Hamworthy Sherborne Series Installation, Commissioning And Service Manual
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Hamworthy Sherborne Series Installation, Commissioning And Service Manual

Hamworthy Sherborne Series Installation, Commissioning And Service Manual

Room sealed, fully modulating, pre-mix, gas fired boilers for heating and domestic hot water installations
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See also: Installation, Commissioning & Servicing Instructions
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
I
NATURAL GAS
2H
I
LPG-PROPANE
3P
IMPORTANT NOTE
THESE INSTRUCTIONS MUST BE READ
AND UNDERSTOOD BEFORE INSTALLING,
COMMISSIONING, OPERATING OR
SERVICING EQUIPMENT

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Summary of Contents for Hamworthy Sherborne Series

  • Page 1 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 LPG-PROPANE IMPORTANT NOTE THESE INSTRUCTIONS MUST BE READ...
  • Page 2 01202 662555 Hamworthy offer a service of site assembly for many of our products in instances where plant room area is restricted. Using our trained staff we offer a higher quality of build and assurance of a boiler built and tested by the manufacturer.
  • Page 3 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 LPG-PROPANE NOTE: THESE INSTRUCTIONS MUST BE READ AND UNDERSTOOD BEFORE INSTALLING, COMMISSIONING, OPERATING OR SERVICING EQUIPMENT.

  • Page 4: Table Of Contents

    Pressure Relief Valve (Safety Valve) Open Vent and Cold Feed Pipe Altitude Gauge (Water Pressure Gauge) Thermometer Drain Valves Circulating Pump Minimum Water Flow Rates Waterside Pressure Drop 8.10 Control Schemes 8.11 Unvented Systems 8.12 Modular Boiler Control Schemes HAMWORTHY HEATING LTD SHERBORNE 500001103/E...
  • Page 5 12.1.2 Fault Finding Procedures 12.1.3 Possible Causes of Boiler Lockout 13.0 SERVICING ............................. 28 14.0 REPLACEMENT OF FAILED COMPONENTS ................34 15.0 RECOMMENDED SPARES ......................36 APPENDIX ‘A’ – INFORMATION RELATING TO PROPANE FIRING 37 HAMWORTHY HEATING LTD SHERBORNE 500001103/E...
  • Page 6 General Fault Finding ......................... 30 Figure 12.2 General Fault Finding ......................... 31 Figure 12.3 General Fault Finding ......................... 32 Figure 12.4 General Fault Finding ......................... 33 Figure 2.2 Performance & General Data Information – LPG Propane…………………………………………37 HAMWORTHY HEATING LTD SHERBORNE 500001103/E...

  • Page 7: Introduction

    1.7.3 Mounting frames are available for single, double installations. and triple bank configuration. For installations of more than three units in a single bank, consult Hamworthy Heating Technical Department for help or assistance. 1.3.3 The Sherborne range of boilers can be wall or frame mounted and are intended for the heating of Commercial / Industrial premises.
  • Page 8 Figure 1.1 Boiler Installation (Typical) HAMWORTHY HEATING LTD SHERBORNE 500001103/E...
  • Page 9 30 - Return 50 - Flow 200 - Flue Cover removal clearance Water connections Boiler Model S70c Return connection Return connection 150 MIN Condense Ø30 Hole Gas 3/4 Electric M20 Electric M20 1660 View on underside HAMWORTHY HEATING LTD SHERBORNE 500001103/E...

  • Page 10: Technical Data

    2.3 Screw threads: All screw threads used in the installations of more than three units in a single bank, Sherborne range of boilers conform to the following:- consult Hamworthy Heating Technical Department for help or assistance. ISO 7/1 or ISO 228/1 for pipe threads where applicable.

  • Page 11: General Requirements

    Part 2: Code of practice for low and medium temperature hot water systems. 3.3 Adequate Water Flow The Hamworthy Sherborne boiler is designed as a CP 342: Centralised hot water supply. Part 2: Buildings other than individual dwellings.

  • Page 12: Time Clock Control

    MUST be carried out on the boiler gas pipework and Further details regarding boiler location are given in BS components. 6644. & BS 5440 part 2. Note:- Main Gas Supply Pressure - Nat Gas - 20mbar Propane - 37mbar HAMWORTHY HEATING LTD SHERBORNE 500001103/E...

  • Page 13: Flue System

    6.1 Flue System General Requirements shown in Figure 2.2. The Hamworthy Sherborne boiler is designed for use with the following flue systems supplied by Hamworthy - 6.4 Maximum Length of Flue Duct. see Figures 6.1.1, 6.1.2, 6.1.3 & 6.1.4: For single boiler installations the maximum allowable...
  • Page 14 Eccentric Adaptor Ø80/100 Support Bend Ø80 Flue Note: If the terminal is fitted vertically within Enlarged detail showing cut 2m of areas accessible to people an appropriate section through concentric adaptor guard should be fitted. HAMWORTHY HEATING LTD SHERBORNE 500001103/E...
  • Page 15 90° Concentric Bend Ø100/150 45° Concentric Bend Ø100/150 Flue make up piece 100 x 250 long Concentric Adaptor 150 x 100 Eccentric Adaptor Ø80/100 Support Bend Ø80 Flue Enlarged detail showing cut section through concentric adaptor HAMWORTHY HEATING LTD SHERBORNE 500001103/E...
  • Page 16 Wall Clamp Ø100 Single Flue 250 long Ø100 Single Flue 500 long Ø100 Single Flue 1000 long Ø100 90° Bend 1000 long Ø100 45° Bend 1000 long Ø100 Eccentric Adaptor Ø80/100 Support Bend Ø80 Flue Enlarged detail HAMWORTHY HEATING LTD SHERBORNE 500001103/E...
  • Page 17 1000 long 500 long Ø100 Single Flue 1000 long Ø100 Wall Clamp Ø100 Modular header or existing flue system if suitable Air Inlet 80 Flue Eccentric Adaptor 80/100 Support Bend 80 Flue Enlarged detail (typical B23) HAMWORTHY HEATING LTD SHERBORNE 500001103/E...

  • Page 18: Surface Temperatures

    75mm (3 in) thick mineral fibre, or its If the Sherborne boiler is installed as a room-sealed thermal equivalent. boiler within a cupboard or compartment, the 2) Circulating pipework not forming part of the useful HAMWORTHY HEATING LTD SHERBORNE 500001103/E...

  • Page 19: Pressure Relief Valve (Safety Valve)

    8.9 Waterside Pressure Drop maintenance the boiler is open to atmosphere. The pipe shall be protected against freezing where this The waterside hydraulic resistance (Pressure drop) is might occur. shown in Figure 2.2. HAMWORTHY HEATING LTD SHERBORNE 500001103/E...

  • Page 20: Unvented Systems

    Hamworthy Heating can also sup- ply an optional Sequencing Interface Module fitted within If the Hamworthy boiler sequencer with an outside tempera- each boiler’s control panel. This interface module will control ture sensor is not used, consideration should be given to the boiler firing rate based on the level of a 0-10V analogue fitting a frost thermostat set at approximately 4°C.
  • Page 21 CONTROLS 2) MULTIPLE BOILER INSTALLATION, FULLY MODULATING SEQUENCED OPERATION VIA HAMWORTHY HEATING LIMITED MILTON BOILER SEQUENCE CONTROL. NOTE: ROTARY SWITCH 'SW1' ON BOILER CONTROL PANEL MAIN PCB - POSITIONS '1' THROUGH '9' SETS BOILER TO MILTON SEQUENCED OPERATION, AND SETS THE BOILER FIRING ORDER.
  • Page 22 Figure 8.12 Site Wiring Diagram (Page 2 of 2) 4) MULTIPLE BOILER INSTALLATION, FULLY MODULATING SEQUENCED OPERATION VIA 0-10V ANALOGUE CONTROL SIGNALS FROM A NON HAMWORTHY HEATING LIMITED BOILER SEQUENCE CONTROL SYSTEM, UTILISING OPTIONAL HAMWORTHY HEATING LIMITED SEQUENCING INTERFACE MODULES.
  • Page 23 Figure 9.1 Wiring Schematic HAMWORTHY HEATING LTD SHERBORNE 500001103/E...

  • Page 24: Electrical Supply Connections

    11.2. Remove the 2 – M6 nuts securing the burner/fan module is supplied from the same mains isolator as the assembly to the front of the heat exchanger – see Figure boiler it is fitted to. 11.1, and carefully remove the burner assembly, taking HAMWORTHY HEATING LTD SHERBORNE 500001103/E...

  • Page 25: Connection Of The Boiler To The Flue System

    Dependent on boiler installation a number of flue options are available refer to Figures 6.1. In all instances, the flue must be obtained from Hamworthy or in the case of Flue support connection to an open flue system, the ducts up to the cradle chimney must be obtained from Hamworthy.
  • Page 26 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. HAMWORTHY HEATING LTD SHERBORNE 500001103/E...

  • Page 27: Water Connections

    2 – M6 nuts previously removed taking care not to damage the probes or Return the burner flange gasket see Figure 10.2. S65 Model Reconnect the pressure feedback tube to the gas valve. Return S70c Model HAMWORTHY HEATING LTD SHERBORNE 500001103/E...

  • Page 28: Condense Trap Connection

    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 HAMWORTHY HEATING LTD SHERBORNE 500001103/E...
  • Page 29 Figure 10.6 Gas Pipe Fitting HAMWORTHY HEATING LTD SHERBORNE 500001103/E...

  • Page 30: Commissioning And Testing

    4) The pipework and valve arrangement is installed Access to the controls is achieved by removing the to Hamworthy Heating recommendations in such a screw on the top of the outer cover and pulling the way that water flow rates will be in accordance with cover away from the wall.
  • Page 31 Water Return † Connection Lockout Reset Button Flue gas Control Panel sampling point Condensate Condensate Level Drain Trap * Condensing Models Only Float Switch* † Position varies by model, condensing model depicted Gas Supply Isolating Valve HAMWORTHY HEATING LTD SHERBORNE 500001103/E...
  • Page 32 Figure 11.2 Gas Valve ~ Venturi Arrangement Figure 11.5 Position of Probes on Burner Assembly 7º 42 max 40 min 92 max 88 min HAMWORTHY HEATING LTD SHERBORNE 500001103/E...

  • Page 33: External Controls

    Also ensure that the are to be used and there are any doubts as to the rotary switch ‘SW1’ on the Sequencing Interface suitability, contact Hamworthy Heating Technical Module PCB is set to position ‘0’. Department for advice.

  • Page 34: Installation Noise

    An overheat neon on the 13.1 Regular annual servicing is recommended, controls fascia will indicate this condition has preferably by a Hamworthy appointed person, to occurred. If, after pushing the overheat reset button, ensure trouble free operation. Although cleaning of...
  • Page 35 M10 nut and bolt on the left lifting the boiler module off the wall plate. Go to hand side mounting. Re-fit the system pipework and check for soundness. Section 13.3.2. 13.3.1 Disengage the appliance flue connector from HAMWORTHY HEATING LTD SHERBORNE 500001103/E...
  • Page 36 Is there a control signal Check fan control wiring to the fan? (24V dc across connections, replace pins 1 & 5 of 5way fan boiler main PCB control connector) * Condensing models only Replace fan HAMWORTHY HEATING LTD SHERBORNE 500001103/E...
  • Page 37 Is flame sensed by the Check wiring from ignition ignition controller? Is the flame signal above controller to flame probe, (Fascia boiler run indicator the minimum (1.2µA)? replace ignition controller illuminated) Continued Replace ignition controller Ref. Fig 12.3 HAMWORTHY HEATING LTD SHERBORNE 500001103/E...
  • Page 38 Check/replace temperature Boiler cycles on/off Temperature control sensor and/or boiler rapidly? circuit faulty main PCB Continued Check/replace pump, bleed Insufficient water circulation Ref. Fig 12.4 trapped air from the system HAMWORTHY HEATING LTD SHERBORNE 500001103/E...
  • Page 39 Fan Fault (Running at wrong speed or running when should be stopped) 3 Flashes Condensate Drain Trap Blocked (Condensing models only) 4 Flashes Overheat (high limit thermostat tripped) 5 Flashes Premature flame detection (Flame sensing circuit fault) HAMWORTHY HEATING LTD SHERBORNE 500001103/E...

  • Page 40: Replacement Of Failed Components

    To replace the thermostat or sensor, the following gas valve assembly to the fan noting the cork procedure must be followed. sealing gasket. NOTE! Record existing temperature setting of 5) Remove the copper feedback connecting elbow HAMWORTHY HEATING LTD SHERBORNE 500001103/E...
  • Page 41 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 HAMWORTHY HEATING LTD SHERBORNE 500001103/E...

  • Page 42: Recommended Spares

    Flue Seal 50Ø ................................532511035 Flue Seal 80Ø ................................532511036 Flue Seal 100Ø ..............................532511037 Viewing port (sight glass) ............................539907001 For service or spares please contact :- Hamworthy Heating Ltd. Fleets Corner Poole Dorset BH17 0HH Phone No................... 01202 662500 Fax. No..................01202 665111 Service ..................

  • Page 43: Appendix 'A' - Information Relating To Propane Firing

    11.0 COMMISSIONING AND TESTING = 9.5-10.0% (Dry flue gas) = 5-6% CO = 0-50ppm: However figure should not exceed 11.5.4 Combustion Checks 200ppm under normal operating conditions. Combustion figures for Propane should be as follows :- HAMWORTHY HEATING LTD SHERBORNE 500001103/E...
  • Page 44 USEFUL USER INFORMATION INSTALLER SITE ADDRESS DATE OF COMMISSIONING: BOILER TYPE BOILER SIZE(S) UNIT NO(S). SERIAL NO(S). FLUE NOTES: HAMWORTHY HEATING LTD SHERBORNE 500001103/E...
  • Page 45 NOTES: HAMWORTHY HEATING LTD SHERBORNE 500001103/E...
  • Page 46 NOTES: HAMWORTHY HEATING LTD SHERBORNE 500001103/E...
  • Page 47 Notes...
  • Page 48 Unit 2, Antrim Line Business Park, Sentry Lane, Newtownabbey BT36 8XX tel: 02890 849826 fax: 02890 847443 Website www.hamworthy-heating.com Associate Companies, Offices and Agents throughout the World. Hamworthy reserves the right to make changes and improvements which may necessitate alteration to the specification without prior notice.

This manual is also suitable for:

Sherborne s65Sherborne s70c

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