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Hamworthy MILBORNE 501 Series User Manual

Hamworthy MILBORNE 501 Series
72 pages
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HAMWORTHY HEATING LTD
MILBORNE
500001130/J
MILBORNE BOILERS
Wall Hung, Pre-Mix, Condensing,
Modular Boilers
381 & 501 Series
Design Installation, Commissioning
and Operating Instructions
NATURAL GAS
I
2H
LPG - PROPANE
I
3p
i
NOTE: THESE INSTRUCTIONS SHOULD BE READ AND UNDERSTOOD BEFORE
ATTEMPTING TO INSTALL, COMMISSION OR OPERATE THIS UNIT
PUBLICATION NO. 500001130
ISSUE ‘J’
JULY 2009

Table of Contents

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Hamworthy MILBORNE 501 Series Specifications

General IconGeneral
BrandHamworthy
ModelMILBORNE 501 Series
CategoryBoiler
LanguageEnglish

Summary

1.0 INTRODUCTION

Installation and Gas Requirements

Boiler installation rules, gas type, and safety regulations.

Boiler Description and Variations

Features, models (381/501), and module configurations.

Boiler Options and Kits

Available accessories like frame sets, circuit kits, and sensors.

2.0 SUPPLY AND DELIVERY

Boiler Packaging and Handling

Details on how the boiler is packaged and safe handling procedures.

Warranty and Liability

Information on warranty coverage and manufacturer's liability terms.

3.0 SIZE AND SPACE REQUIREMENTS

Plantroom Space and Dimensions

Required clearances and physical dimensions for installation.

Frame Set and Pipework Kit

Information on the Hamworthy Heating Ltd frame set and pipework kit.

4.0 SITE LOCATION AND PREPARATION

Site Location Criteria

Guidelines for choosing a suitable location for the boiler.

Gas Supply Requirements

Standards and specifications for gas pipework and connections.

Flueing and Terminal Locations

Flue system requirements and terminal placement rules.

Water Supply Connections

Requirements for connecting the boiler to the heating system's water supply.

Condensate Connections

Guidelines for draining condensate from the boiler and flue system.

Electrical Supply Requirements

Electrical connection standards, safety, and supply details.

5.0 BOILER ASSEMBLY

General Assembly and Flue System

Instructions for assembling the boiler and its flue system.

Water Connections and Systems

Details on water connections, pump selection, and system configuration.

6.0 PRE-COMMISSIONING

Gas Supply Checks

Verifying gas installation soundness, purging, and meter checks.

Ventilation Checks

Ensuring adequate air supply to the plantroom for combustion and ventilation.

Pipework, Valves, and Pump Checks

Verifying installation of pipework, valves, and pump functionality.

Flue System Checks

Confirming correct flue system design, installation, and clarity.

Electrical Checks

Ensuring correct and isolatable electrical connections and operational external controls.

7.0 CHECKS PRIOR TO LIGHTING

Boiler Gas System Leak Check

Procedure to check for gas leaks in the boiler system before operation.

Pre-Lighting Checks

Essential checks before lighting the boiler, including controls and gas configuration.

Gas Inlet Pressure Test

Measuring static and dynamic gas pressure to ensure adequate burner output.

Commissioning the Boiler

Steps for commissioning the boiler, including initial lighting and combustion checks.

Initial Lighting Procedure

Step-by-step guide for lighting the boiler and verifying flame signal.

8.0 CONTROLS OPERATION

Control System Overview

Description of the Master/Slave control system and its functions.

System Design Principles

Recommendations for system design, primary circuits, and pump control.

Heating Circuit Control

Details on controlling high and low temperature heating circuits and DHW.

Building Management System (BMS) Integration

Connecting and controlling the boiler via a BMS using analog signals.

Emergency Mode Activation

Procedure to activate emergency mode in case of Master control malfunction.

8.4 Set-up for Multiple Boiler Installations

Module Cabling and Addressing

Connecting modules and assigning addresses for multi-boiler systems.

8.5 Programmable Room Thermostat

Thermostat Location and Mounting

Guidelines for correctly positioning and mounting the room thermostat.

8.6 Master Control Panel Error Codes

User Parameter Adjustments

How users can adjust parameters like temperature set-points.

Changing Operating Temperature Set-Points

Adjusting temperature set-points for different heating circuits.

Monitor Mode Operations

Accessing and interpreting data from the boiler's monitor mode.

8.9.1 Programming Mode

Password Protected Parameter Settings

Procedure for entering password and modifying parameters.

8.9.2 Combustion Test Parameters

Accessing Combustion Test Display

Steps to access the display for combustion testing.

8.10 Programming Procedure

Master Control Primary Functions

Essential parameters to set for all installations, including gas type and frost protection.

Setting Domestic Hot Water (DHW) Functions

Configuring parameters related to domestic hot water operation and priority.

Setting High Temperature Heating Circuit Functions

Configuring parameters for constant temperature operation of high temp heating.

Setting Low Temperature Heating Circuit Functions

Configuring parameters for constant temperature operation of low temp heating.

Setting High Temperature Heating for Variable Temperature

Configuring parameters for compensated temperature operation of high temp heating.

Setting Low Temperature Heating for Variable Temperature

Configuring parameters for compensated temperature operation of low temp heating.

9.0 FAULT FINDING

Safety Features Overview

Explanation of safety mechanisms like limit thermostats and flame sensing.

Fault Finding Procedures

Steps to diagnose and resolve general and specific boiler faults.

Common Boiler Lockout Causes

List of probable causes for the boiler entering a lockout state.

10.0 SERVICING

Regular Servicing Recommendations

Guidelines for annual servicing and additional checks.

Cleaning the Burner

Procedure for cleaning the burner and its components.

Cleaning the Heat Exchanger

Steps for cleaning the boiler's heat exchanger.

Cleaning the Condensate Drain

Routine maintenance for cleaning the condensate drain device.

Cleaning the Ignition Electrode

Maintenance for the ignition electrode to ensure proper function.

11.0 RECOMMENDED SPARES

Identifying Spare Parts

Information on how to identify and order correct spare parts using serial numbers.

APPENDIX A - GAS DATA

Natural Gas Data

Technical data for natural gas operation, including input and output ratings.

LPG Propane Data

Technical data for LPG propane operation, including orifice sizes.

LPG Conversion Procedure

Step-by-step guide for converting the boiler from natural gas to LPG.

APPENDIX B - ELECTRICAL CONNECTIONS AND CONTROLS

Electrical Supply and Wiring

Details on electrical supply, wiring regulations, and connection methods.

Pump and BMS Connections

Wiring diagrams for pumps, BMS, and thermostats.

APPENDIX C - FLUE DATA

Flue System General Requirements

Guidelines for flue system design, materials, and installation.

Flue Gas Volumes and Temperatures

Data on waste gas volumes and temperatures for flue system design.

Condensate Discharge

Requirements for managing condensate from the flue system.

APPENDIX D - VENTILATION

Air Supply Requirements

Guidelines for air supply via natural or mechanical ventilation for boiler rooms.

APPENDIX E - WATER DATA

Water Circulation System

Recommendations for water circulation, pump selection, and system configuration.

Safety Valve and Pressure Gauges

Information on safety valve requirements and pressure/temperature gauges.

Water Flow Controls and Frost Protection

Details on flow controls, shut-off valves, and frost protection measures.

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