Hamworthy S150 Manuel utilisateur

IMPORTANT NOTE

THESE INSTRUCTIONS MUST BE READ

AND UNDERSTOOD BEFORE INSTALLING,

COMMISSIONING, OPERATING OR

SERVICING EQUIPMENT

Shaftesbury Slimline

Gas/Oil Fired Cast Iron Sectional Boilers

150kW to 290kW

Installation, Commissioning

and Servicing Instructions

NATURAL GAS

CLASS D (35 sec fuel oil)

Technical Enquiries 01202 662527/662528

To supplement the detailed technical brochures, technical advice on the application and use of products in the

Hamworthy Heating range is available from our technical team in Poole and our accredited agents.

Site Assembly 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.

Commissioning 01202 662555

Commissioning of equipment by our own engineers, accredited agents or specialist sub – contractors will ensure the

equipment is operating 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 a rapid response breakdown, repair or replacement service through head office at Poole and accred-

ited agents throughout the UK.

Spare Parts 01202 662525

A comprehensive spare parts service is operated from our factory in Poole, providing replacement parts for both current

and discontinued products. Delivery of parts and components is normally from stock within seven days. However, a next

day delivery service is available for breakdowns and emergencies.

Customer Services

HAMWORTHY HEATING LTD

SHAFTESBURY SLIMLINE

500001129/A

Shaftesbury Slimline

Gas/Oil Fired Cast Iron Sectional Boilers

150kW to 290kW

Installation, Commissioning

and Servicing Instructions

NATURAL GAS

CLASS D (35 sec fuel oil)

NOTE: THESE INSTRUCTIONS SHOULD BE READ AND UNDERSTOOD BEFORE

ATTEMPTING TO INSTALL, COMMISSION OR OPERATE THIS UNIT

THE SHAFTESBURY SLIMLINE BOILER IS INTENDED FOR USE AS A COMMERCIAL

APPLIANCE

THE GASED FIRED VARIANTS OF THIS BOILER ARE FOR USE ON GROUP H NATURAL

GAS (2ND FAMILY). THE OIL FIRED VARIANTS ARE FOR USE ON CLASS D (35sec FUEL

OIL). PLEASE ENSURE RELEVANT INFORMATION REQUIRED WITHIN DOCUMENT IS

FOUND RELATING TO SPECIFIC FUEL TO BE FIRED BEFORE FIRING BOILER.

THIS BOILER COMPLIES WITH ALL RELEVANT EUROPEAN DIRECTIVES.

EC TYPE CERTIFICATE No. E0113/5074

PRODUCT IDENTIFICATION No. 461AS113

PUBLICATION NO. 500001129

ISSUE ‘A’

OCTOBER 2004

HAMWORTHY HEATING LTD

SHAFTESBURY SLIMLINE

500001129/A

CONTENTS

PAGE

1.0 INTRODUCTION ...............................................................................................................................1

2.0 SUPPLY AND DELIVERY................................................................................................................. 2

3.0 POSITIONING, SIZE AND SPACE REQUIREMENTS ..................................................................... 3

4.0 SITE LOCATION AND PREPARATION ........................................................................................... 4

4.1 Site Location

4.2 Gas Supply

4.3 Flueing

4.4 Water Supply

4.5 Electrical Supply

5.0 BOILER ASSEMBLY ....................................................................................................................... 8

5.1 Assembly of Heat Exchanger

5.2 Fitting of Boiler Insulation

5.3 Assembly of Boiler Casing

5.4 Electrical Supply

5.5 Filling the System

6.0 COMMISSIONING ........................................................................................................................... 22

7.0 REPLACEMENT OF PARTS .......................................................................................................... 23

APPENDIX ‘A’ – TECHNICAL DATA.................................................................................................................. 26

HAMWORTHY HEATING LTD

SHAFTESBURY SLIMLINE

500001129/A

iii

PICTORIAL AND DIAGRAMATICAL DATA

FIGURES PAGE

Figure 2.1 Exploded View of Heat Exchanger ............................................................................................. 2

Figure 3.1 Shaftesbury Slimline - Dimensional Overview......................................................................... 3

Figure 4.4 Water Connections .................................................................................................................... 6

Figure 5.1.1 Fitting Ceramic Rope to Rear Casting ..................................................................................... 8

Figure 5.1.2 Applying Paste......................................................................................................................... 8

Figure 5.1.3 Fitting Nipple to Housing ............................................................................................................ 8

Figure 5.1.4 Tapping Nipple into Position....................................................................................................... 8

Figure 5.1.5 Fitting Intermediate Section ........................................................................................................ 9

Figure 5.1.6 Tapping Intermediate Section into Position.................................................................................. 9

Figure 5.1.7 Preparing Next Intermediate Section........................................................................................... 9

Figure 5.1.8 Applying Ceramic Rope ........................................................................................................... 10

Figure 5.1.11 Fitting the Fire Brick ................................................................................................................. 10

Figure 5.1.12 Fitting Front Casting................................................................................................................. 10

Figure 5.1.14 Fitting Tie Rods...................................................................................................................... 11

Figure 5.1.15 Fitting Rp 2” Cap ..................................................................................................................... 11

Figure 5.1.16 Fitting Door Eyelet ................................................................................................................... 11

Figure 5.1.17 Fitting Divider Plates ................................................................................................................ 12

Figure 5.1.18 Pictorial View of Divider Plates in Position ................................................................................. 12

Figure 5.2.1 Fitting Boiler Insulation ............................................................................................................. 13

Figure 5.2.2 Securing Insulation Tapes........................................................................................................ 13

Figure 5.3.1

Figure 5.3.37 Step by Step Casing Assembly Details ................................................................................ 14-19

Figure 5.4.1 Electrical Wiring Diagram ...................................................................................................... 20

Figure 5.4.2 Volt Free Contacts Diagram .................................................................................................. 21

Figure 7.1 Boiler Body List of Spares ..................................................................................................... 23

Figure 7.2 Casing List of Spares............................................................................................................. 24

Figure 7.3 Control Panel Spares............................................................................................................. 25

TABLES

Table A1 Technical Data Chart ............................................................................................................. 26

Table A2 Matched Burner / Boiler Combinations (Natural Gas) ........................................................... 27

Table A3 Matched Burner / Boiler Combinations (Oil) .......................................................................... 27

Table A4 Oil Nozzle Selection............................................................................................................... 28

HAMWORTHY HEATING LTD

SHAFTESBURY SLIMLINE

500001129/A

HAMWORTHY HEATING LTD

SHAFTESBURY SLIMLINE

500001129/A

1.0 INTRODUCTION

1.1 The Shaftesbury Slimline boiler range

consists of 6 gas or oil fired cast iron sectional

boilers with outputs ranging from 150kW to 290kW.

Refer to Technical Data in Appendix A.

Shaftesbury Slimline boilers can be used

individually, or in a multi-boiler configuration, and

are suitable for use on either open-vented or sealed

low temperature hot water heating systems. For hot

water production they can be used in conjunction

with calorifiers or indirect hot water cylinders.

Portland and Weymouth pressurisation units are

available from Hamworthy Heating Ltd for sealed

systems.

1.2 Shaftesbury Slimline sectional boilers can be

supplied pre-assembled or unassembled ready for

on-site assembly.

The heat exchanger consists of:

a. A front section.

b. Plain intermediate sections.

c. A rear section.

The complete assembly is held together by four

threaded tie rods running the length of the heat

exchanger.

The section to section flue gas seal is made by:

d. A mastic strip around the outer perimeter of

each section.

e. A mastic strip around the perimeter of the

combustion chamber of each section.

The sections are cast with extended surface fins to

increase the heat exchange area and thus enhance

thermal efficiency in use.

Shaftesbury Slimline boilers have an operating

efficiency of over 92% based on gross CV.

The heat exchanger assembly is completed by cast

iron front and rear combustion chamber plates and

access plates for the cleaning and inspection of the

heat exchanger flue ways (on front and rear), all of

which are internally lined with a ceramic fibre

insulation board. The smoke box/flue connector is

bolted to the upper part of the rear section and

sealed with a ceramic fibre gasket.

The Shaftesbury Slimline boiler can be fitted with

either a high/low or modulating burner for operation

on Natural Gas I2H (Second Family) or high/low

burner for operation on Class D (35 second) fuel oil.

The boiler is supplied with a pre-wired control panel

which contains:

a. A fuse

b. An illuminated mains on/off switch

c. A boiler thermostat

d. A boiler run lamp

e. A temperature limiter (overheat thermostat) to

shut down the boiler should the water

temperature in the heat exchanger exceed

110oC - with manual reset.

f. An overheat lamp

g. An hours run meter

h. A water temperature thermometer

(temperature gauge)

i. A flying lead and plug to connect to the burner

j. An additional thermostat, boiler run lamp,

hours run meter and flying lead/plug for high/

low burners.

k. A volt free relay kit for normal run, overheat

and lockout.

The boiler is housed in a powder coated sheet steel

casing which is supplied flat-packed for on-site

assembly. Refer to Section 5.3 for casing assembly

procedure.

HAMWORTHY HEATING LTD

SHAFTESBURY SLIMLINE

500001129/A

2.0 SUPPLY AND DELIVERY

2.1 The boiler is normally supplied as a set of

equipment comprising the following:

a. Cast Iron Sections mounted on pallets

b. Accessory kit and tie rods

c. Casing panels and insulation blankets

d. Control panel

e. Matched burner: fuel oil or gas

f. Flue collector box

g. Oil burner nozzle(s) - where applicable

Remove all packing material and inspect the

equipment to ensure that all parts are present and

undamaged.

If in any doubt, DO NOT USE THE EQUIPMENT.

Instead, contact HHL Technical Department.

Figure 2. 1 - Exploded View of Shaftesbury Slimline Heat Exchanger

Key to Figure 2.1 (above)

C2. Internal Nipples

VI. Cast Iron Front Section

WI. Cast Iron Intermediate Section(s)

XI. Cast Iron Rear Section

Key to Figure 3.1 (across page)

1. Main Switch with on/off light

2. Boiler thermometer

3. Safety limit with manual reset (110°C)

4. Screw for furnace pressure take-off, 10mm

dia.

5. Burner opening: 130mm dia. standard.

6. Opening drain cock: 3/4”

7. Flame sight glass

8. First step thermostat

9. Second step thermostat

10. Control system display.

11. Run Timer

HAMWORTHY HEATING LTD

SHAFTESBURY SLIMLINE

500001129/A

3.0 POSITIONING, SIZE AND SPACE REQUIREMENTS

3.1 General

The installer must make the necessary arrangements on site to ensure that the positioning and the fitting of the

boiler, the supply of combustion air, ventilation of the boiler house, connection of the gas supply, the removal of

the combustion gases via a flue system and the electrical connections are in conformity with the operational

characteristics of the material and in accordance with the rules of the trade and the prevailing regulations.

Full details on the assembly of the boiler is given in Section 5 of this manual.

Figure 3.1 - Dimensions and Fittings

Model No. of

Sections

Boiler Dimensions Combustion Chamber Dim.

Height Width Depth Height Width Depth

S150 7 150kW 1560mm 760mm 1200mm 630mm 440mm 810mm

S190 8 190kW 1560mm 760mm 1200mm 630mm 440mm 945mm

S220 9 220kW 1560mm 760mm 1470mm 630mm 440mm 1080mm

Heat

Output

S250 10 250kW 1560mm 760mm 1470mm 630mm 440mm 1215mm

S270 11 270kW 1560mm 760mm 1740mm 630mm 440mm 1350mm

S290 12 290kW 1560mm 760mm 1740mm 630mm 440mm 1485mm

Maximum Water Temperature: 90°C

Maximum Installation Pressure: 4 bar

1 9

4 5

2 1011

Boiler outlet 2” dia.

Flue Gas

Boiler inlet 2” dia.

See below

HAMWORTHY HEATING LTD

SHAFTESBURY SLIMLINE

500001129/A

4.0 SITE LOCATION AND PREPARATION

4.1 SITE LOCATION.

The floor or plinth for the boilers must be both flat and level to ensure correct alignment of

fittings and connections.

The floor or plinth must be sufficiently strong to support the weight of both the boilers.

The floor or plinth must be fireproof in accordance with BS 6644.

The plant room must have sufficient space for installation of boilers, pipework, pumps

controls, flues ventilation, access and servicing and other items of plant.

4.2 GAS SUPPLY.

•Gas supply pipes must be in accordance with BS 6891 or IGE/UP/2.

•Gas connections to the burner must be sized correctly. See burner manufacturer’s

literature to correctly size.

•Gas installation must be soundness tested to BS 6891 or IGE/UP/1 & IGE/UP/1A.

•Gas installation must be purged to BS 6891 or IGE/UP/1 & IGE/UP/1A.

•Inlet gas pressure to boiler nominal 20mbar (minimum 17.5mbar) dynamic.

•Gas Supply Pipes should be suitable for an upstream pressure of 50mbar max. for

Natural Gas.

•Boiler house gas isolation valve must be clearly identified and installed close to the

entrance / exit.

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