Hamworthy S150 User manual

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
I
2H
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
I
2H
CLASS D (35 sec fuel oil)
i
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
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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
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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
to
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
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HAMWORTHY HEATING LTD SHAFTESBURY SLIMLINE 500001129/A
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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
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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
C2
VI
XI
WI

HAMWORTHY HEATING LTD SHAFTESBURY SLIMLINE 500001129/A
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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
8
4 5
6
7
3
2 1011
Boiler outlet 2” dia.
Flue Gas
Boiler inlet 2” dia.
See below

HAMWORTHY HEATING LTD SHAFTESBURY SLIMLINE 500001129/A
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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.

HAMWORTHY HEATING LTD SHAFTESBURY SLIMLINE 500001129/A
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4.3 FLUEING
•Flue termination, routing and construction must comply with the requirements of the
fourth edition of the Clean Air Act 1993, BS 6644 and IGE/UP/10.
•It is absolutely forbidden to reduce the diameter of the flue take-off between boiler and
flue.
•Any flue must be self supporting and separable from the boiler for servicing
requirements.
•Flue construction is recommended of a twin wall, insulated type to maintain buoyancy
within the flue.
•Horizontal flue runs must be kept as short as possible and be inclined at minimum 2°
towards the terminal.
•To ensure safe operation of the boiler, the chimney system shall be capable of the
complete evacuation of the products of combustion at all times.
•The effective height of the chimney termination above the boiler flue outlet must be
such as to allow sufficient buoyancy to overcome the resistance of bends, tees and
runs of the flue pipe involved and should be sited in a down-draught free zone.
•Ensure that all flue and chimney seals are good.

HAMWORTHY HEATING LTD SHAFTESBURY SLIMLINE 500001129/A
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4.4 WATER SUPPLY
•Feed and Expansion tanks to comply with static height requirements of HSE
document PM5.
•Cold feed and open vent pipes to comply with requirements of BS 6644.
•Pressurised system to comply with BS 7074.
•It is recommended that the system pipework is flushed twice before water
treatment.
•In hard water areas precautions such as water treatment should be implemented to
prevent the build up of sludge and scale.
•Leaks in the system pipework should be fixed to prevent dilution of water
treatment.
•Flow and Return pipes are Rp 2”. This size must be maintained throughout the
system.
•The drain cock is sized at Rp 3/4”
•It is forbidden for the boilers to operate unless fitted with a circulating pump.
•Circulating pumps must be selected to ensure a temperature differential of
between 5oC and 35oC
Figure 4.4 - Water Connections
Safety Valve & Manometer
Circulating Pump
Valve
Valve
Expansion Tank

HAMWORTHY HEATING LTD SHAFTESBURY SLIMLINE 500001129/A
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4.5 ELECTRICAL SUPPLY
WARNING! THIS APPLIANCE MUST BE EARTHED IN ACCORDANCE WITH IEE
REGULATIONS
•Boiler electrical supplies must not be switched by a time clock.
•Boilers are suitable for 230Volt, 50Hz supply.
•External fuses should be rated for 6 amps
•Wiring must be completed in heat resistant cable size 1.0mm² csa.
•Each boiler should have individual means of isolation.
•Electrical isolators must facilitate complete electrical isolation.
•Electrical isolators must have contact separation of minimum 3mm in all poles.
•Electrical isolators must be installed in readily accessible locations.
•Electrical supplies to boiler modules should only serve the boiler.
•Where volt free contacts are used, these too must be individually isolatable.
•Time clock control should be via the boiler modules stop/start circuit (230v).
ADDITIONAL INFORMATION REGARDING ELECTRICAL SUPPLIES IS GIVEN IN BS
EN60335, Part 1.
NOTE: The appliance must be isolated from the electrical supply if electric arc welding
is carried out on connecting pipework.

HAMWORTHY HEATING LTD SHAFTESBURY SLIMLINE 500001129/A
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5.0 BOILER ASSEMBLY
5.1 - Assembly of Cast Iron Sections
5.1.1. Select the rear section
casting. Apply mastic to all mating
edges of the casting and fit ceramic
rope as shown.
5.1.2. Select upper and lower rear nipples and apply a coating of
paste as indicated above.
5.1.3. Loosely locate nipple into position in housing
as shown above.
5.1.4. Using a 2 kg hammer gently tap the nipple into
position.

HAMWORTHY HEATING LTD SHAFTESBURY SLIMLINE 500001129/A
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5.1.5. Offer intermediate section to rear section
and push firmly into position.
5.1.6. Using a 2 kg hammer tap the
intermediate section into place.
5.1.7. Prepare the mating edges of the
intermediate section with mastic and fit
ceramic rope as shown.

HAMWORTHY HEATING LTD SHAFTESBURY SLIMLINE 500001129/A
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5.1.8. Apply ceramic rope to intermediate
section as shown.
5.1.9. Position next intermediate section
following steps 5.1.2 to 5.1.6.
NOTE: Ensure that the number stamped in
top right hand corner of casting faces
towards the front of the boiler.
5.1.12. Once all sections are in place, attach
mounting bars to top and bottom as indicated
and tighten.
5.1.10. Continue to fit intermediate sections as
previously described until the required number
of intermediate sections have been fitted.
5.1.11. Finally, following steps 5.1.5 to 5.1.6
position and fit front section.
NOTE: Ensure that the number stamped in
top right hand corner of casting faces
towards the front of the boiler.

HAMWORTHY HEATING LTD SHAFTESBURY SLIMLINE 500001129/A
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5.1.13. Fit 4 off tie rods and secure. Once
tie bars are fully tightened, remove mounting
bars and discard.
5.1.15. Fit top and bottom flanged nipples
with the bolts and washers supplied.
NOTE: Ensure that gasket is fitted before
attaching flange to casting.
5.1.14. Using ceramic rope, gasket material,
studs, nuts and washers supplied, fit flue
box to rear of boiler as shown.

HAMWORTHY HEATING LTD SHAFTESBURY SLIMLINE 500001129/A
5.1.16. Position 4 off studs in corresponding
holes in front casting.
5.1.17. Utilising these studs attach front
plate to front casting.
12
5.1.18. Select divider plates and stoppers,
fitting as shown.
Fit as follows:
S150 2 off small dividers, 2 off large dividers, 2
off stoppers.
S190 2 off small dividers, 2 off large dividers, 2
off stoppers.
S220 4 off large dividers, 2 off stoppers.
S250 4 off large dividers only.
S270 4 off large dividers only.
S290 4 off large dividers only.
5.1.19. Pictorial plan view of divider plate and stopper in
position.
Divider (large) HHL Ref: 573405571
Divider (small) HHL Ref: 573405570
Stopper.
Casting front section. HHL Ref. 573405572

HAMWORTHY HEATING LTD SHAFTESBURY SLIMLINE 500001129/A
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5.0 BOILER ASSEMBLY
5.2 - Assembly of Boiler Insulation.
5.2.1. Remove insulation from casing packaging and wrap around boiler body, taking care not to over-stretch the
insulating material as this may cause loss of heat. Secure insulation to body with straps supplied (marked A
below) in figure 5.2.1
5.2.2. Insulation securing tapes should be secured as shown in figure 5.2.2
Figure 5.2.1
Figure 5.2.2
Pull Pull

HAMWORTHY HEATING LTD SHAFTESBURY SLIMLINE 500001129/A
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5.3. Assembly of casing covers.
Upper Guide Rail
Lower Guide Rail
Figure 5.3.2 - Guide Rails Fitted
Figure 5.3.1 - Exploded View of Casing