Hamworthy UF150-1, Installation, Commissioning And Operating Instructions

Page 1: ...on Commissioning and Operating Instructions Models UF100 1 UF150 1 UF200 1 UF250 1 UF300 1 UF350 1 UF200 2 UF300 2 UF400 2 UF500 2 UF600 2 UF700 2 UF300 3 UF450 3 UF600 3 UF750 3 UF900 3 UF1050 3 NATU...

Page 2: ...operating safely and efficiently Service Contracts Regular routine servicing of equipment by Hamworthy service engineers inspects the safety and integrity of the plant reducing the risk of failure and...

Page 3: ...UIRED WITHIN DOCUMENT IS FOUND BEFORE FIRING BOILER COUNTRY OF DESTINATION UNITED KINGDOM REPUBLIC OF IRELAND THIS BOILER COMPLIES WITH ALL RELEVANT EUROPEAN DIRECTIVES PRODUCT IDENTIFICATION No 86CS3...

Page 4: ...ed Systems 5 5 Electrical Connections 6 0 PRE COMMISSIONING 19 6 1 Gas Supply 6 2 Ventilation 6 3 Pipework Valves and Pump 6 4 Flue 6 5 Electrical 7 0 CHECKS PRIOR TO LIGHTING 21 7 1 Boiler Gas System...

Page 5: ...50 3MW Primary circuit and Gas manifold pipe kit 10 Figure 3 2 4 UF300 UF350 2MW Primary circuit and Gas manifold pipe kit 11 Figure 3 2 5 UF300 UF350 4MW Primary circuit and Gas manifold pipe kit 12...

Page 6: ...hanical Ventilation Flow Rates 44 Figure E1 Water Data 44 Figure E1 1 Hydraulic Resistance 44 Figure E1 3 1 Schematic 1 External time clock enabled boiler 47 Figure E1 3 2 Schematic 2 Two heating circ...

Page 7: ...ndix C The flue outlets from more than one unit may be connected to a single chimney No draught diverter is fitted to the boiler nor is a fixed diverter required in the flue system However a draught s...

Page 8: ...boiler control 1 11 Options refer to individual kit instructions for details 1 11 1 Optional water pipe work kits are available for two or three high vertical units for up to 12 modules These kits are...

Page 9: ...e boiler must be kept upright during handling The flue manifold connecting the vertical modules is supplied separately to the boiler Warranty Full warranty assistance will be covered when the applianc...

Page 10: ...om the boilers All ancillary items such as isolation valves and boiler make up connectors are factory fitted and tested The whole is shrink wrapped for security and basic protection Refer to Kit instr...

Page 11: ...turn 624 Gas 400 400 1300 750 750 Minimum boiler to boiler spacing 3 Modules high 2 Modules high 1 Module high 57 Relief valve 866 614 175 789 1376 Flue 1403 234 Drain 937 Gas 977 Return 1380 Flow Fig...

Page 12: ...789 76 Drain 58 5 Gas 57 Relief valve 173 Flow Return Relief Valve G3 4 Not supplied 341 Flue 582 120 323 Gas 338 Return 741 Flow 624 Gas 350 Flow Return 206 Flue 114 Drain Flow R 2 11 Return R 2 11...

Page 13: ...17 Flow 2080 Flue 381 Flue 1128 1403 234 Drain 954 Gas 952 Return 1355 Flow 1466 Flue 155 Flue 1551 Gas 1549 Return 1969 Flow Flue O130 Gas R 1 1 4 11 Flow R 2 11 Return R 2 11 624 Gas 350 Flow Return...

Page 14: ...ing the system plus drain and air bleed valves Flexible hoses connect the manifold to the flow and return ports on the boilers Non return valves on the pump supply prevent reverse flow through non fir...

Page 15: ...3 System Safety Relief Valve 2253 1943 1643 187 1029 668 400 1658 1348 144 76 1985 1230 750 1006 573 804 349 236 Figure 3 2 2 UF100 UF150 2MW Primary circuit and Gas manifold pipe kit UF100 UF150 DN10...

Page 16: ...pipe O34 Gas Manifold DN65 R3 System Safety Relief Valve G1 5 Pressurisation unit Expansion Vessel 773 1006 750 174 1388 1753 76 668 400 1029 2314 1948 1643 184 347 2342 1399 805 325 UF200 UF250 DN15...

Page 17: ...e pipe O34 Gas Manifold DN65 R3 System Safety Relief Valve G1 5 Pressurisation unit Expansion Vessel 805 347 2314 1948 1753 174 1388 76 668 400 184 750 1006 773 2528 1399 1029 1643 325 UF300 UF350 DN1...

Page 18: ...ipe O34 Gas Manifold DN65 G1 5 Pressurisation unit Expansion Vessel 1753 209 1326 76 668 400 2408 1643 184 750 1006 873 802 347 2527 1399 1029 391 210 R3 System Safety Relief Valve 1981 UF300 UF350 DN...

Page 19: ...st be fireproof in accordance with BS 6644 The plant room must have sufficient space for installation of boilers pipe work pumps controls flues ventilation access and servicing and other items of plan...

Page 20: ...d hot and with all boilers firing the max pressure at the flue sample point should not exceed those stated in Appendix C Fig C1 Flue data Any stabiliser fitted must be in or close to the vertical chim...

Page 21: ...h an appropriate inhibitor eg Sentinel X100 and the PH MUST be managed between 7 8 5 In hard water areas 180mg CaCO3 litre precautions such as water treatment are strongly recommended to prevent the b...

Page 22: ...5 Condense pipe work must be non corrosive and not copper Hamworthy recommend Polypropylene plastic waste pipe Condense may be discharged to a standard drain subject to National or Local regulations L...

Page 23: ...lectrical supplies to boiler modules should only serve the boiler using the conduits supplied High low voltage cables should be separated into individual conduits Where an external alarm is required t...

Page 24: ...20 C T across the flow and return Should the flow rate drop the boiler controls will modulate the burner to maintain 20 C T As a safety precaution a flow switch is fitted to the boiler heat exchanger...

Page 25: ...the boiler is commissioned 6 1 Gas Supply Ensure that gas installation pipe work and meter has been soundness tested and purged to IGE UP 1 or IGE UP 1A as appropriate Test and purge certificates shou...

Page 26: ...se valve B and remove manometer connections and tighten test points 7 0 CHECKS PRIOR TO LIGHTING IMPORTANT BEFORE PROCEEDING ENSURE THAT THE PRE COMMISSIONING CHECKS ON PAGE 14 HAVE BEEN CARRIED OUT A...

Page 27: ...n Check that the outlet terminal is located correctly and in accordance with regulations 7 Ensure that the gas supply has been properly purged and verified for gas soundness A purge and soundness cert...

Page 28: ...ignite 5 With the burner firing the flame signal displayed should be approximately 6 11 A Refer to separate Navistem manual HHL part no 500001310 At the end of the ignition proving period 5 seconds t...

Page 29: ...TNB THL1 THL1 A STOE SA F TNB TW1 STOE SA F TNB TW2 TVZ STOE SA F TNB STOE SA F TNB STOE TNB Duration 9500 9517 9519 9518 9519 9534 9540 9544 9540 9544 9652 120s 51s 51s 51s 51s 51s 51s 24h 51s 51s 51...

Page 30: ...nition controller close the gas valve The boiler should shutdown after approximately one second and attempt a re ignition Check that the flame has been extinguished 2 Alternatively the flame probe lea...

Page 31: ...ti clockwise Figure 8 6 4 Adjusting gas valve throttle High Fire Target Nat Gas 9 0 0 2 CO2 LPG 10 55 0 2 CO2 If combustion level is outside of this range use the Throttle Screw to adjust the mixture...

Page 32: ...burner settings will require adjustment CONTACT HAMWORTHY HEATING TECHNICAL DEPARTMENT FOR FURTHER DETAILS 7 Shut down the boiler and isolate from the electrical supply Remove instrumentation and repl...

Page 33: ...eneral Overview of Boiler Controls Air vent Inlet gas pressure test point Flow switch Temperature sensor Flue gas Temperature sensor Return Overheat thermostat Pressure sensor HT spark generator Tempe...

Page 34: ...stigation to ascertain the reason for overheating The most common cause of overheating is lack of water flow rate through the boiler possibly due to external pump problem 9 2 Ignition Controller 1 The...

Page 35: ...HAMWORTHY HEATING LTD 29 UPTON FLOOR STANDING SERIES 500001340 C Figure 9 3 1 Wiring Diagram...

Page 36: ...as valve manifold venturi from the fan inlet noting it s orientation and inspect the fan scroll and impellor clean and check for damage 10 Clean and check the venturi for contamination 11 Remove the f...

Page 37: ...NG SERIES 500001340 C Figure 10 2 1 Spark Electrode position Figure 10 2 2 Flame Probe position SECTION C C 19 1 100 0 25 19 1 SECTION D D 20 1 66 0 25 3 5 1 20 1 SECTION A A 17 5 1 3 5 1 66 0 25 2 5...

Page 38: ...he front of the heat exchanger assembly secured by two screws Disconnect the electrical connections and remove the screws Beware the terminals are 230v 11 5 Water Flow switch Part no 533901860 UF100 U...

Page 39: ...ast the four retaining clips Refit control knob 11 10 Low gas pressure switch Part no 533901497 UF100 UF150 Part no 533925004 UF200 to UF350 Isolate the gas supply using the valve located in the botto...

Page 40: ...w Switch UF100 UF150 179328 Water Flow Switch UF200 to UF350 179329 Overheat Thermostat 179330 Pressure Sensor 179331 HT Ignitor Electrode UF100 UF150 UF300 UF350 179332 HT Ignitor Electrode UF200 UF2...

Page 41: ...0 7 Max Output Non Condensing Pn 80 60 C kW 181 7 363 4 545 1 229 4 458 8 688 2 Minimum Output Module 80 60 C kW 36 3 45 9 Minimum Output Module 50 30 C kW 39 6 49 4 Ignition Heat Input Gross kW 128 3...

Page 42: ...s Low temperature boiler yes no yes B1 boiler yes no no Cogeneration space heater yes no no Combination heater yes no no Item Symbol Unit Seasonal space heating energy efficiency S 94 92 93 91 92 94 F...

Page 43: ...s should be separated and routed along individual conduits 4 Multiple modules It is highly recommended that each boiler is connected via its own mains isolator to facilitate servicing and maintenance...

Page 44: ...f electrical supply and control signals Signal cables must not be run in the same conduit as mains voltage cables Option 1 reference should be made to Building Regulations and CIBSE Guide Energy Effic...

Page 45: ...0 2084 145 0 206 10 0 55047 70 0 1753 150 0 183 5 0 42158 75 0 1481 155 0 163 0 0 32555 80 0 1256 160 0 145 5 0 25339 85 0 1070 165 0 130 10 0 19873 90 0 915 170 0 117 15 0 15699 95 0 786 175 0 105 2...

Page 46: ...back down the slope to an open MODEL UF100 1 UF200 2 UF300 3 UF150 1 UF300 2 UF450 3 Flue Connection B23p open flue mm 130 200 200 130 200 200 Approx Flue Gas Temperature 80 60 C C 72 72 Approx Flue G...

Page 47: ...dilution whilst ensuring that excessive suction is not applied to the boilers If in doubt refer to HHL Technical C1 5 Disconnection Provisions should be made for disconnection of the flue pipe for ser...

Page 48: ...oiler Consideration should be given to possible freezing of condense water traps and pipe work This must be avoided at all times by routing pipe work within the building where possible In addition to...

Page 49: ...ocity air streams do not occur within the space housing the boiler Boiler house ventilation Low level inlet 4cm per kW of total rated input Net High level output 2cm per kW of total rated input Net Co...

Page 50: ...th pipe kit Bar g 1 0 1 2 1 5 Water content not including pipe kit l 9 0 12 6 16 2 19 8 23 4 27 0 Design Flow Rate 20 C T Rise l s 1 2 1 8 2 4 3 0 3 6 4 2 Waterside Pressure Loss 20 C T Rise m bar 225...

Page 51: ...er is its safety valve Each boiler module is provided with a G connection for the fitting of a safety valve not supplied BS 6644 provides comprehensive information for the selection and location of sa...

Page 52: ...pressurisation unit for any heating system the following parameters are required 1 Static height of highest component in system metres 2 System volume If this is not known a general rule of thumb of...

Page 53: ...PTON FLOOR STANDING SERIES 500001340 C Hydraulic Schemes For Single Boiler Installations Figure E 1 3 1 Schematic 1 External Time Clock Enabled Boiler Figure E 1 3 2 Schematic 2 Two Heating Circuits w...

Page 54: ...LOOR STANDING SERIES 500001340 C Figure E 1 3 3 Schematic 3 Master and Slave Sequence Control With Reverse Return Primary Hydraulic Schemes For Multiple Boiler Installations Figure E 1 3 4 Schematic 4...

Page 55: ...5 Schematic 5 Primary Circuit With Individual Boiler Shunt Pumps Hydraulic Schemes Figure E 1 3 6 Schematic 6 Reverse Return Primary Circuit with Individual Motorised Boiler Isolation Note Motorised...

Page 56: ...ser I Commissioning F Heating engineer Menu Operating Line User Level Function Setting LPB System 6600 F Device address 1 6630 F Cascade Master Automatically Configuration 5710 F Heating circuit 1 Off...

Page 57: ...thy Flow and return manifold kit Legend E End user I Commissioning F Heating engineer Menu Operating Line User Level Function Setting Configuration 5890 F Relay output QX1 Boiler pump Q1 Optional extr...

Page 58: ...dule 3 Heating Circuit 2 6054 F Function input H2 Module 2 Room Stat HC1 6062 F Function input H2 Module 3 Room Stat HC2 Domestic Hot Water 1610 F Nominal Set Point 60 C Domestic Hot Water additional...

Page 59: ...y purpose Legend E End user I Commissioning F Heating engineer Menu Operating Line User Level Function Setting LPB System 6600 F Device address Boiler 1 set to 1 master Boiler 2 set to 2 Additional bo...

Page 60: ...tting LPB System 6600 F Device address 1 Configuration 5710 F Heating circuit 1 Off 5950 F Function input H1 Output req VK1 10v 5951 F Contact type H1 NO 5953 F Voltage value H1 0 1v 5954 F Function v...

Page 61: ...t to Slave with remote setting Configuration 5710 F Heating Circuit 1 Boilers all set to off 6200 F Save sensors Boilers all yes 6117 F Central compensation set up Boilers all set to 5 Note Merley to...

Page 62: ...HAMWORTHY HEATING LTD 56 UPTON FLOOR STANDING SERIES 500001340 C INSTALLER SITE ADDRESS BOILER TYPE BOILER SIZE S UNIT NO S SERIAL NO S FLUE USEFUL USER INFORMATION...

Page 63: ......

Page 64: ...les Service McDowall Modular Services 2 Penson Road Queenslie Industrial Estate Glasgow G33 4AG tel 0141 336 8795 fax 0141 336 8954 email MMS McDowallModularServices hamworthy heating com North East E...