetration Dimension A mm 110 110 Burner Manufacturer...

Page 26: ...HAMWORTHY HEATING LTD LILLIPUT HE 500001047 F 21 INSTALLER SITE ADDRESS BOILER TYPE BOILER SIZE S UNIT NO S SERIAL NO S FLUE NOTES...

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