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NOTE: THESE INSTRUCTIONS SHOULD BE READ AND UNDERSTOOD BEFORE
ATTEMPTING TO INSTALL, COMMISSION OR OPERATE THIS UNIT
PUBLICATION NO. 500001130
ISSUE 'J'
JULY 2009
HAMWORTHY HEATING LTD
MILBORNE BOILERS
Wall Hung, Pre-Mix, Condensing,
Modular Boilers
381 & 501 Series
Design Installation, Commissioning
and Operating Instructions
NATURAL GAS
LPG - PROPANE
I
2H
I
3p
i
MILBORNE
500001130/J
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Table of Contents
Related Manuals for Hamworthy MILBORNE381 Series
Summary of Contents for Hamworthy MILBORNE381 Series
- Page 1 Design Installation, Commissioning and Operating Instructions NATURAL GAS LPG - PROPANE NOTE: THESE INSTRUCTIONS SHOULD BE READ AND UNDERSTOOD BEFORE ATTEMPTING TO INSTALL, COMMISSION OR OPERATE THIS UNIT PUBLICATION NO. 500001130 ISSUE ‘J’ JULY 2009 HAMWORTHY HEATING LTD MILBORNE 500001130/J...
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Page 2: Table Of Contents
Three Boiler Arrangement ......................4 Figure 2.6 Two Boiler Back-to-Back Arrangement ..................5 Figure 3.1 Boiler Dimensions ........................6 Figure 3.2.1 Single Boiler Installation Dimensions ..................7 Figure 3.2.2 Two Boiler Installation Dimensions ..................7 HAMWORTHY HEATING LTD MILBORNE 500001130/J... - Page 3 Setting High Temperature Heating Circuit Functions for Constant Temp ........43 Figure 8.10.4 Setting Low Temperature Heating Circuit Functions for Constant Temp ........43 Figure 8.10.5 Setting High Temperature Heating Circuit Functions for Variable Temps ........44 HAMWORTHY HEATING LTD MILBORNE 500001130/J...
- Page 4 Mechanical Ventilation Flow Rates .................... 63 Figure E1.1 Water Data ..........................64 Figure E1.6 Pump Selection Chart ....................... 65 Figure E1.1.1 Typical Piping Layouts ......................66 TABLES Table 7.1 Flue Gas Analysis CO2 Readings ..................... 25 HAMWORTHY HEATING LTD MILBORNE 500001130/J...
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Page 5: 1.0 Introduction
(HHL supply) up to a maximum length a packaged primary circuit. of 30 metres. It is recommended by Hamworthy Heating, that the No draught diverter is fitted to the boiler nor is a fixed primary pump MUST be controlled from the Master diverter required in the flue system. -
Page 6: Supply & Delivery
Warranty Full warranty assistance will be covered when the appliance is commissioned by Hamworthy Heating Ltd, see Terms & Conditions for full details. Hamworthy Heating Ltd will not accept any liability resulting from damage due to tampering, improper use, handling, installation errors, operation and maintenance. -
Page 7: Figure 2.2 Boiler Packaged Dimensions
The whole is shrink wrapped for security and basic protection. Room sealed with separate air ducts Figure 2.3 - Single boiler arrangement showing frame, flue header, water pipework and primary circuit pump kit HAMWORTHY HEATING LTD MILBORNE 500001130/J... -
Page 8: Figure 2.4 Two Boiler Arrangement
Figure 2.4 - Two boiler arrangement showing frame, flue header, water pipework and primary circuit pump kit Figure 2.5 - Three boiler arrangement showing frame, flue header, water pipework and primary circuit pump kit HAMWORTHY HEATING LTD MILBORNE 500001130/J... -
Page 9: Figure 2.6 Two Boiler Back-To-Back Arrangement
Figure 2.6 - Two boiler back to back arrangement showing frame, flue headers, water pipework and primary circuit pump kit HAMWORTHY HEATING LTD MILBORNE 500001130/J... -
Page 10: Size & Space Requirements
3.1 The Milborne boiler range has been designed to utilise minimum wall space, therefore it is important that the plantroom has sufficient ceiling height to allow for installation and connection to the flue system allowing for sufficient access at sides and below boiler for pipework connections. See Figure 3.1 Figure 3.1 - Dimensions HAMWORTHY HEATING LTD MILBORNE 500001130/J... -
Page 11: Figure 3.2.1 Single Boiler Installation Dimensions
3.2 The Hamworthy Heating Ltd frame set and pipework kit is designed to provide a compact solution for connecting the boilers to the gas supply and flow and return water connections. FLUE HEADER WALL DUCT 160mm DIAMETER OPTIONAL 6 PORT HEADER... -
Page 12: Site Location & Preparation
Inlet gas pressure to boiler measured at the gas valve, nominal 20mbar (minimum 17.5mbar) dynamic - refer to Appendix A • Boiler house gas isolation valve must be clearly identified and installed close to the entrance / exit. G 3/4” Figure 4.2 - Gas Connection Point HAMWORTHY HEATING LTD MILBORNE 500001130/J... -
Page 13: Figure 4.3.1 Flue Connection
For external flue runs and termination, either use the dedicated kits supplied by Hamworthy or refer to a chimney specialist . Flue termination, routing and construction must comply with the requirements of the •... -
Page 14: Figure 4.3.2 Minimum Space Requirements For Flue Terminals
Vertically from a terminal on the same wall 1500 Horizontally from a terminal on the same wall From the wall on which the terminal is mounted From a vertical structure on the roof Above intersection with roof HAMWORTHY HEATING LTD MILBORNE 500001130/J... -
Page 15: Figure 4.4 Water Connection Point
5 minutes after the boiler has ceased firing. This must be acknowledged in the system design. It is recommended by Hamworthy Heating, that the primary pump MUST be controlled from the Master boiler to ensure synchronised operation - refer to fig. 4.6. Where twin head pumps are installed a changeover control (not HHL supply) external to the boiler is required. -
Page 16: Figure 4.5.1 Boiler Condensate Connection (Side View)
Provision must be made for removal of condensate from the boiler and flue system. • Condense is mildly acidic, typically pH3 - pH5. • Condense pipework must be non-corrosive and not copper. Hamworthy recommend • plastic waste pipe. Condense may be discharged to a standard drain subject to National or Local •... - Page 17 NOTE: The appliance must be isolated from the electrical supply if electric arc welding is carried out on connecting pipework. FOR TYPICAL SCHEMATIC DETAILS SEE FIGURE 4.6 FOR DETAILED WIRING INSTRUCTIONS SEE FIGURES 9.3.1 & 9.3.2 AND APPENDIX B HAMWORTHY HEATING LTD MILBORNE 500001130/J...
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Page 18: Figure 4.6 Typical Installation Schematic
Polypropylene condensate discharge kit. To re- 573407385 move condensate from vertical and horizontal flue sections. 50mm Flue pipe wall bracket 573407249 Figure 5.2.2.2 - Single Milborne Horizontal Flue Figure 5.2.2.1 - Single Milborne Vertical Flue HAMWORTHY HEATING LTD MILBORNE 500001130/J... - Page 19 80mm non-return valve (specific to each module). The header can be located close to, or remote from, the boilers using the 80mm fittings available from Hamworthy, to connect the boiler modules to the header. When using the flue gas header for boiler assemblies connected in cascade, the prescribed distance required between the assemblies is 150 mm - see figure 5.2.3.1...
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Page 20: Figure 5.2.2.1 Single Milborne 381 / 501 Flue Installation Vertical
Figure 4.6 - Typical Schematic Details HAMWORTHY HEATING LTD MILBORNE 500001130/J... -
Page 21: Boiler Assembly Instructions
Figure 4.3. Air supply inlets must be positioned at least 300 mm from flue terminals to prevent flue gas re-circulation. Hamworthy Heating recommend that flue terminals discharges are positioned higher than air inlets. For C twin type pipe installations the maximum equivalent length of 30 metres includes both the requirements for the air inlet pipe and flue pipe. -
Page 22: Figure 5.2.3.1 Modular Boiler Installation Using Hhl Kits
Figure 5.2.3.1 - Modular Milborne Flue Installation using Hamworthy kits Pictorial View Description Code HHL Part No. Polypropylene 45° bend ø125 mm 573407340 Polypropylene 90° bend ø125 mm 573407341 Polypropylene 45° bend ø160 mm 573407317 Polypropylene 90° bend ø160 mm 573407316 Polypropylene pipe ø125 mm x 500mm... -
Page 23: Figure 5.3.1 Water Connections
Where using Hamworthy Heating Ltd frame set and pipework kits, assembly of these is detailed in Operation and Maintenance manual 500001156 supplied with kit. -
Page 24: 6.0 Pre-Commissioning
Ensure that ventilation and air supply to plantroom is correct. 6.3 Pipework, Valves and Pump Ensure that; • Pipework and valve arrangement is installed to Hamworthy Heating recommendations. • Circulating system is full of water, vented and pressurised appropriately. •... -
Page 25: 7.0 Checks Prior To Lighting
4) System may be considered sound if over a period of 2 minutes any drop in pressure is less than 0.5 mbar (0.2" wg.). Note:- Allow a manometer stabilisation period of approximately 1 minute before each 2 minute check period. Following soundness tests close valve B and remove manometer connections and tighten test points. HAMWORTHY HEATING LTD MILBORNE 500001130/J... -
Page 26: Figure 7.2.1 Gas Valve Adjustments
The gas pressure measured during these tests must be no less than 17.5 mbar for Natural Gas or 37.5 mbar for LPG. Fig 7.2.1 Gas valve adjustments HAMWORTHY HEATING LTD MILBORNE 500001130/J... -
Page 27: Figure 7.2.2 Gas Inlet Pressure Test Point
6. If the above procedure occurs correctly, open the gas isolation valve, press the reset button (S1) and the fault indication will extinguish. The boiler will commence the ignition sequence and the burner will light. 7. With the boiler firing, the flame signal displayed should be approximately 40μA but not less than 10μA. HAMWORTHY HEATING LTD MILBORNE 500001130/J... -
Page 28: Figure 7.4.4 Control Panel Modules
The first digit of the display will indicate the fan speed. H = maximum speed. Heat Demand for domestic hot water circuit or from The second two digits of the display indicate heating circuits 1 and 2; temperature, e.g. T1 = 80°C HAMWORTHY HEATING LTD MILBORNE 500001130/J... -
Page 29: Figure 7.4.8 Throttle Adjustment
CO value. See fig 7.4.11. Note: To increase the gas flow turn the offset screw clockwise, to decrease the gas flow turn the offset screw anti-clockwise. HAMWORTHY HEATING LTD MILBORNE 500001130/J... -
Page 30: 8.0 Controls Operation
8.2 System Design -processor based package, controlling and monitoring all safety and functional aspects of the boiler Hamworthy Heating strongly recommend the use of a performance and it’s integration with external system primary circuit configuration, with a suitably matched controls. -
Page 31: Figure 8.1.1 Control Panel Overview (Master)
S6 - Prog / Ok D4 - Power on green LED S3 - Set Values U2 - LED Display D5 - Faults display red LED S4 - Increase U3 - LED Display Figure 8.1.2 - System overview illustration HAMWORTHY HEATING LTD MILBORNE 500001130/J... -
Page 32: Figure 8.2.6.1 Load Control Graph
A 2V input will set the boiler(s) on at minimum flow pipework between the boilers and the primary temperature (parameter 18(HT) or 24 (LT)). A 9V circuit low loss header. When using Hamworthy Frame input will set the boiler(s) to maximum temperature and Header Kits this pocket is provided. -
Page 33: Figure 8.3.1 Jumper J14 Connection On Pcb
(X1 or X2) may be connected to the adjacent boilers. If this is the case, supply MASTER the free terminal with 24V, for example BUS J14 terminal Xn - see figure 8.3.3. Figure 8.3.3 Plug J14 disconnected 24Vcc X 1 HAMWORTHY HEATING LTD MILBORNE 500001130/J... -
Page 34: Figure 8.4.1 Milborne Multiple Installation
Milborne multiple installation (1 Milborne 382/502 Master with 2 Milborne 382/502 Slaves Milborne 382/502 Slave Milborne 382/502 Master Milborne 382/502 Slave Slave Slave Slave Slave Slave Slave No 3 No 4 No 1 No 2 No 5 No 6 Master Figure 8.4.1 - Milborne Multiple Installation HAMWORTHY HEATING LTD MILBORNE 500001130/J... -
Page 35: Figure 8.4.2 Jumper Settings
Block 2 Block 3 Block 4 Block 5 Block 6 Block 7 Block 8 Block 9 Block 10 Block 11 Block 12 Block 13 Block 14 Block 15 4 Boiler modules to each block Figure 8.4.2 HAMWORTHY HEATING LTD MILBORNE 500001130/J... -
Page 36: Figure 8.4.3 Example Installation Consisting 7 Boiler Modules In Same Cascade Sequence
Boiler module 1 Block 1 Boiler module 2 Block 1 Block 1 Boiler module 3 Boiler module 4 Block 1 Boiler module 1 Block 2 Boiler module 2 Block 2 Block 2 Boiler module 3 HAMWORTHY HEATING LTD MILBORNE 500001130/J... -
Page 37: Figure 8.5.1 Thermostat Location
8.5.2 Mounting the thermostat The thermostat is suitable for wall with rear cable entry. Alternatively the thermostat may also be mounted to a standard electrical back box or round conduit box. Figure 8.5.2 - Thermostat Mounting HAMWORTHY HEATING LTD MILBORNE 500001130/J... -
Page 38: Figure 8.5.3 Thermostat Wiring
Figure 8.5.3 - Thermostat wiring For programming details please refer to the instructions provided with the room thermostat. Alternatively contact Hamworthy Heating Ltd for a copy of instruction manual. 8.6 Master control panel error codes The following tables display the Master control errors messages. These messages relate to faults that can occur within the Master control panel, or from the sensors and circuits connected to the Master control panel. -
Page 39: Figure 8.6.1 Error Codes
Figure 8.6.3 Master control permanent lock-out errors (A) - manual reset Display Nr PC Nr Fault Action Internal E2PROM error Reset, check and replace Master board Internal communication error Reset, check and replace Master board HAMWORTHY HEATING LTD MILBORNE 500001130/J... -
Page 40: Figure 8.6.4 Master Control Blocking Errors (E) Auto Reset
Flame detected after closing the gas valve Check and replace the gas valve Internal error Check and replace Slave board Fan error - speed not achieved Check the fan and electrical connections. Replace the fan HAMWORTHY HEATING LTD MILBORNE 500001130/J... -
Page 41: Figure 8.6.6 Boiler Module Blocking Errors (E) Auto Reset
Press S6 to store the value. The chosen ◊ High temp. heating circuit flow _T (pos. 1) value will stop flashing and the display will be ◊ restored to the mode display. Domestic Hot Water_T (pos. 2) HAMWORTHY HEATING LTD MILBORNE 500001130/J... -
Page 42: Figure 8.6.8 User Parameter Adjustments
Press S6 (Prog/OK) to store the new value. The two right LED digits will stop flashing. After 3 secs., the display will return to the mode display with the new set value. Figure 8.7.1 - procedure for adjusting Low Temperature Heating circuit HAMWORTHY HEATING LTD MILBORNE 500001130/J... -
Page 43: Figure 8.7.1 User Parameter Adjustments
1st circuit or high temp. circuit pump function status (of) or (on) 10. Domestic hot water circuit pump function status (of) or (on) 11. Main pump function status (of) or (on) Figure 8.8.2 - display value sequence HAMWORTHY HEATING LTD MILBORNE 500001130/J... -
Page 44: Figure 8.8.2 User Parameter Adjustments
Press S6 (Prog/OK) to accept and store the new value. The display will return to the display at step 6. To check and alter further parameters return to step 7 and follow through. Figure 8.9.1 - programming parameters HAMWORTHY HEATING LTD MILBORNE 500001130/J... -
Page 45: Figure 8.9.2 Combustion Test Parameters
S5 (-) for minimum (L). The other two digits show the flow temperature at maximum or minimum firing rate. Press S6 (OK) to exit ‘test mode’ and return to the display. Figure 8.9.2 - combustion test parameters HAMWORTHY HEATING LTD MILBORNE 500001130/J... -
Page 46: Figure 8.10.1 Master Control Primary Functions - Must Be Set In All Instances
The priority method may reduce the power available to other circuits if there is a high demand in the prioritised circuit and the boiler sizing is lean. If all circuits are required to operate without interruption the priority should be set to shared, ie setting ‘0’ or ‘1’. HAMWORTHY HEATING LTD MILBORNE 500001130/J... -
Page 47: Figure 8.10.3 Setting High Temperature Heating Circuit Functions For Constant Temp
Set time taken for mixing valve to close from fully open position. Eg 7 sec. Max 255 secs P.30 Mixing valve static period Set time mixing valve is to remain static after moving. Eg 5 secs. Max 255 secs HAMWORTHY HEATING LTD MILBORNE 500001130/J... -
Page 48: Figure 8.10.5 Setting High Temperature Heating Circuit Functions For Variable Temps
As 19 above. Eg. For 40°C set-point. Setting to 7 will re-start the hysteresis on burner at 33°C P.27 Low temperature circuit As 20 above. Eg. For 40°C set-point. Setting to 1 will stop the hysteresis off burner at 41°C HAMWORTHY HEATING LTD MILBORNE 500001130/J... -
Page 49: Figure 8.10.6 Setting Low Temperature Heating Circuit Functions For Variable Temps
As 19 above. Eg. For 40°C set-point. Setting to 7 will re-start hysteresis on the burner at 33°C P.27 Low temperature circuit As 20 above. Eg. For 40°C set-point. Setting to 1 will stop the hysteresis off burner at 41°C HAMWORTHY HEATING LTD MILBORNE 500001130/J... -
Page 50: 9.0 Fault Finding
Engineer. 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 51: Figure 9.3.1 Master - Wiring Schematic
Figure 9.3.1 - Milborne 382 / 502 - Wiring Schematic HAMWORTHY HEATING LTD MILBORNE 500001130/J... -
Page 52: Figure 9.3.2 Slave - Wiring Schematic
Figure 9.3.2 - Milborne 382 / 502 Slave - Wiring HAMWORTHY HEATING LTD MILBORNE 500001130/J... -
Page 53: Figure 10.3.1 Unscrewing Upper Panel
10.3.5 and figure 10.3.6 Figure 10.3.2 Removal of venturi Burner securing screws Figure 10.3.6 Caution! After cleaning the burner, new gaskets Figure 10.3.3 must be used for the burner and air-gas manifold flange. HAMWORTHY HEATING LTD MILBORNE 500001130/J... -
Page 54: Figure 10.4.1 View Of Combustion Chamber Entrance
- see figure 10.4.2. Figure 10.5.3 Remove any debris from the combustion chamber with a vacuum cleaner. Finally, wash with water. Caution! After cleaning the exchanger, new sealing gaskets must be used . Figure 10.5.4 Figure 10.5.1 HAMWORTHY HEATING LTD MILBORNE 500001130/J... -
Page 55: Figure 10.6.1 Ignition Electrode
10.7 Reassembly - having carried out the detailed servicing procedure, re-assemble all components, having fitted replacement gaskets where required. Check all gas connections are tightened securely Figure 10.8 before opening the gas service cock. Re-connect HAMWORTHY HEATING LTD MILBORNE 500001130/J... -
Page 56: 11.0 Recommended Spares
Data Plates affixed to the combustion chamber front panel. The Electrical Serial Number is located inside the Control panel on the maximum power rating label. These numbers MUST be quoted when ordering spare parts. Figure 11.1 Figure 11.2 HAMWORTHY HEATING LTD MILBORNE 500001130/J... -
Page 57: Figure 11.3 Recommended Replacement Parts
R (Ώ) T (°C) R (Ώ) 67799 14694 4161 1451 53452 12090 3538 1266 42449 9999 3021 1108 33925 8313 2589 27279 6944 2229 22069 5828 1925 17959 4913 1669 Figure 11.4 - sensor resistance values HAMWORTHY HEATING LTD MILBORNE 500001130/J... - Page 58 Gas supply pipe gasket ……………………………………………………………..573407250 Gas valve ……………………………………………………………..573407090 Gas valve venturi ……………………………………………………………..573407019 For service or spares please contact :- Hamworthy Heating Ltd Tel; ···························· 01202 662500 Fleets Corner Fax ···························· 01202 665511 Poole Service ······················· 01202 662555 Dorset BH17 0HH Spares ·······················...
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Page 59: Appendix Agas Data
For single module installations, ie 1 x Milborne 381 / 501, the boiler must not be installed in a room or compartment located below ground level. BS6798. For multiple module installations, ie 1 x Milborne 382 / 502 or greater, the boiler must not be installed in a plant room located below ground level. BS6644. HAMWORTHY HEATING LTD MILBORNE 500001130/J... -
Page 60: Figure A3 Gas Valve And Air Inlet Assemblies
Figure A3 convert the boilers from Natural Gas to LPG on site. To order additional LPG conversion kits please contact Hamworthy Heating Ltd to order the required number of kits quoting part number 573407132. One 3 off securing screws kit will be required for each module, ie;... -
Page 61: Figure A6 Lpg Orifice Fitted
381/382 boilers 21= Natural Gas with equivalent flue length < 15m 22= Natural Gas with equivalent flue length > 15m 23= LPG with equivalent flue length < 15m 24= LPG with equivalent flue length > 15m HAMWORTHY HEATING LTD MILBORNE 500001130/J... -
Page 62: Appendix Belectrical Connections & Controls
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. 7. Any pump controlled by the boiler must be installed using an adequate contactor. NOTE: FOR BASIC TERMINATION DIAGRAM SEE FIGURE 4.6 HAMWORTHY HEATING LTD MILBORNE 500001130/J... -
Page 63: Figure B1.2 Pump Contactor Connection
For an optional programmable room thermostat, use terminals 9 & 10 for the high temperature heating room sensor and terminals 11 & 12 for the low temperature heating room sensor - see figure B.1.3 Figure B.1.3 HAMWORTHY HEATING LTD MILBORNE 500001130/J... -
Page 64: Appendix Cflue Data
Consideration must be given to the correct calculation of the required flue size. If in any doubt consult Hamworthy Heating Ltd who can supply a full flue design and installation service. C1.2 Waste Gas Volume and Temperature. -
Page 65: Figure C1.1 50Mm Flue Equivalent Lengths
A drain with an integral trap is fitted to each module suitable for connection to a 20mm 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 No. -
Page 66: Appendix Dventilation
3) Mechanical extract ventilation with natural inlet ventilation MUST NOT be used. For Mechanical ventilation systems an automatic control should be provided to cut off the gas supply to the boiler, in the event of failure of air flow in either inlet or extract fans. HAMWORTHY HEATING LTD MILBORNE 500001130/J... -
Page 67: Figure D1 Mechanical Ventilation Flow Rates
The calculated extract flow rate is the actual inlet flow rate minus the appropriate figure in the table above. HAMWORTHY HEATING LTD MILBORNE 500001130/J... -
Page 68: Appendix Ewater Data
E1.5 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. See Figure E1.1.1 for typical position. -
Page 69: Figure E1.6 Pump Selection Chart
Maximum system hot working pressure, generally given in bar gauge. From the parameters given, Hamworthy Heating can size the pressurisation unit and also the expansion vessel. Care must be taken in sizing expansion vessels to ensure maximum acceptance factors are not exceeded. -
Page 70: Figure E1.1.1 Typical Piping Layouts
Tempo rary Do uble Drain ch eck valve f ill line (Prima ry loo p) val ve va lve UNVENTED SYSTEM: Primary loop, Hamworthy recommended system. P ressure & Temper ature Drain gauges Ma ins wa ter Auto matic Safety... - Page 71 NOTES: HAMWORTHY HEATING LTD MILBORNE 500001130/J...
- Page 72 USEFUL USER INFORMATION INSTALLER SITE ADDRESS BOILER TYPE BOILER SIZE(S) UNIT NO(S). SERIAL NO(S). FLUE HAMWORTHY HEATING LTD MILBORNE 500001130/J...