Hamworthy Sherborne Series User guide

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 I2H
LPG-PROPANE I3P

HAMWORTHY HEATING LTD
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SHERBORNE 500001167/E
NOTE: THESE INSTRUCTIONS MUST BE READ & UNDERSTOOD BEFORE INSTALLING,
COMMISSIONING, OPERATING OR SERVICING EQUIPMENT.
THE SHERBORNE BOILER IS INTENDED FOR USE AS A COMMERCIAL APPLIANCE & CAN
BE OPERATED AS EITHER ROOM SEALED OR OPEN FLUE.
THIS BOILER IS FOR USE ON GROUP H NATURAL GAS (2ND FAMILY) I2H OR LPG-
PROPANE (3RD FAMILY) I3P. PLEASE ENSURE RELEVANT INFORMATION REQUIRED
WITHIN DOCUMENT IS FOUND RELATING TO SPECIFIC GAS TO BE FIRED BEFORE
FIRING BOILER.
THIS BOILER COMPLIES WITH ALL RELEVANT EUROPEAN DIRECTIVES.
EC TYPE CERTIFICATE Nos. (GAD) EC-87/01/20, (BED) BE-87/01/02.
PRODUCT IDENTIFICATION No. 87BM20.
PUBLICATION NO. 500001167
ISSUE ‘E’
AUGUST 2010
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 I2H
LPG-PROPANE I3P

HAMWORTHY HEATING LTD
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SHERBORNE 500001167/E
CONTENTS
1.0 INTRODUCTION ................................................................................................................................ 4
2.0 SUPPLY & DELIVERY....................................................................................................................... 5
3.0 SIZE & SPACE REQUIREMENTS .................................................................................................... 6
4.0 BOILER LAYOUT AND DESCRIPTION............................................................................................ 8
4.1 Accessory Pack
5.0 SITE LOCATION & PREPARATION................................................................................................. 9
5.1 Site Location
5.2 Gas Supply
5.3 Water Supply & Return
5.4 Flues
5.5 Condensate Connections
5.6 Electrical Supply
5.7 Mounting the boiler to the wall
5.8 Connection of boiler(s) to the flue system
5.8.1 Connection of Through Wall Horizontal Balanced Flue Terminal - 80/125mm
5.8.2 Connection of extended lengths of horizontal/vertical balanced flue - 100/150mm
5.8.3 Connection of twin pipe horizontal/vertical room sealed 100mm
5.8.4 Connection of twin pipe horizontal/vertical room sealed - 100mm
5.8.5 Connection of single pipe horizontal/vertical room sealed - 100mm
5.8.6 Open Vented Systems
5.8.7 Sealed Systems
5.9 Electrical Connections
6.0 PRE-COMMISIONING ...................................................................................................................................................15
6.1 Gas Supply
6.2 Ventilation
6.3 Pipework, valves & pump
6.4 Flue
6.5 Electrical
7.0 BOILER CHECKS ..........................................................................................................................................................16
7.1 Boiler Gas System Leak Check
7.2 Checks prior to lighting the boiler
7.3 Initial lighting
7.3.1 Lighting the boiler
7.3.2 Safety checks
7.3.3 Flame signal assessment
7.3.4 Adjusting the settings to the boiler
7.4 Ignition controller check
7.5 Gas supply pressure check
7.6 Combustion check
7.7 User Instructions
8.0 CONTROLS OPERATION............................................................................................................................................19
8.1 Fascia Details
8.2 Display Details
8.3 Operating Modes
8.4 Information Button
8.4.1 Extended Information Modes
8.5 Error Code Display
8.5.1 Internal Error Code Display
8.6 User Settings & Functions
8.6.1 Start-up / Initialisation
8.6.2 Users Parameter Settings
8.6.4 Functions
8.6.4.1 Chimney Sweep mode
8.6.4.2 Controller Stop mode
8.6.4.3 Time of day function
8.7.10 Display of operating phases
8.8 Control Panel Assembly
8.9 Wiring Diagram
8.10 Wiring Diagram (LMU)
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9.0 FAULT FINDING .............................................................................................................................. 29
9.1 Temperature limit thermostat
9.2 Fault finding procedures
9.3 Possible causes of boiler lockout
10.0 SERVICING ...................................................................................................................................... 30
10.2 Annual service
10.2.1 Preliminary checks & cleaning
10.2.2 Heat exchanger cleaning
10.2.2.1 SE64he
10.2.2.2 SE71c
10.2.3 Re-assembly
11.0 REPLACEMENT OF FAILED COMPONENTS ............................................................................... 32
11.1 Hot surface igniter & flame probe assembly
11.2 Flow/return sensor
11.3 Temperature limiter
11.4 Main gas valve/venture
11.5 Fan Assembly
11.6 Main Controls PCB
12.0 RECOMMENDED SPARES ............................................................................................................. 34
APPENDICES PAGE
APPENDIX A GAS DATA ............................................................................................................................. 35
APPENDIX B ELECTRICAL CONNECTIONS & CONTROLS .................................................................... 36
APPENDIX C FLUE DATA ........................................................................................................................... 38
C1.1 General Requirements
C1.2 Waste Gas Volume & Temperature
C1.3 Materials
C1.4 Suction
C1.5 Disconnection
C1.6 Flue Discharge
C1.7 Surface Temperatures
C1.8 Location
C1.9 Condense Discharge
APPENDIX D VENTILATION........................................................................................................................ 44
D1.1 Air Supply, General Requirements
D1.2 Air Supply by Natural Ventilation
D1.3 Air Supply by Mechanical Ventilation
APPENDIX E WATER DATA ....................................................................................................................... 46
E1.1 Water Circulation System
E1.2 Minimum System Water Pressure
E1.3 Pressure Relief Valve (Safety Valve)
E1.4 Open Vent & Cold Feed Pipe
E1.5 Altitude Gauge (Water Pressure Gauge)
E1.6 Thermometer
E1.7 Drain Valves
E1.8 Circulating Pump
E1.9 Minimum Water Flow Rates
E1.10 Waterside Pressure Drop
E1.11 Water Flow Controls
E1.12 Frost Protection
E1.13 Unvented Systems

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1.0 INTRODUCTION
The boiler must be installed by competent people holding 'GAS SAFE' registration or equivalent. All installations MUST
conform to the relevant Gas Safety & Building Regulations. Health & Safety requirements must also be taken into
account when installing any equipment. Failure to comply with the above may lead to prosecution.
Sherbornes are designed to use Group H Natural Gas (2nd Family) & LPG-Propane (3rd Family). Information on
propane firing in in Appendix A. Boilers MUST NOT be used with other gases. The boiler MUST only be used on a
governed supply.
The Sherborne range of boilers consists of two models:
A high efficiency SE64he with outputs of 13.6 - 64kW & a Condensing SE71c with outputs of 13.6 - 71.3kW
The boiler is fitted with a fan assisted pre-mix burner. Operation is initiated by a full sequence ignition control that
incorporates a Hot Surface Ignition system & rectification supervision of the flame across the range of outputs.
The boiler is designed for direct connection to a room sealed or conventional flue system. Data for the various flue
arrangements is given in Appendix C.
Sherborne boilers can be wall or frame mounted & are intended for the heating of Commercial/Industrial premises. They
may also be used to supply hot water for premises via an indirect cylinder. The boilers are not suitable for direct
connection to domestic hot water supplies or gravity systems.
Sherborne boilers have a low water content & water flow rates MUST be maintained at or above the recommended
levels shown in Appendix E.
Sherbornes are suitable for connection to open vented fully pumped systems & un-vented (pressurised) heating
systems. On un-vented systems have extra safety requirements which must be satisfied including interlocks which will
shut the boiler(s) off should a high or low pressure fault occur.
Pressurisation units must also incorporate a low level water switch which protects the water pumps & will cause the
boiler plant to shut down if a low water condition occur. HHL Department can provide assistance if in doubt.
In all heating installations should use some form of water treatment to reduce formation of lime scale & black iron
oxide sludge. If a pressurisation unit is used, it is prudent to include an hours run meter to give an indication of
pump running time & hence raw water make-up. Any leaks should be attended to as soon as possible to avoid
scale build up within the boiler's waterways.
Sherborne boilers can be installed in banks of up-to three units with either reverse return water flow, (optional kits
available) or with single pipe headers, (non HHL supply). See Appendix E for typical schematic layout.
HHL recommend a ‘Primary Loop’ circuit to prevent changes in system performance affecting flow through the boiler(s).
For installations of more than three units in a single bank, consult HHL Technical Department for help or assistance.
Each Sherborne boiler is supplied with volt free contact outputs for Normal Run, & General Fault, & 0~10v
analogue control input compatibility.
1.1 Options
• Flue kits - (Appendix C)
• Mounting frames for single, double & triple bank configuration (Refer to kit instructions for details)
• Optional reverse return header kits for double & triple bank configuration (Refer to kit instructions for details)
1.2 Controls peripherals
The controls system has the potential to accept the following control options:
• An external sensor which allows direct weather compensation on an individual boiler (Not for multiple systems)
• A clip-in module (LPB Bus) which allows communication with multiple boilers when used with a cascade control.
• The cascade control which allows management of up to 12 boilers, & interface with a BMS system.
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2.0 SUPPLY & DELIVERY
Your boiler is despatched to site as a tested unit. The main
boiler block is supplied in a crate, with the flue assembly &
accessories in separate cartons. Each boiler is delivered by a tail
lift vehicle & lowered to ground level. It is the installers
responsibility to convey the boiler to the plantroom.
The boiler is supplied in three packages.
- boiler assembly
- accessory pack assembly
- flue assembly
The crate is designed to be transported on site by a standard pallet truck. The package dimensions are shown in the table
below:
Reverse Return Header Sets
Where reverse return header sets are used these are packaged separately from the boilers. Ancillary items such as
isolation valves & flexible boiler connectors are packaged in a cardboard box on the same pallet. The dimensions of these
packages are shown below:
Delivery Verification
When taking delivery please ensure that you have received the correct number of boilers & ancillary packages to
fulfil your order. If any item is missing please contact our after sales service team. Please provide details of your
order such as order number & contract number as well as a detailed description of the missing item.
Header Kit Frame Kit
Model Depth Width Height Weight
Sherborne SE 64he 740mm 550mm 870mm 83kg
Sherborne SE 71c 87kg
Accessory pack 840mm 750mm 550mm 25kg
Standard Concentric Flue assy 1050mm 260mm 150mm 3kg
Model Configuration Length
mm
Weight
kg
SE 64he & 71c 2 boilers 1200 35
SE 64he & 71c 3 boilers 1200 50
SE 64he & 71c Frame 1400 20

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3.0 SIZE & SPACE REQUIREMENTS
335
268
85
35
150
450
510
720150 150
Ø30 Hole
Gas 3/4
Electric M20
Elect ric M20
Cover removal
clea ranc e
30 - Return
50 - Flow
200 - Flue
76 - Flow 140 - Flue 154 - Return
185
460
280
600
A
B800
Water connections
85
200
320
Boiler Model
Return connection
A
B
S64heE
495
Return connection
S 71cE
630
View on underside
150
150
1660
290
140
650 700
150 MIN
Condense

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The Sherborne boiler range has been designed to utilise minimum wall space, therefore it is important the plantroom has
sufficient ceiling height to allow for installation & connection to the flue system.
A minimum distance of 50mm around the flue pipe must be maintained from easily flammable materials
Also important is allowance for sufficient access at front, sides, top & bottom of boiler for flue & pipework connections.
A minimum space of 450mm in front of the boiler is required for removal of the cover.
Do not run cabling through the cover.
SE 64h e
SE 71c
RETUR N RETUR N
FLOW
FLOW
S AFE TY VALVE R
3/4
SAFETY VALVE R 3/4
FLEXIBLE HOSE
UNION c/w GASKET
Rc2”
(NOT HHL SUPPLY)
(NOT HHL SUPPLY)
MANUAL VENT R 1/2
MANUAL VENT R 1/2
(NOT HH L SU PPLY)
(NOT HHL SUPPLY)
OPTIONAL
BOILER FRAME
HHL 560202007
100 CRS 460 TO BASE OF BOILER CASING
420
77 230
100

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4. Boiler Layout & Description
4.1 Accessory Pack