Hamworthy Sherborne Series Installation, Commissioning And Servicing Instructions
Room sealed, fully modulating, pre-mix, gas fired boilers for heating & domestic hot water installations
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Sherborne Series Boilers
Room Sealed, Fully Modulating, Pre-Mix,
Gas Fired Boilers for Heating & Domestic
Hot Water Installations
Installation, Commissioning
and Servicing Instructions
SE 71c - FULLY CONDENSING
SE 64he - HIGH EFFICIENCY
NATURAL GAS I
2H
LPG-PROPANE I
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 & Domestic Hot Water Installations Installation, Commissioning and Servicing Instructions SE 71c - FULLY CONDENSING SE 64he - HIGH EFFICIENCY NATURAL GAS I LPG-PROPANE I IMPORTANT NOTE...
- Page 3 Sherborne Series Boilers Room Sealed, Fully Modulating, Pre-Mix, Gas Fired Boilers for Heating & Domestic Hot Water Installations Installation, Commissioning and Servicing Instructions SE 71c - FULLY CONDENSING SE 64he - HIGH EFFICIENCY NATURAL GAS I LPG-PROPANE I NOTE: THESE INSTRUCTIONS MUST BE READ & UNDERSTOOD BEFORE INSTALLING, COMMISSIONING, OPERATING OR SERVICING EQUIPMENT.
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Page 4: Table Of Contents
Start-up / Initialisation 8.6.2 Users Parameter Settings 8.6.4 Functions 8.6.4.1 Chimney Sweep mode 8.6.4.2 Controller Stop mode 8.6.4.3 Time of day function 8.7.10 Display of operating phases Control Panel Assembly Wiring Diagram 8.10 Wiring Diagram (LMU) HAMWORTHY HEATING LTD SHERBORNE 500001167/E... - Page 5 Open Vent & Cold Feed Pipe E1.5 Altitude Gauge (Water Pressure Gauge) E1.6 Thermometer E1.7 Drain Valves E1.8 Circulating Pump E1.9 Minimum Water Flow Rates E1.10 Waterside Pressure Drop E1.11 Water Flow Controls E1.12 Frost Protection E1.13 Unvented Systems HAMWORTHY HEATING LTD SHERBORNE 500001167/E...
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Page 6: Introduction
A clip-in module (LPB Bus) which allows communication with multiple boilers when used with a cascade control. • The cascade control which allows management of up to 12 boilers, & interface with a BMS system. HAMWORTHY HEATING LTD SHERBORNE 500001167/E... -
Page 7: Supply & Delivery
If any item is missing please contact our after sales service team. Please provide details of your order such as order number & contract number as well as a detailed description of the missing item. Header Kit Frame Kit HAMWORTHY HEATING LTD SHERBORNE 500001167/E... -
Page 8: Size & Space Requirements
200 - Flue Cover removal clearance Water connections S 64he S 71c Boiler Model Return c onnection Return c onnection 150 MIN Condense Ø30 Hole Gas 3/4 Electric M20 Electric M20 1660 View on underside HAMWORTHY HEATING LTD SHERBORNE 500001167/E... - Page 9 MANUAL VENT R (NOT HHL SUPPLY) SE 71c SAFETY VALVE R (NOT HHL SUPPLY) SAFETY VALVE R (NOT HHL SUPPLY) SE 64he FLEXIBLE HOSE UNION c/w GASKET OPTIONAL BOILER F RAME Rc 2 ” HHL 560202007 HAMWORTHY HEATING LTD SHERBORNE 500001167/E...
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Page 10: Boiler Layout And Description
4. Boiler Layout & Description 4.1 Accessory Pack HAMWORTHY HEATING LTD SHERBORNE 500001167/E... -
Page 11: Site Location & Preparation
7.0 & 8.0. • Leaks in the system pipework should be fixed to prevent dilution of water treatment. • Maximum working water pressure is 7 bar. • For minimum water pressure see Appendix E . HAMWORTHY HEATING LTD SHERBORNE 500001167/E... -
Page 12: Flues
Refer to Hamworthy Heating Technical dept. for assistance. Note: Due to high thermal efficiency of the Sherborne boiler & the resultant low flue gas tem- •... -
Page 13: Condensate Connections
& flue system. • Condense is mildly acidic, typically pH3 - pH5. • Pipework must be non-corrosive & not copper. Hamworthy recommend 32mm dia. Plastic waste pipe. • Condense may be discharged to a standard drain subject to National or Local regulations. -
Page 14: Connection Of Boiler(S) To The Flue System
The top of the plastic boiler cover has a D shaped recess for the vertical flue exit point. Using a suitable fine toothed hacksaw or jigsaw, cut around the inside of the recess to provide the flue outlet. HAMWORTHY HEATING LTD SHERBORNE... -
Page 15: Connection Of Twin Pipe Horizontal/Vertical Room Sealed 100Mm
The top of the plastic boiler cover has a D shaped recess for the vertical flue exit point. Using a suitable fine toothed hacksaw or jigsaw, cut around the inside of the recess to provide the flue outlet. HAMWORTHY HEATING LTD SHERBORNE... -
Page 16: Open Vented Systems
Boilers must not be capable of isolation from the safety valve. Valves between boiler & safety valve to be three way type such that when boiler is isolated from safety valve it is open to atmosphere. Hamworthy Heating Ltd recommend the use of the connection for the safety valve as detailed in Figure 3.2. -
Page 17: Pre-Commisioning
Ensure that ventilation & air supply to plantroom is correct. Air supply slots in the boiler cover are clear & open. 6.3 Pipework, Valves & Pump Ensure that; • Pipework & valve arrangement is installed to Hamworthy Heating recommendations. • Circulating system is full of water, vented & pressurised appropriately. •... -
Page 18: Boiler Checks
Check the resistance of the hot surface igniter. This should be checked cold, using a suitable ohmmeter, by disconnecting the igniter from the control panel cable & measuring the resistance across the pins of the 2 way connector. The reading should be between 70 & 110 ohms. HAMWORTHY HEATING LTD SHERBORNE 500001167/E... -
Page 19: Initial Lighting
For Natural Gas the gas control valve zero governor control system is configured for a nominal gas inlet pressure of 20mbar measured at the rear of the boiler, with a maximum inlet pressure of 25mbar. For LPG firing boilers, the nominal gas inlet pressure is 37mbar with a maximum inlet pressure of 45mbar. HAMWORTHY HEATING LTD SHERBORNE 500001167/E... -
Page 20: Combustion Check
For LPG Propane firing—see appendix A CONTACT HAMWORTHY HEATING TECHNICAL DEPARTMENT FOR FURTHER DETAILS 5. Shut down the boiler & isolate from the electrical supply. Remove all instrumentation & replace any test points & plugs. -
Page 21: Controls Operation
In it’s standard version the screen displays the boiler status (operating mode, time heating time program, boiler temperature, presence of flame & possible fault) The arrowheads on the left hand side indicate water pressure between 0-4bar or 0-10bar depending on the pres- sure sensor used (if one is used) HAMWORTHY HEATING LTD SHERBORNE 500001167/E... -
Page 22: Operating Modes
Control differential Set point of 2-position or modulating controller (PID) Current boiler temperature setpoint Room Temperature setpoint DHW temperature setpoint Maximum degree of modulation in heating mode Maximum speed at maximum output in heating mode HAMWORTHY HEATING LTD SHERBORNE 500001167/E... -
Page 23: Error Code Display
The table below contains fault finding information for some of the codes. If the code displayed is not shown on this table or the actions do not fix the fault contact HHL for advice. After the problem is fixed press and hold the reset button for 1 second to reset the controls HAMWORTHY HEATING LTD SHERBORNE 500001167/E... - Page 24 Fault air pressure switch (does not close) Fault heating circuit flow switch / pressure switch Fault air pressure switch (does not open) Chimney sweep function active Controller stop function active LMU... in parameter setting mode HAMWORTHY HEATING LTD SHERBORNE 500001167/E...
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Page 25: User Settings & Functions
Time program HC1 switch-off time 2 period 00:00...24:00 hh:mm 10 min 24:00 Time program HC1 switch-on time 3 period 00:00...24:00 hh:mm 10 min 24:00 Time program HC1 switch-off time 3 period 00:00...24:00 hh:mm 10 min 24:00 HAMWORTHY HEATING LTD SHERBORNE 500001167/E... -
Page 26: Functions
The operating phases according to the controls sequence diagram can be displayed. Assignment of the display code & the LMU...’s phase designation is as follows: Note: -If operating phases are passed very quickly or skipped, the relevant display code will not appear. HAMWORTHY HEATING LTD SHERBORNE 500001167/E... - Page 27 HAMWORTHY HEATING LTD SHERBORNE 500001167/E...
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Page 28: Control Panel Assembly
The control system is contained within the control panel/pod on the side of the boiler. The front panel can be re- moved by removing the two screws at either side of the panel. The following pictures show the basic layout of the panel HAMWORTHY HEATING LTD SHERBORNE 500001167/E... -
Page 29: Wiring Diagram
8.9 Wiring Diagram HAMWORTHY HEATING LTD SHERBORNE 500001167/E... -
Page 30: Wiring Diagram (Lmu)
8.10 Wiring Diagram (LMU) HAMWORTHY HEATING LTD SHERBORNE 500001167/E... - Page 31 7) Unnecessary pressing of reset when boiler is running Should a fault code appear which cannot be reset, or a fault code repeatedly occurs, contact Hamworthy Heating for assistance. Do not continue to operate or use the boiler as this may cause damage to the controls.
- Page 32 & working condition & still comply with the relevant standards & codes of practice - see Section 4. Regular servicing is recommended preferably by a Hamworthy appointed person & at least annually, to ensure trouble free operation. For Sherborne, HHL would recommend an additional 6 monthly examination following commissioning, acknowledging site conditions &...
- Page 33 Test all gas joints broken or disturbed for soundness before firing. Re-light the boiler, check & adjust the combustion as described in Section 7. • Check thermostat settings & adjust if required. • Re-fit the boiler cover & tidy floor around boiler as necessary. HAMWORTHY HEATING LTD SHERBORNE 500001167/E...
- Page 34 Re-light the boiler • Check & adjust the combustion as detailed in Section 7 11.5 Fan Assembly Part No. 563901376 To replace the fan it is preferable to remove the complete gas valve/venturi & fan assembly. HAMWORTHY HEATING LTD SHERBORNE 500001167/E...
- Page 35 • Carefully remove the screws securing the pcb to the panel & withdraw the control. • Re-assemble in reverse order. • Re-light the boiler & check for operation. Location of orifice plate - LPG only HAMWORTHY HEATING LTD SHERBORNE 500001167/E...
- Page 36 Viewing port (sight glass) ........................... .539907001 Flue Seal 50Ø ............................... 532511035 Flue Seal 80Ø ............................... 532511036 Flue Seal 100Ø ..............................532511037 For service or spares please contact :- Hamworthy Heating Limited Fleets Corner Poole Dorset BH17 0HH Phone Number ................01202 662500 Fax Number ..................
- Page 37 GAS DATA Nominal Gas Inlet Pressure mbar Maximum Gas Inlet Pressure mbar Minimum Gas Inlet Pressure mbar Gas Flow Rate (maximum) /h (kg/h) 2.9 (5.5) Target CO % at High / Low fire ±0.25% 10.0 HAMWORTHY HEATING LTD SHERBORNE 500001167/E...
- Page 38 The boiler controls provide a 24V DC signal that can be fed through a volt free contact for operation. Refer to BS 6644 for further information on installing the electrical supply. NOTE: FOR BASIC TERMINATION DIAGRAM SEE FIGURE 4.5 HAMWORTHY HEATING LTD SHERBORNE 500001167/E...
- Page 39 External Control Wiring for Multiple Module Installation HAMWORTHY HEATING LTD SHERBORNE 500001167/E...
- Page 40 TERMINAL LOCATION & ADJACENT BUILDING FABRIC. C1.1 General Requirements The Hamworthy Sherborne series of boilers are designed to be used with natural draught flues or a room sealed system supplied by Hamworthy Heating. Flue systems should be designed in accordance with regulations & with reference to BS 6644 &...
- Page 41 A drain with an integral trap is fitted to the rear of each module suitable for connection to a 32mm plastic waste pipe (not Hamworthy Heating Ltd supply), which must be connected to a tundish (not Hamworthy Heating Ltd supply). Discharge piping from a tundish should be of synthetic material due to the mild acidity of the condensate (pH3-5), with all discharge piping having a minimum fall of 30mm/m away from the boiler.
- Page 42 Ø80/100 S uppo rt 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 500001167/E...
- Page 43 45° Concent ric Bend Ø100/1 50 Flue make up piece 100 x 250 long Concentric Adaptor 150 x 100 Eccent ric Adaptor Ø80/100 Support Bend Ø80 Flue Enlarged detail showing cut section through concentric adaptor HAMWORTHY HEATING LTD SHERBORNE 500001167/E...
- Page 44 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 500001167/E...
- Page 45 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 500001167/E...
- Page 46 The air supply should be free from contamination such as building dust & insulation fibres from lagging. To avoid unnecessary cleaning & servicing of the boiler modules, the boilers should not be fired whilst building work is HAMWORTHY HEATING LTD SHERBORNE...
- Page 47 & to maintain the difference between inlet & extract flow rates shown above. The calculated extract flow rate is the actual inlet flow rate minus the appropriate figure in the table above. HAMWORTHY HEATING LTD SHERBORNE 500001167/E...
- Page 48 See BS 6644 for detailed information on Open Vent & Cold Feed Pipes. E1.5 Altitude Gauge (Water Pressure Gauge) Every boiler or group of boilers should be provided with an altitude gauge complete with isolating valve. HAMWORTHY HEATING LTD SHERBORNE 500001167/E...
- Page 49 Temporary Doubl e Drain check fill line va l v e (Pri m ary l o op) valve valve UNVENTED SYSTEM: Prim ary loop, Hamworthy recommended system. Expansion pipe Pressure & Float Val v e Temperature va lve Drain gauges...
- Page 50 E1.7 Drain Valves Each boiler should have a 15mm NB drain valve (not Hamworthy Heating Ltd supply) fitted in the boiler return to drain the boiler only. The heating system in total should have drain valves as recommended by BS 6644.
- Page 51 Schematic for Single Boiler System Schematic for Single Boiler, Primary Circuit System Schematic for Multiple Boiler (External 0~10V), Primary Circuit System Schematic for Multiple Boiler (HHL Cascade), Primary Circuit System HAMWORTHY HEATING LTD SHERBORNE 500001167/E...
- Page 52 USEFUL USER INFORMATION INSTALLER SITE ADDRESS BOILER TYPE BOILER SIZE(S) UNIT NO(S). SERIAL NO(S). FLUE NOTES HAMWORTHY HEATING LTD SHERBORNE 500001167/E...