Hamworthy Sherborne S65, Installation, Commissioning And Service Manual

Page 1: ...NG OPERATING OR SERVICING EQUIPMENT Sherborne Series Boilers Room Sealed Fully Modulating Pre Mix Gas Fired Boilers for Heating and Domestic Hot Water Installations Installation Commissioning and Servicing Instructions S70c FULLY CONDENSING S65 HIGH EFFICIENCY 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: ...EASE ENSURE RELEVANT INFORMATION REQUIRED WITHIN DOCUMENT IS FOUND RELATING TO SPECIFIC GAS TO BE FIRED BEFORE FIRING BOILER THIS BOILER COMPLIES WITH ALL RELEVANT EUROPEAN DIRECTIVES EC TYPE CERTIFICATE Nos GAD EC 87 01 20 BED BE 87 01 02 PRODUCT IDENTIFICATION No 87BM20 PUBLICATION NO 500001103 ISSUE E JANUARY 2005 Sherborne Series Boilers Room Sealed Fully Modulating Pre Mix Gas Fired Boilers f...

Page 4: ...n 6 3 Design Waste Gas Volume and Temperature 6 4 Maximum Length of Flue Duct 6 5 Disconnection 6 6 Flue Discharge 6 7 Surface Temperatures 6 8 Flue System Location 7 0 AIR SUPPLY 12 7 1 Air Supply By Natural Ventilation Open Flue 7 2 Air Supply By Natural Ventilation Room Sealed 7 3 Air Supply By Mechanical Ventilation Open Flue 8 0 WATER CIRCULATION SYSTEM 12 8 1 General 8 2 Pressure Relief Valv...

Page 5: ...ction 10 6 Gas Connection 10 7 Fitting the Control Panel 10 8 Fitting the Front Cover 11 0 COMMISSIONING AND TESTING 24 11 1 Electrical Installation 11 2 Gas Installation 11 3 Water Circulation System 11 4 Commissioning the Boiler 11 5 Boiler Checks Prior to Lighting 11 6 External Controls 11 7 Installation Noise 11 8 User s Instructions 12 0 FAULT FINDING 28 12 1 Safety Features Summary 12 1 2 Fa...

Page 6: ...igure 8 12 Site Wiring Diagram 15 16 Figure 9 1 Wiring Schematic 17 Figure 10 3 1 Connection of Flue System Concentric Ducts Horizontal 19 Figure 10 3 1 1 Connection of Flue System Concentric Ducts Horizontal 19 Figure 10 3 2 Connection of Flue System Concentric Ducts Vertical 20 Figure 10 3 3 Connection of Flue System Separate Ducts 21 Figure 10 3 4 Connection of Flue System Open Flue 21 Figure 1...

Page 7: ... boiler s off should a high or low pressure fault occur Note The boiler is not suitable for direct connection to domestic hot water supplies or gravity circulation systems The pressurisation unit must also incorporate a low level water switch which protects the water pumps and will directly or indirectly shut down the boiler plant should a low water condition occur Consideration should also be giv...

Page 8: ...HAMWORTHY HEATING LTD SHERBORNE 500001103 E Figure 1 1 Boiler Installation Typical 2 ...

Page 9: ...20 150 150 Ø30 Hole Gas 3 4 Electric M20 Electric M20 Cover removal clearance 30 Return 50 Flow 200 Flue 76 Flow 140 Flue 154 Return 185 460 280 600 A B 800 Water connections 85 200 320 Boiler Model Return connection A B S65 495 Return connection S70c 630 View on underside 150 150 1660 290 140 150 MIN Condense 3 ...

Page 10: ...ERAL DATA Sherborne S65 Sherborne S70C Boiler Input kW Gross maximum 77 7 Boiler Input kW Nett maximum 70 0 Boiler Input kW Gross minimum 15 5 Boiler Input kW Nett minimum 14 5 Boiler Output kW minimum 13 6 Boiler Output kW condensing maximum 71 3 Boiler Output kW non condensing maximum 64 0 66 6 FLUE DATA Nominal Flue Dia mm Single pipe 100 dual concentric 80 125 or 100 150 Approx Flue Gas Temper...

Page 11: ...all relevant information but the following extracts from the above references are emphasised since failure to comply with these requirements will almost certainly result in an unsatisfactory installation Third edition of the 1956 Clean Air Act Memorandum Department of the Environment Scottish Development Department Welsh Office 3 2 Feed Water Quality If the boiler feed water has a high degree of h...

Page 12: ... Any combustible material adjacent to the boiler and the flue system must be so placed or shielded to ensure that its temperature does not exceed 65 C Further details regarding boiler location are given in BS 6644 BS 5440 part 2 5 0 GAS SUPPLY 5 1 Service Pipes The local gas region must be consulted at the installation planning stage in order to establish the availability of an adequate supply of ...

Page 13: ...ain The boiler is provided with a condense drain suitable for connection to 22mm plastic waste pipe not supplied which must be connected to a tundish not supplied Discharge piping from a tundish should be of a synthetic material due to the mild acidity of the condensate pH 3 5 with all discharge piping having a minimum fall of 30mm m away from the boiler Consideration should be given to possible f...

Page 14: ...rminal 007 Assembly Ø80 125 Wall plate Ø125 014 Ref 028 Ref Ø100 150 90 Concentric Bend Ref 027 45 Concentric Bend Ø100 150 Ø100 150 Adjustable Ø100 150 x 1m long 029 030 Ref Concentric Flue Ref Concentric Flue Ref Horizontal terminal Assembly Ø100 150 031 Eccentric Adaptor Enlarged detail showing cut Ø80 100 Ø80 Flue Support Bend 023 Ref Ref 001 Flue make up piece Ø100 x 250 long 020 Ref Ø150 x 1...

Page 15: ...ccentric Adaptor Flue type C33 150 x 100 Ø80 100 Ø80 Flue Support Bend Ref 020 Ref 043 023 Ref Ref 001 Ref 029 Ref 030 Ref 033 027 Ref 028 Ref 038 Ref 044 Ref Ref 032 Flat Roof Flashing Adjustable Flashing Concentric Flue Concentric Flue Ø100 150 x 1m long Ø100 150 Adjustable Assembly Ø100 150 Wall Clamp Ø150 Vertical Terminal 90 Concentric Bend 45 Concentric Bend Ø100 150 Ø100 150 Ø150 Flue Ø150 ...

Page 16: ...0 4m min 10m max Ref 023 Ref 001 Ø80 Flue Support Bend Outlet 0 4m min 10m max Ø80 100 Outlet 10m max Inlet 10m max Single Flue Single Flue Single Flue 250 long Ø100 1000 long Ø100 500 long Ø100 Wall Clamp Ø100 Horizontal Flue Terminal Ø100 Flue 1000 long Ø100 45 Bend 1000 long Ø100 90 Bend Eccentric Adaptor Wall Clamp ø100 Flat Roof Flashing Adjustable Flashing Support Bend Vertical terminal Ref ...

Page 17: ...0 long Ø100 Single Flue Ref 026 Vertical terminal Ø100 Flue Ref 023 Ø80 100 Eccentric Adaptor Ref 017 Wall Clamp Ø100 Ref 022 021 Ref 020 Ref Single Flue 500 long Ø100 1000 long Ø100 Single Flue Single Flue 250 long Ø100 Ref 017 Wall Clamp Ø100 Ref 019 1000 long 45 Bend Ø100 Ref 018 1000 long 90 Bend Ø100 flue system if suitable Modular header or existing Enlarged detail typical B23 Eccentric Adap...

Page 18: ...ave a total minimum free area of Low Level inlet 550cm2 per boiler High Level outlet 275cm2 per boiler 7 2 Air Supply Room sealed installation If the Sherborne boiler is installed as a room sealed boiler within a room there is no requirement for the room to have additional ventilation If the Sherborne boiler is installed as a room sealed boiler within a cupboard or compartment the enclosure shall ...

Page 19: ...ed between the boiler and the first water isolating valve The minimum bore mm of these pipes per installation is as follows The vent pipe must rise continually must not be valved except by a design which when closed for maintenance the boiler is open to atmosphere The pipe shall be protected against freezing where this might occur Boiler Output Feed Vent 60kW 150kW 25 32 150kW 300kW 32 38 Figure 8...

Page 20: ...6759 Part 1 for information See also BS 6880 Part 1 for design considerations 8 12 1 Boiler Control Schemes 8 12 2 Single Boiler Installations For single boiler installations the Sherborne range of boilers can be operated in fully modulating mode controlled from a simple time clock or BMS system via a remote stop start loop see Figure 8 12 8 12 3 Modular Boiler Installations For modular installati...

Page 21: ...ER 2 BOILER NUMBER 3 TO HAMWORTHY HEATING LIMITED MILTON BOILER SEQUENCE CONTROL REFER TO MILTON INSTALLATION MANUAL FOR FURTHER DETAILS NOTE VOLT FREE CONTACT TERMINALS NOT SHOWN FOR CLARITY CONTACT TERMINALS NOTE VOLT FREE BLR 1 ON OFF BLR 2 ON OFF BLR 3 ON OFF CONTACT CONTACT CONTACT SEQUENCER SEQUENCER SEQUENCER NOT UTILISED NOT UTILISED NOT UTILISED CONTROLS CONTROLS CONTROLS INTERLOCK INTERL...

Page 22: ...NPUTS CONTROL INPUT CONTROL INPUT ROTARY SWITCH SW1 ROTARY SWITCH SW1 ROTARY SWITCH SW1 ROTARY SWITCH SW1 BOILER MODULE NUMBER 1 BOILER MODULE NUMBER 2 SEQUENCING INTERFACE MODULE SEQUENCING INTERFACE MODULE BOILER MAIN CONTROL PCB BOILER MAIN CONTROL PCB CONTACT TERMINALS CONTACT TERMINALS NOTE VOLT FREE NOTE VOLT FREE NOT UTILISED NOT UTILISED NOT UTILISED NOT UTILISED CONTROLS CONTROLS INTERLOC...

Page 23: ... 9 9 10 10 2 1 4 3 2 1 3 4 5 BN GN YE BU 1 2 3 4 5 GAS VALVE 2 1 3 1 2 1 2 HSI PROBE 1 2 1 TEST POINT FLAME SIGNAL 1 2 3 1 2 3 4 GND PWM GND HS DC SERVO FAN V N L 2 1 3 4 5 1 2 3 GN YE BN BU GN YE 1 2 3 BN BU WH WH BK PROBE FLAME BK 230V AC 50Hz SUPPLY OVERHEAT VOLT FREE CONTACTS LOCKOUT VOLT FREE CONTACTS NORMAL RUN VOLT FREE CONTACTS SEQUENCER DATA BUS CONNECTIONS REMOTE HIGH LOW CONTROL CONNECT...

Page 24: ...same mains isolator as the boiler it is fitted to A 0 10V analogue control signal from the external sequence control system is required ground and signal connections The interface module is configured to give a linear response to the 0 10V signal between 2 0V 20 rate and 10 0V 100 rate Below the 2 0V the boiler will operate at 20 rate until the input signal falls below 0 3V at which point the boil...

Page 25: ...commissioning a check has been made to ensure that the pipe is clear and free from obstruction 10 3 1 Connection of Through Wall Horizontal Balanced Flue Terminal 80 125mm The flue terminal should be cut to length as detailed in Figure 10 3 1 Wall Mounted option or Figure 10 3 1 1 Frame Mounted option Check all measurements before cutting and take care not to damage the inner tube when cutting the...

Page 26: ...sary In terminating the flue system ensure that the joint through the wall roof is made good and weatherproofed Whilst carrying out the above procedure ensure that all seals are correctly located and provide gas tight joints The top of the plastic boiler cover has a D shaped recess that marks the position of the vertical flue exit point Using a suitable fine toothed hacksaw or jigsaw carefully cut...

Page 27: ...hacksaw or jigsaw carefully cut around the inside of the recess to provide the flue outlet Having fitted the flue system to the boiler carefully refit the burner assembly and secure to the heat exchanger using the 2 M6 nuts previously removed taking care not to damage the probes or the burner flange gasket see Figure 10 2 Reconnect the pressure feedback tube to the gas valve Figure 10 3 4 Connecti...

Page 28: ...body Secure the conduit adapters to the wall frame and the control panel and fit the flexible conduits Feed the cables through the conduits connecting to the appropriate connections on the PCB see Figures 8 12 and 9 1 for wiring Sump body Gasket Drain connection Condensate trap Plug connection details Care must be taken to ensure correct connections are made to the relevant terminals and that the ...

Page 29: ...HAMWORTHY HEATING LTD SHERBORNE 500001103 E Figure 10 6 Gas Pipe Fitting 23 ...

Page 30: ... should attempt the following Before attempting to commission any boiler ensure that personnel involved are aware of what action is about to be taken and begin by making the following checks 1 Flueway passages to chimney are clear 2 Adequate ventilation as per Section 7 AIR SUPPLY exists in the boiler house or compartment room 3 The system is fully charged with water ready to receive heat All nece...

Page 31: ... Switch Gas Supply Isolating Valve Control Panel Lockout Reset Button Control Thermostat Limit Thermostat Fan Venturi Gas Valve Air Inlet Chamber Flue Outlet Wall Frame Condensing Models Only Position varies by model condensing model depicted Cover Fixing Point Thermostat Pocket Flame Probe View Port Hot Surface Igniter Fan burner securing nut Flue gas sampling point 25 ...

Page 32: ...MWORTHY HEATING LTD SHERBORNE 500001103 E Figure 11 2 Gas Valve Venturi Arrangement Figure 11 5 Position of Probes on Burner Assembly 92 max 88 min 40 min 42 max 49 min 51 max 7º 1 3 2 18 25 11 5 16 17 26 ...

Page 33: ...he module disconnect the manometer and close the pressure test point Record all readings for future reference on the relevant commissioning sheet Isolate the electrical supply and rotate SW1 to set the required mode of operation for the boiler Make Break links R1 to R4 as dictated by site requirements Re energise electrical supply and switch on the boiler and allow system to warm up sufficiently t...

Page 34: ...when the supply has been restored 12 1 2 Fault Finding Procedures General fault finding is shown in Figures 12 1 to 12 4 If the boiler still cannot be operated satisfactorily after following the chart consult the local office of Hamworthy Heating for assistance 12 1 3 Possible Causes Of Boiler Lockout 1 Ignition failure due to no power at the Hot Surface Igniter 2 Ignition failure due to faulty ga...

Page 35: ...m the sump casting Remove the 2xM6 screws securing the condense trap to the sump and disconnect the section of pipe routed back to the wall frame S65 Model support the sump from underneath and remove the 4xM6 securing nuts Lower the sump casting to expose the heat exchanger and baffles S70C Model having drained the system down remove the return lower connection and heat exchanger connecting pipe f...

Page 36: ...iler main PCB set correctly Is the on off switch on Fascia power on indicator illuminated Is the temperature limiter reset Fascia overheat indicator illuminated Check fuses and supply connections Check and turn temperature control knob to maximum Check and clear blockage Check and close remote circuit Check fan power supply wiring connections Check fan control wiring connections replace boiler mai...

Page 37: ... the flame signal above the minimum 1 2µA Is there an HSI signal from the ignition controller Is there power to the HSI probe Check wiring connections to ignition controller Check fan control wiring connections replace fan Check fan control wiring connections replace fan Check wiring to ignition controllerl replace ignition controller Check wiring to gas valve replace boiler main PCB Check wiring ...

Page 38: ...w sequence control switches to high fire Continued Ref Fig 12 4 Insufficient water circulation Temperature control circuit faulty Temperature control set above Milton control temperature Boiler under Milton sequence control modulates down as temperature rises Replace temperature sensor Check and set rotary switch to correct position Check and set rotary switch to correct position Check and set rot...

Page 39: ...unning at wrong speed or running when should be stopped Condensate Drain Trap Blocked Condensing models only Overheat high limit thermostat tripped Premature flame detection Flame sensing circuit fault Boiler Fault Indication Certain boiler fault conditions are indicated by a sequence of flashes of the fascia fan running indicator Scale build up in boiler waterways Check replace pump bleed trapped...

Page 40: ... thermostat phials Remove the screw securing the fascia panel to the controls housing and carefully lower the front panel and hang on the two hooks provided on the control panel body Disconnect the sensor cable plug from the PCB and remove the sensor Prise out the indicator disc from the centre of the control knob and loosen the collet nut securing the knob to the shaft Pull off the control knob a...

Page 41: ...r casting Withdraw the assembly from the air inlet duct 4 Remove the 2xM5 screws securing the venturi gas valve assembly to the fan noting the cork sealing gasket 5 Re assemble in reverse order using new gaskets where necessary Ensure all screws are tightened and electrical plugs are firmly and correctly located 6 Re light the boiler check and adjust the combustion as detailed in Section 11 4 14 6...

Page 42: ...380 Boiler main PCB S70c Nat Gas 533901381 Boiler main PCB S65 LPG 533901415 Boiler main PCB S70c LPG 533901416 Fascia PCB 533901382 Ignition Sequence Controller 533901379 Fan assembly 533901376 Control Thermostat Sensor 533901378 Control Thermostat Potentiometer cable assembly 563901312 Sequencing Interface Module 533901421 MECHANICAL ITEMS Burner Assembly 563301029 Spares Gasket Set 563605209 Sm...

Page 43: ... 37mbar The following tables and paragraphs using the same numbering system as the main installer s guide highlight the different values and procedures to be used when firing propane and should be used in conjunction with the Main Installer s Guide 2 2 Performance and General Data Information LPG Propane GENERAL DATA Sherborne S65 Sherborne S70c Boiler Input kW Gross maximum 76 0 Boiler Input kW N...

Page 44: ...HAMWORTHY HEATING LTD SHERBORNE 500001103 E USEFUL USER INFORMATION INSTALLER SITE ADDRESS DATE OF COMMISSIONING BOILER TYPE BOILER SIZE S UNIT NO S SERIAL NO S FLUE NOTES 38 ...

Page 45: ...HAMWORTHY HEATING LTD SHERBORNE 500001103 E NOTES 39 ...

Page 46: ...HAMWORTHY HEATING LTD SHERBORNE 500001103 E NOTES 40 ...

Page 47: ...Notes ...

Page 48: ...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...