Hamworthy Weymouth Series, Installation, Commissioning And Servicing Instructions

Page 1: ...RUCTIONS MUST BE READ AND UNDERSTOOD BEFORE INSTALLING COMMISSIONING OPERATING OR SERVICING EQUIPMENT Weymouth Series Pressurisation Units Installation Commissioning and Servicing Instructions Weymouth Standard Advanced Models ...

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: ...PPLICATIONS THESE PRESSURISATION UNITS COMPLY WITH THE ESSENTIAL REQUIREMENTS OF THE MAHINERY DIRECTIVE 89 392 EEC AMENDED BY 91 368 EEC THE LOW VOLTAGE DIRECTIVE 73 23 EEC AMENDED BY 93 68 EEC AND THE ELECTROMAGNETIC COMPATIBILITY DIRECTIVE 89 336 EEC AMENDED BY 91 263 EEC AND 92 31 EEC PUBLICATION NO 500001112 ISSUE C JUNE 2008 Weymouth Series Pressurisation Units Installation Commissioning and ...

Page 4: ...OF THE PRESSURISATION UNIT 4 4 1 Unit Operation 4 4 2 Safety Functions Advanced Only 4 5 0 GENERAL REQUIREMENTS 4 5 1 Related Documents 4 5 2 Mains Water Connections 5 5 3 Expansion Vessels 5 5 4 Safety Relief Valve 5 6 0 INSTALLATION 6 6 1 Location 6 6 2 Pipework Connections 6 6 3 Electrical Connection 7 6 3 1 Mains Connection 7 6 3 2 Safety Switches Circuits On Advanced Only 7 ...

Page 5: ...d Only 11 7 7 4 Hi Pressure Switch Advanced Only 11 8 0 FAULT FINDING 12 9 0 SERVICING SCHEDULE 13 9 1 6 Monthly 13 9 2 12 Monthly 13 9 3 4 Yearly 13 10 0 SERVICING AND REPLACEMENT OF COMPONENTS 14 10 1 Hamworthy Heating Recommended Spares 14 10 2 Standard Pump Removal 14 10 3 Advanced Pump Removal 15 10 3 1 Pump Fitting On Both Units 15 10 4 Inlet Valve On Both Units 15 10 5 Pressure Switches On ...

Page 6: ...tandard 9 Figure 14b Float Adjustment Advanced 9 Figure 15a Priming Screw Standard 10 Figure 15b Priming Screw Advanced 10 Figure 16 Pressure Switch Adjustment 10 Figure 17 Pressure Switch Adjustment Apparatus 11 Figure 18 Fault Finding Guide 12 Figure 19 Pump Fittings 14 Figure 20 Standard Pump Wiring Terminals 14 Figure 21 Advanced Pump Removal 15 Figure 22 Advanced Pump Removal 15 Figure 23 Adv...

Page 7: ...t is the header tank with a float valve In the front of the cabinet is the systems pressure indication gauge The range has 2 models 1 The Standard with the following features 2 The Advanced with Pump control pressure switch All the features of the standard plus Non return valve High Low pressure switches 0 6 bar system pressure gauge Isolating Valve between tank and pump 2 0 TECHNICAL DATA The bas...

Page 8: ... To suit system conditions Maximum water flow temp C 82 Maximum static height m 30 Minimum system operating pressure bar 3 3 Maximum system operating pressure bar 6 3 Safety relief valve setting Not HHL supply bar 4 0 Nominal pressure differential bar 0 4 Electrical Data Pressure switch contact rating 15A 240V AC Electrical Supply 230V AC 50Hz 1Ph Start current amps 9 Run current amps 2 8 3 0 SEAL...

Page 9: ...sure drops If there has been some fluid loss the pressurisation provides replacement Figure 4 Expansion Vessel Operation 1 Diaphragm position at the cold fill charge pressure The vessel is empty of system fluid 2 Diaphragm position at the hot working pressure The system volume has expanded due to the temperature rise The gas in the vessel is compressed Acceptance factor 0 35 maximum recommended 3 ...

Page 10: ...essure system appliances are installed by competent persons in accordance with the above regulations Failure to install appliances correctly could lead to prosecution It is in your own interest and that of safety to ensure that this law is complied with The installation of the pressurisation unit and expansion vessel MUST be in accordance with the relevant require ments of the Pressure System Regu...

Page 11: ...nce with BS6644 BS7074 SALES REF NO HAMWORTHY PART NO TYPE TOTAL VOL DIAPHRAGM PART NO CONNECTION WT kgs HOT WATER APPLICATIONS EPDM DIAPHRAGM 0 100 C MAX HAF 60V 532712002 VERTICAL 60 532712030 R1 BSPT MI 13 HAF 80V 532712003 VERTICAL 80 532712031 R1 BSPT MI 14 HAF 100V 532712004 VERTICAL 100 532712032 R1 BSPT MI 15 HAF 200V 532712005 VERTICAL 200 532712033 R1 BSPT MI 40 HAF 300V 532712006 VERTIC...

Page 12: ...igure 9 1 Mains water connection BSP Male The units have a type AF air gap to prevent backflow in accordance with Water Supply Water Fittings Regulations 1999 The water supply connection must conform to all local WRAS regulations 2 Overflow connection 22 mm and Female Overflow should be piped to where it will be safe but visible so it will be noticed and corrected 3 System connection The system co...

Page 13: ...ction must be via a fused isolator rated at 13 Amps and positioned locally to the unit 6 3 2 Safety Switches Circuits On Advanced Only The SPDT hi and lo pressure switches can be incorporated into circuits to interrupt a boiler control signal in order to shut down the boiler in the event of a system fault condition The boiler control system must be designed so that manual resetting is required aft...

Page 14: ...r check the expansion vessel charge pressure the lock shield valve between the Weymouth unit and the vessel must be closed The drain cock fitted on the base of the expansion vessel must be open to allow any water in the vessel to escape A suitable gauge should be used to check the charge pressure Generally a Schrader car type valve is fitted near the top of the expansion vessel If the charge press...

Page 15: ... P restrictor red see fig 12 The HP restrictor is fitted in the inlet side of the float valve assembly This should be unscrewed in order to change the restrictor see fig 13 The LP Restrictor is clipped to the side of the valve assembly Figure 13 Changing Advanced Restrictor Inserts 3 If the cold water is from a tank then the tank must be at least 2m above the inlet for the header tank to remain fu...

Page 16: ...re at which they are set This scale is to be used for indication only As all the pressure switches and the pressure gauge take readings from the same place the unit s pressure gauge can be used to give an accurate reading when setting switching levels The switches should be set last after all the other commissioning tasks are complete Figure 16 Pressure Switch Adjustment All the pressure switches ...

Page 17: ...Isolate the Weymouth unit from the mains electrical supply from the boiler circuits 3 Introduce a small leak until the unit s pressure gauge reading equals the required Lo pressure setting 4 Stop the leak 5 The lo pressure switch is lowest on the panel which pivots around corner for easy access see figure 23 7 Set the lo pressure switch to its highest level adjustment is shown in fig 16 8 The term...

Page 18: ...ing Pressure switches set incorrectly Non return valve not sealing correctly System Leak Adjust pressure switches see section 7 Clean valve seat or replace valve if necessary see section 10 7 Trace leak and ensure system is sound Pump runs continuously Cold fill pressure switch set incorrectly Cold fill pressure switch faulty System leak Adjust pressure switches see section 7 Replace faulty switch...

Page 19: ...by slightly opening the expansion vessel drain valve to initiate a leak Note Ensure that the drain valve is closed after this operation 9 2 12 Monthly 1 Check the ball float valve diaphragm seat for integrity and replace if necessary Also check the plastic float for soundness 2 Check the expansion vessel for signs of external corrosion If any deterioration is observed then it is recommended that t...

Page 20: ...e Gauge 557002009 Pressure Gauge 557002009 Pressure Switch Assembly 533925005 Pressure Switch Assembly 533925005 Non return valve cartridge 531911039 Non return valve cartridge 531911040 NOTE For any service replacement parts the unit serial No on the Data Plate inside the unit MUST be quoted For service or spares contacts please refer to the inside front cover of this guide 10 2 Standard Pump Rem...

Page 21: ... unit The connections are shown in Figure 25 below Figure 25 Weymouth Advanced Pump Wiring Terminal 10 3 1 Pump Fitting On Both Units Pump fitting for each unit is basically the reverse of pump removal Care should be taken not to over tighten the 2 pump mounting screws on the Standard units as this can shear the welded thread Once re fitted and connected the pump needs to be bled Instructions of t...

Page 22: ...hich can be reconnected any way round The Hi and Lo pressure switches Advanced only must be reconnected as shown in fig 27 3 Pressure switch must be set to correct level Setting instructions are given in section 7 Figure 27 Switch Wiring Advanced Only 10 6 Pressure Gauge On Both Units part n 537002009 1 Undo the capillary nut holding the end into the pipe see fig 26 2 Depress the tags on the oppos...

Page 23: ...del and serial n Consult Hamworthy Heating for details 1 Turn off the boiler and electrically isolate the unit 2 Close the system isolating valve and isolate the mains water supply to the header tank 3 Drain the pressurisation unit and expansion vessel Note Leave the drain cock open Disconnect the expansion vessel pipe work 4 Unscrew the diaphragm top connection normally a brass nut at the opposit...

Page 24: ...HAMWORTHY HEATING LTD 18 WEYMOUTH 500001112 C APPENDIX Contents Page Figure A1 Wiring Diagrams 19 Figure A2 Heating System Calculation Sheet 20 ...

Page 25: ...HAMWORTHY HEATING LTD 19 WEYMOUTH 500001112 C Figure A1 Wiring Diagrams ...

Page 26: ...ve the Hi pressure switching level 3 Cold Fill Pressure Switch Setting Calculation Pf Ph Pf 0 2 0 2 Pf bar 10 2 10 2 4 Safety Valve Lift Pressure Calculation Ps Actual fitted expansion vessel volume Vva Vva litres Actual fitted expansion vessel acceptance factor ava Vv x 0 35 x 0 35 ava ava Vva Actual working pressure Pwa Pf ava Pwa Pwa bar 1 ava 1 Note If Pwa Pwa then increase expansion vessel vo...

Page 27: ...Notes ...

Page 28: ...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...