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Hamworthy Sherborne Series User Manual

Hamworthy Sherborne Series
54 pages
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IMPORTANT NOTE
THESE INSTRUCTIONS MUST BE READ
AND UNDERSTOOD BEFORE INSTALLING,
COMMISSIONING, OPERATING OR
SERVICING EQUIPMENT
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

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Hamworthy Sherborne Series Specifications

General IconGeneral
Modulation Range5:1
Boiler TypeCondensing
Fuel TypeNatural Gas
NOx EmissionsClass 5
CasingSteel

Summary

Customer After Sales Services

Technical Enquiries

Advice on application and use of products from technical team and agents.

Site Assembly

Service for restricted plant rooms, offering higher quality build.

Commissioning

Ensures equipment operates safely and efficiently by engineers or agents.

Maintenance Agreements

Routine servicing by engineers to inspect safety and integrity.

Breakdown service, repair, replacement

Rapid response service provided through head office and agents.

Spare Parts

Service for replacement parts for current and discontinued products.

Introduction

1.1 Options

Details flue kits, mounting frames, and header kits.

1.2 Controls peripherals

Compatibility with external sensors, LPB Bus, and cascade control.

Supply and Delivery

Delivery Verification

Procedure to check received boilers and ancillary packages against order.

Size and Space Requirements

Boiler Layout and Description

4.1 Accessory Pack

List of items included in the accessory pack with quantities.

Site Location and Preparation

5.1 Site Location

Requirements for a flat, level, strong, and fireproof installation location.

5.2 Gas Supply

Pipework, connection, pressure, and isolation requirements for gas supply.

5.3 Water Supply & Return

Feed/expansion tanks, pipework flushing, and pressure requirements.

5.4 Flues

Details flue termination, routing, construction, materials, and drainage.

5.5 Condensate Connections

Instructions for removal, pipework, and drainage of acidic condensate.

5.6 Electrical Supply

Requirements for earthing, supply voltage, fuses, and isolation.

5.7 Mounting the boiler to the wall

Instructions for positioning, fixing, and frame mounting the boiler.

Flue System Connections

5.8.1 Through Wall Horizontal Balanced Flue

Detailed installation steps for 80/125mm through-wall terminals.

5.8.2 Extended Horizontal/Vertical Balanced Flue

Installation steps for 100/150mm extended flue lengths.

5.8.3 Twin Pipe Horizontal/Vertical Room Sealed

Installation steps for 100mm twin pipe room sealed systems.

5.8.4 Twin Pipe Horizontal/Vertical Room Sealed

Installation steps for 100mm twin pipe room sealed systems.

5.8.5 Single Pipe Horizontal/Vertical Room Sealed

Installation steps for 100mm single pipe room sealed systems.

5.9 Electrical Connections

Details wiring terminals for various boiler functions and signals.

Pre-Commissioning Checks

6.1 Gas Supply

Ensures soundness and purging tests are completed.

6.2 Ventilation

Confirms correct ventilation and air supply to the plantroom.

6.3 Pipework, Valves & Pump

Checks system fullness, venting, pressure, and pump operation.

6.4 Flue

Verifies correct flue design, installation, and clear passages.

6.5 Electrical

Confirms electrical connections are correct, isolatable, and controls operational.

Boiler Checks

7.1 Boiler Gas System Leak Check

Procedure to check isolating valve and main gas valve for leaks.

7.2 Checks Prior to lighting the boiler

Checks gas supply, ignition, sensors, and wiring before lighting.

7.3 Initial Lighting

Step-by-step guide for safely lighting the boiler.

7.3.1 Lighting the boiler

Sequence of operations for boiler ignition and startup.

7.3.2 Safety Checks

Verifies shutdown on gas isolation and re-ignition attempts.

7.3.3 Flame Signal Assessment

Checks the ionisation signal strength during firing.

7.3.4 Adjusting the settings of the boiler

Procedure for setting the flow temperature setpoint.

7.4 Ignition Controller Check

Tests ignition controller by checking shutdown on gas valve closure.

7.5 Gas Supply Pressure Check

Verifies inlet pressure for Natural Gas and LPG.

7.6 Combustion Checks

Site checks for CO2 and CO levels to confirm performance.

Controls Operation

8.1 Fascia Details

Description of control panel buttons and their respective functions.

8.2 Display Details

Explanation of symbols and information displayed on the screen.

8.3 Operating Modes

Selection of automatic, standby, normal, and reduced heating modes.

8.4 Information Button

Accessing boiler information and diagnostic codes via the info button.

8.4.1 Extended Information Modes

Accessing detailed operational and diagnostic data.

8.5 Error Code Display

Display of fault codes and lockout conditions on the screen.

8.5.1 Internal Error Code Display

Obtaining additional fault information from internal error codes.

8.5.2 Error Code Table

Table detailing potential causes and actions for error codes.

User Settings and Functions

8.6.1 Start-up / Initialisation

Initial setpoints after power-on or lockout reset.

8.6.2 Users Parameter Settings

Procedure for modifying user adjustable parameters.

8.6.4 Functions

Details special operating modes like Chimney Sweep and Controller Stop.

8.6.4.1 Chimney Sweep mode

Mode for making measurements at maximum boiler output.

8.6.4.2 Controller Stop mode

Allows manual adjustment of heat output in heating mode.

8.6.4.3 Time of day function

Explains setting and operation of the time of day function.

8.7.10 Display of operating phases

Meaning of LMU internal operating phases and their display codes.

8.8 Control Panel Assembly

Details the layout and components of the boiler's control panel.

8.9 Wiring Diagram

Schematic illustrating the boiler's electrical connections.

8.10 Wiring Diagram (LMU)

Detailed wiring diagram for the LMU (Local Module Unit).

Fault Finding

9.1 Temperature Limit Thermostat

Location, reset procedure, and causes for the limit thermostat tripping.

9.2 Fault Finding Procedures

General guidance and contact information for fault finding assistance.

9.3 Possible Causes of Boiler Lockout

Lists common reasons for the boiler entering a lockout condition.

Servicing

10.2 Annual Service

Procedures and checks required for the annual service.

10.2.1 Preliminary Checks & Cleaning

Steps for preliminary checks and cleaning during annual service.

10.2.2 Heat Exchanger Cleaning

Detailed procedure for cleaning the heat exchanger.

10.2.3 Re-assembly

Steps for re-assembling the boiler after servicing.

Replacement of Failed Components

11.1 Hot Surface Igniter & Flame Probe Assembly

Part numbers and replacement steps for igniter and flame probe.

11.2 Flow / Return Sensor

Part number and replacement steps for flow/return sensors.

11.3 Temperature Limiter Renewal

Part numbers and replacement steps for the temperature limiter.

11.4 Main Gas Valve / Venturi

Part number and replacement steps for the gas valve and venturi.

11.5 Fan Assembly

Part number and replacement steps for the fan assembly.

11.6 Main control PCB

Part numbers and replacement steps for the main control PCB.

Recommended Spares

Electrical Items

List of recommended electrical spare parts with part numbers.

Mechanical Items

List of recommended mechanical spare parts with part numbers.

Appendix A - Gas Data

Natural Gas

General and gas data for Natural Gas fired boilers.

LPG Propane

General and gas data for LPG Propane fired boilers.

Appendix B - Electrical Connections and Controls

B1.1 Electrical Supply

Details wiring requirements and mains supply considerations.

Appendix C - Flue Data

C1.0 FLUE SYSTEM

General requirements and recommendations for flue systems.

C1.1 General Requirements

Design and installation guidelines for flue systems.

C1.2 Waste Gas Volume & Temperature

Data on waste gas volume and temperature for flue design.

C1.3 Suction

Requirements for flue system suction and draught stabilisers.

C1.4 Maximum Length of Flue Duct

Details allowable linear equivalent lengths for flue ducts.

C1.9 Condensate Discharge

Considerations for handling flue condensate discharge.

Appendix D - Ventilation

D1.1 Air Supply

General air supply recommendations for combustion and ventilation.

D1.2.1 Air Supply by Natural Ventilation - Open Flue applications

Ventilation requirements for open flue systems.

D1.2.2 Air Supply by Natural Ventilation - Room Sealed Installations

Ventilation requirements for room sealed systems.

D1.3 Air Supply by Mechanical Ventilation

Requirements for mechanical ventilation systems.

Appendix E - Water Data

E1.1 Water Circulation System

Boiler water content and flow rate requirements.

E1.2 Minimum System Water Pressure

Minimum system water pressure requirements.

E1.3 Pressure Relief Valve (Safety Valve)

Information on safety valve selection and capacity.

E1.4 Open Vent & Cold Feed Pipe

Pipe sizing and installation for open vent and cold feed pipes.

E1.5 Altitude Gauge (Water Pressure Gauge)

Requirement for an altitude gauge with isolating valve.

E1.9 Minimum Water Flow Rates

Maintaining required water flow rates whilst the boiler is firing.

E1.11 Water Flow Controls

Ensuring minimum water flow is maintained with external controls.

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