Hamworthy Sherborne Series, Installation, Commissioning And Service Manual

Page 1: ...G 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 Servi...

Page 2: ...ating 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...

Page 3: ...ASE 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 CERTIFICA...

Page 4: ...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...

Page 5: ...tion 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...

Page 6: ...gure 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 Hor...

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...

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

Page 9: ...0 150 150 30 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 Ret...

Page 10: ...RAL 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...

Page 11: ...ll 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 installati...

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 give...

Page 13: ...Drain 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 sh...

Page 14: ...al terminal 007 Assembly 80 125 Wall plate 125 014 Ref 028 Ref 100 150 90 Concentric Bend Ref 027 45 Concentric Bend 100 150 100 150 Adjustable 100 150 x 1m long 029 030 Ref Concentric Flue Ref Concen...

Page 15: ...ce Eccentric Adaptor Flue type C33 150 x 100 80 100 80 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 F...

Page 16: ...let 0 4m min 10m max Ref 023 Ref 001 80 Flue Support Bend Outlet 0 4m min 10m max 80 100 Outlet 10m max Inlet 10m max Single Flue Single Flue Single Flue 250 long 100 1000 long 100 500 long 100 Wall C...

Page 17: ...000 long 100 Single Flue Ref 026 Vertical terminal 100 Flue Ref 023 80 100 Eccentric Adaptor Ref 017 Wall Clamp 100 Ref 022 021 Ref 020 Ref Single Flue 500 long 100 1000 long 100 Single Flue Single Fl...

Page 18: ...ve 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 boil...

Page 19: ...d 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 whi...

Page 20: ...759 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 boi...

Page 21: ...R 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 T...

Page 22: ...PUTS 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...

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...

Page 24: ...ame 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...

Page 25: ...ommissioning 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 c...

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...

Page 27: ...acksaw 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 exchang...

Page 28: ...ody 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 Figu...

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...

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...

Page 32: ...WORTHY 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 7 1 3 2 18 25 11 5 16 17...

Page 33: ...e 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...

Page 34: ...hen 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...

Page 35: ...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 t...

Page 36: ...ler 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...

Page 37: ...the flame signal above the minimum 1 2 A 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 co...

Page 38: ...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 Mi...

Page 39: ...nning 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...

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 sen...

Page 41: ...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 n...

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 Contr...

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...

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: ...y 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 Addre...