Hamworthy Milborne 500 Series User manual

IMPORTANT NOTE
THESE INSTRUCTIONS MUST BE READ
AND UNDERSTOOD BEFORE INSTALLING,
COMMISSIONING, OPERATING OR
SERVICING EQUIPMENT
MILBORNE 500 SERIES
BOILERS
Wall Hung, Pre-Mix, Condensing,
Modular Boilers
Design Installation, Commissioning
and Operating Instructions
NATURAL GAS I
2H
LPG - PROPANE I
3p

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 MILBORNE 500 SERIES 500001130/A
MILBORNE 500 SERIES
BOILERS
Wall Hung, Pre-Mix, Condensing,
Modular Boilers
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 ‘A’
JUNE 2005

HAMWORTHY HEATING LTD MILBORNE 500 SERIES 500001130/A
ii
CONTENTS
PAGE
1.0 INTRODUCTION ............................................................................................................................... 1
2.0 TECHNICAL FEATURES.................................................................................................................. 2
3.0 CONSTRUCTION DETAILS & DIMENSIONS .................................................................................. 3
4.0 CONTROLS PHILOSOPHY .............................................................................................................. 4
5.0 INSTALLER INSTRUCTIONS .......................................................................................................... 5
6.0 CONDENSATE DISCHARGE ........................................................................................................... 6
7.0 PIPEWORK CONNECTIONS, MANIFOLD KITS, PUMP SELECTION............................................ 7
8.0 FLUE SYSTEM................................................................................................................................11
9.0 VENTILATION ................................................................................................................................. 16
10.0 GAS SUPPLY.................................................................................................................................. 18
11.0 POWER SUPPLY AND WIRING..................................................................................................... 18
12.0 EMERGENCY MODE ...................................................................................................................... 23
13.0 SET-UP FOR MODULAR MILBORNE INSTALLATIONS.............................................................. 24
14.0 PROGRAMMABLE ROOM THERMOSTAT ................................................................................... 27
15.0 COMMISSIONING........................................................................................................................... 29
16.0 MASTER CONTROL PANEL ERROR MESSAGES ...................................................................... 33
17.0 MASTER CONTROL PANEL DESCRIPTION ................................................................................ 37
18.0 USER’S PARAMETER MODIFICATION ........................................................................................ 38
19.0 PROGRAMMING MODE ................................................................................................................. 41
20.0 PROPANE (LPG) ............................................................................................................................ 51
21.0 CONVERTING FROM NATURAL GAS TO LPG............................................................................ 51
22.0 TECHNICAL DATA TABLES.......................................................................................................... 54
23.0 OPTIONS AND KITS....................................................................................................................... 55

HAMWORTHY HEATING LTD MILBORNE 500 SERIES 500001130/A
iii
PICTORIAL AND DIAGRAMATICAL DATA
FIGURES PAGE
Figure 3.1 Basic Dimensions...................................................................................................................... 3
Figure 5.1 Unpacking the Boiler.................................................................................................................. 5
Figure 6.1 Condensate Discharge .............................................................................................................. 6
Figure 6.2 Condensate Discharge .............................................................................................................. 6
Figure 7.1 Pipework Schematic No. 1 ......................................................................................................... 7
Figure 7.2 Pipework Schematic No. 2 ......................................................................................................... 8
Figure 7.3 Single Milborne 502 Pipework Kit ............................................................................................... 9
Figure 7.4 2 x Milborne 502 Pipework Kit .................................................................................................... 9
Figure 7.5 Flow Resistance Graph............................................................................................................ 10
Figure 8.1 Single Milborne 501 Flue Installation......................................................................................... 11
Figure 8.2 Single Milborne 502 Flue Installation......................................................................................... 11
Figure 8.3 Twin Pipe Flue Adaptation Kit................................................................................................... 12
Figure 8.4 Flue Manifold........................................................................................................................... 12
Figure 8.5 Typical Flue Placement Options ............................................................................................... 13
Figure 11.1 External Device Circuit............................................................................................................. 19
Figure 11.2 Pump Wiring Diagram.............................................................................................................. 20
Figure 11.3 Connections to an External Alarm............................................................................................. 20
Figure 11.4 Interlock Circuits ...................................................................................................................... 21
Figure 11.5 Milborne 502 Master - Wiring Diagram...................................................................................... 21
Figure 11.6 Milborne 502 Slave - Wiring Diagram........................................................................................ 22
Figure 12.1 Master Card Emergency Enable............................................................................................... 23
Figure 12.2 Master Card Emergency Enable............................................................................................... 23
Figure 12.3 Master Card Emergency Enable............................................................................................... 23
Figure 13.1 Milborne Multiple Installation..................................................................................................... 24
Figure 13.2 Setting Jumpers, Typical Example............................................................................................ 25
Figure 13.3 Example of Boiler Installation, 7 boiler Modules in same Cascade Sequence.............................. 26
Figure 13.4 Setting Up / Positioning of Room Thermostats .......................................................................... 27
Figure 15.1 Gas Valve Adjustment Points ................................................................................................... 29
Figure 15.2 Gas Inlet Pressure Test Point................................................................................................... 30
Figure 15.3.1 Analysis Point.......................................................................................................................... 30
Figure 15.3.2 LPG Flow Adjustment.............................................................................................................. 30
Figure 15.3.3 Starting the Boiler .................................................................................................................... 30
Figure 15.3.4 Control Panel Modules............................................................................................................ 31
Figure 15.3.5 Master Control Panel Controls, General Overview..................................................................... 31
Figure 15.3.6 LED Positions.......................................................................................................................... 31
Figure 15.3.8 Air Flow Adjustment................................................................................................................. 32
Figure 15.3.11 Gas Flow Adjustment............................................................................................................... 32
Figure 17.1 Control Panel Overview ........................................................................................................... 36
Figure 18.1 Changing Operating Temperature Set-Points............................................................................ 38
Figure 18.2 Entering into Monitor Mode ...................................................................................................... 39
Figure 18.3 User Level Parameters ............................................................................................................ 40
Figure 19.1 Programming Mode / Parameter Lists....................................................................................... 41
Figure 21.2 Gas Valve Air Inlet Positions .................................................................................................... 51
Figure 21.3 Venturi / Gas Valve Positions ................................................................................................... 52
Figure 21.4 Removing Venturi from Gas Valve............................................................................................ 52
Figure 21.5 Venturi Separated.................................................................................................................... 52
Figure 21.6 LPG Orifice Location................................................................................................................ 52
Figure 21.7 LPG Orifice Fitted .................................................................................................................... 52
Figure 21.8 LPG Orifice Options................................................................................................................. 53