Hamworthy UF150-1 Guide

UPTON SERIES BOILERS
Floor Standing, Condensing , Open Flue,
Fully Modulating, Pre-Mix,
Gas Fired Boilers for Heating & Domestic
Hot Water Installations
Installation, Commissioning
and Operating Instructions
Models:
UF100-1, UF150-1, UF200-1, UF250-1, UF300-1 UF350-1
UF200-2, UF300-2, UF400-2, UF500-2, UF600-2 UF700-2
UF300-3, UF450-3, UF600-3, UF750-3, UF900-3 UF1050-3
NATURAL GAS I2H
LPG Propane I3P
IMPORTANT NOTE
THESE INSTRUCTIONS MUST BE READ AND
UNDERSTOOD BEFORE INSTALLING,
COMMISSIONING, OPERATING OR SERVICING
EQUIPMENT

Technical Enquiries
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
Hamworthy offer a service of site assembly for many of our products where plant room access 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
Commissioning of equipment by our own engineers, accredited agents or specialist sub-contractors will ensure the equipment is
operating safely and efciently.
Service Contracts
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 efciency. Service contracts enable you to plan and budget more efciently.
Breakdown service, repair, replacement
Hamworthy provide a rapid response breakdown, repair or replacement service through head ofce at Poole and accredited
agents throughout the UK.
Spare Parts
We offer a comprehensive range of spare parts, providing replacement parts for both current and discontinued products. Delivery
options are available to suit you. Please refer to our website for more details.
Telephone: [phone] E-mail: [email protected] Fax: [phone]
Customer After Sales Services

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UPTON FLOOR STANDING SERIES 500001340/C
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NOTE: THESE INSTRUCTIONS MUST BE READ AND UNDERSTOOD BEFORE
INSTALLING, COMMISSIONING, OPERATING OR SERVICING EQUIPMENT.
THE UPTON BOILER IS INTENDED FOR USE AS A COMMERCIAL APPLIANCE AND IS NOT
CERTIFIED FOR USE IN DOMESTIC APPLICATIONS.
THIS BOILER IS FOR USE ON GROUP H NATURAL GAS (2ND FAMILY) I2H AND LPG
PROPANE (3RD FAMILY) I3P. PLEASE ENSURE RELEVANT INFORMATION REQUIRED
WITHIN DOCUMENT IS FOUND BEFORE FIRING BOILER.
COUNTRY OF DESTINATION : UNITED KINGDOM & REPUBLIC OF IRELAND
THIS BOILER COMPLIES WITH ALL RELEVANT EUROPEAN DIRECTIVES.
PRODUCT IDENTIFICATION No. 86CS33
PUBLICATION NO. 500001340
ISSUE C
MONTH August 2017
UPTON SERIES BOILERS
Floor Standing, Condensing , Open Flue,
Fully Modulating, Pre-Mix,
Gas Fired Boilers for Heating & Domestic
Hot Water Installations
Installation, Commissioning
and Operating Instructions
Models:
UF100-1, UF150-1, UF200-1, UF250-1, UF300-1 UF350-1
UF200-2, UF300-2, UF400-2, UF500-2, UF600-2 UF700-2
UF300-3, UF450-3, UF600-3, UF750-3, UF900-3 UF1050-3
NATURAL GAS I2H
LPG Propane I3P

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CONTENTS
PAGE
1.0 INTRODUCTION ................................................................................................................................ 1
2.0 SUPPLY AND DELIVERY.................................................................................................................. 3
3.0 SIZE AND SPACE REQUIREMENTS ............................................................................................... 5
4.0 SITE LOCATION AND PREPARATION.......................................................................................... 13
4.1 Site Location
4.2 Gas Supply
4.3 Flue System
4.4 Water Supply - including heat exchanger warranty conditions
4.5 Condensate Connections
4.6 Electrical Supply
5.0 BOILER ASSEMBLY ....................................................................................................................... 18
5.1 General
5.2 Water Connections
5.3 Flue Connections
5.4 Sealed Systems
5.5 Electrical Connections
6.0 PRE-COMMISSIONING ................................................................................................................... 19
6.1 Gas Supply
6.2 Ventilation
6.3 Pipework, Valves and Pump
6.4 Flue
6.5 Electrical
7.0 CHECKS PRIOR TO LIGHTING ...................................................................................................... 21
7.1 Boiler Gas System Leak Check
7.2 Checks Prior to Lighting the Boiler
7.3 Commissioning the Boiler
8.0 INITIAL LlGHTING ........................................................................................................................... 22
8.1 Operational Checks
8.2 Controls Operation
8.3 Ignition Controller Check
8.4 Gas Pressure Check
8.5 Combustion Checks
8.6 User Instructions
9.0 FAULT FINDING .............................................................................................................................. 28
9.1 Safety Temperature Limiter (Limit Thermostat)
9.2 Ignition Controller
9.3 Water Flow Switch
10.0 SERVICING ...................................................................................................................................... 30
11.0 REPLACEMENT OF FAILED COMPONENTS ............................................................................... 32
12.0 RECOMMENDED SPARES ............................................................................................................. 34

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PAGE
APPENDICES
APPENDIX A GAS DATA............................................................................................................................. 33
APPENDIX B ELECTRICAL CONNECTIONS AND CONTROLS............................................................... 34
APPENDIX C FLUE DATA ........................................................................................................................... 36
APPENDIX D VENTILATION........................................................................................................................ 39
APPENDIX E WATER DATA ....................................................................................................................... 41
PICTORIAL AND DIAGRAMATICAL DATA
Figure 2.1 Boiler Packaging....................................................................................................................... 3
Figure 2.2 Boiler Package Dimensions ..................................................................................................... 4
Figure 3.1.1 Dimensions and clearances UF100—UF150........................................................................... 5
Figure 3.1.2 Dimensions and clearances UF200—UF250........................................................................... 6
Figure 3.1.3 Dimensions and clearances UF300—UF350........................................................................... 7
Figure 3.2.1 Primary circuit and Gas Manifold pipe kit................................................................................. 8
Figure 3.2.2 UF100 & UF150 2MW Primary circuit and Gas manifold pipe kit ............................................ 9
Figure 3.2.3 UF200 & UF250 3MW Primary circuit and Gas manifold pipe kit ......................................... 10
Figure 3.2.4 UF300 & UF350 2MW Primary circuit and Gas manifold pipe kit .......................................... 11
Figure 3.2.5 UF300 & UF350 4MW Primary circuit and Gas manifold pipe kit .......................................... 12
Figure 3.3 Pipe kit data............................................................................................................................ 13
Figure 4.2 Gas connection....................................................................................................................... 13
Figure 4.4 Water connections.................................................................................................................. 15
Figure 4.5.1 Boiler condensate connection ................................................................................................ 16
Figure 4.6 Navistem Electrical Connections............................................................................................ 17
Figure 7.1 Gas system leak check .......................................................................................................... 20
Figure 7.2.1 On / OFF Switch ..................................................................................................................... 21
Figure 8.3.1 Operating phases ................................................................................................................... 23
Figure 8.5.1 Combustion analyser probe setting........................................................................................ 24
Figure 8.5.2 Insertion of analyser probe..................................................................................................... 24
Figure 8.5.3 Combustion settings ............................................................................................................... 25
Figure 8.5.4 General overview of boiler controls ........................................................................................ 27
Figure 9.3.1 Wiring Schematic.................................................................................................................... 29
Figure 10.2.1 Spark electrode position ......................................................................................................... 31
Figure 10.2.2 Flame sensing probe position ................................................................................................ 31
Figure 11.11 Air Pressure switch................................................................................................................. 33
Figure 11.12 Air Filter media ....................................................................................................................... 33

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APPENDIX PAGE
Figure A1 Gas Data ................................................................................................................................ 35
Figure A2 General Data .......................................................................................................................... 35
Figure A3 Product information - ErP Regulation (813/2013) ................................................................. 36
Figure B1 Electrical Supply..................................................................................................................... 37
Figure B1.2 External Control Wiring for Multiple Boiler Installation ........................................................... 38
Figure B1.3 Sensor resistance values ....................................................................................................... 39
Figure C1 Flue Data ................................................................................................................................ 40
Figure D1 Mechanical Ventilation Flow Rates ........................................................................................ 44
Figure E1 Water Data ............................................................................................................................. 44
Figure E1.1 Hydraulic Resistance.............................................................................................................. 44
Figure E1.3.1 Schematic 1 - External time clock enabled boiler .................................................................. 47
Figure E1.3.2 Schematic 2 -Two heating circuits with DHW & boiler shunt pump ....................................... 47
Figure E1.3.3 Schematic 3 - Master and slave sequence control with reverse return primary .................... 48
Figure E1.3.4 Schematic 4 - Reverse return primary circuit ......................................................................... 48
Figure E1.3.5 Schematic 5 -Primary circuit with individual boiler shunt pumps ........................................... 49
Figure E1.3.6 Schematic 6 - Reverse return primary circuit with individual motorised boiler isolation ........ 49

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UPTON FLOOR STANDING SERIES 500001340/C
1.0 INTRODUCTION
1.1 This boiler must be installed by a competent person. Please read the technical and user instructions before installing
and lighting the boiler. All installations MUST conform to the relevant Gas Safety and 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.
This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental
capabilities, or lack of experience and knowledge, unless they have been given supervision or instructions
concerning cleaning, maintenance and use of the appliance by a person responsible for their safety. Children
should be supervised to ensure that they do not play with the appliance.
1.2 This boiler is intended for use on Group H Natural Gas (2nd Family) I2H or LPG Propane (3rd Family) I3P.The firing
information is to be found in Appendix ‘A’. Boilers MUST NOT use gas other than that for which they are designed and
adjusted.
1.3 The Upton is a gas fired, fully modulating, condensing, fan assisted, open flued central heating / hot water boiler. Using
the latest gas / air ratio control technology it is able to provide clean efficient operation across a large output range.
1.3.1 The boiler can be supplied in a modular format, a maximum of three vertically stacked modules being arranged into
a single unit sharing a common flue.
1.3.2 Each boiler module utilises a metal fibre, fan assisted, pre-mix burner.
1.3.3 Operation is initiated and controlled by a Navistem boiler management system with a user interface LCD display for
accessing and changing boiler parameters.
1.3.4 Each of the boiler models is designed for direct connection to a flue system. The Technical Data is given in
Appendix ‘C’. The flue outlets from more than one unit may be connected to a single chimney.
No draught diverter is fitted to the boiler nor is a fixed diverter required in the flue system. However a draught stabiliser
may be required for some installations.
1.3.5 The Upton is floor mounted and is intended for the heating of Commercial and Industrial premises.
It may also be used to supply hot water for these premises via an indirect cylinder.
1.3.6 The Upton has a low water content and water flow rates MUST be maintained at or above the recommended levels
shown in Appendix ’E’.
1.4 This boiler must be connected an un-vented (pressurised) heating system, it must not be used on open vented
systems. Care must be taken to ensure all extra safety requirements are satisfied and that the relevant interlocks will shut
the boiler(s) off should a high or low pressure fault occur.
1.4.1 The pressurisation unit must also incorporate a low level water switch which protects the water pumps and will
directly or indirectly shut down the boiler plant should a low water condition occur.
1.4.2 Consideration should also be given to the maximum working pressure of the boiler as given in Appendix ’E’.
Consult Hamworthy Heating Technical Department for help or assistance if in doubt.
1.5 The Upton boiler is not suitable for direct connection to domestic hot water supplies.
1.6 The Upton boiler can be installed with reverse return water flow, (optional HHL pipe kits are available, complete with
individual shut pumps and low loss header for up to 12 modules in two or three vertically stacked units). See Appendix ‘E’,
figure E1.1 for typical schematic layouts
1.7 Regulatory disposal and managed recycling of this product can prevent damage to the environment and
health risks.
a) For the disposal of the product and the component parts, the services of an accredited waste disposal
company should be used.
b) For more information on waste disposal/management, contact the Local Authority responsible for waste
management or the point of sales where the product was purchased.

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UPTON FLOOR STANDING SERIES 500001340/C
1.8 BOILER MODELS
1, 2 or 3 high models
Upton UF100-1 ......................................... Single 100kW module
Upton UF200-2 ......................................... Two 100kW vertically stacked modules
Upton UF300-3 ......................................... Three 100kW vertically stacked modules
Upton UF150-1 ......................................... Single 150kW module
Upton UF300-2 ......................................... Two 150kW vertically stacked modules
Upton UF450-3 ......................................... Three 150kW vertically stacked modules
Upton UF200-1 ......................................... Single 200kW module
Upton UF400-2 ......................................... Two 200kW vertically stacked modules
Upton UF600-3 ......................................... Three 200kW vertically stacked modules
Upton UF250-1 ......................................... Single 250kW module
Upton UF500-2 ......................................... Two 250kW vertically stacked modules
Upton UF750-3 ......................................... Three 250kW vertically stacked modules
Upton UF300-1 ......................................... Single 300kW module
Upton UF600-2 ......................................... Two 300kW vertically stacked modules
Upton UF900-3 ......................................... Three 300kW vertically stacked modules
Upton UF350-1 ......................................... Single 350kW module
Upton UF700-2 ......................................... Two 350kW vertically stacked modules
Upton UF1050-3 ....................................... Three 350kW vertically stacked modules
1.9 The fully assembled unit is supplied covered with a protective sleeve. The flue assemblies for the stacked models are
supplied separate packs.
1.10 Each Upton module can be controlled by a 0-10V analogue control input capability which is available via the
Navistem boiler control.
1.11 Options - refer to individual kit instructions for details
1.11.1 Optional water pipe work kits are available for two or three high vertical units for up to 12 modules. These kits are
free-standing allowing installation to the system prior to installing the boiler and incorporate all necessary valves, inter
connecting pipework, and flow and return headers. Refer to individual kit instructions for details.
1.11.2 Controls peripherals
The Navistem boiler management system has the potential to accept the following control options:
1.11.2.1 Clip in Fault Alarm & Run Signal AGU2.550A109
Optional kit for a Run/Fault signal.
(available as a kit from Hamworthy Heating Ltd)
Kit Part No. 563605666
1.11.2.2 Clip in LPB Bus comms OCI345
LPB sequencing of the cascade controlled by Merley / RVS
(available as a kit from Hamworthy Heating Ltd)
Kit Part No. 563605667
1.11.2.3 Additional kits available from Hamworthy Heating :
1 Zone Heating Circuit Kit - 563605692
2 Zone Heating Circuit Kit - 563605693
3 Zone Heating Circuit Kit - 563605694 (Note: cannot be used in conjunction with Fault Alarm & Run Signal Clip-In Kit)
Additional Heating Circuit Kit - 563605673
Outside Air Temperature Sensor - 533901457
Room Sensor QAA55 - 563605696
Room Sensor QAA75 - 563605695
Merley Sequence Controller - Loose Kit 563605671 or Fully Assembled 563605672
(Allows cascade management of up to 16 boilers, and interface with a BMS system)

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UPTON FLOOR STANDING SERIES 500001340/C
2.0 SUPPLY AND DELIVERY
The boiler is despatched to site as a pre-assembled and tested unit. Each boiler is delivered by a tail lift vehicle
and lowered to ground level. It is the installers responsibility to convey the boiler to the plantroom and to remove it
from the pallet.
NOTE: The Upton boilers MUST not be stacked. When handling and manoeuvring the boiler care must be taken
to avoid damage to the casing. The flue system is packaged separately.
The boiler must be kept upright during handling.
The flue manifold connecting the vertical modules is supplied separately to the boiler .
Warranty
Full warranty assistance will be covered when the appliance is commissioned by Hamworthy Heating Ltd, see
Terms & Conditions for full details.
Hamworthy Heating Ltd will not accept any liability resulting from damage due to tampering, improper
use, handling, installation errors, operation and maintenance. It is important to check for damage upon
receipt of product, which if found must be notified to Hamworthy Heating Ltd immediately.
In the event of failure or breakdown, isolate the equipment and contact Hamworthy Technical Support
Tel - 0845 450 2866
Figure 2.1 - Boiler Packaging

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UPTON FLOOR STANDING SERIES 500001340/C
Figure 2.2 - Boiler Packaged Dimensions
Delivery Verification
When taking delivery please ensure that you have received the correct number of boilers and individual flue kits 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 and contract number as well as a detailed description of the missing item.
Frame Set and Pipe work Header Kits
Where pipe work kits are supplied, these are packaged separately from the boilers. All ancillary items such as
isolation valves and boiler make-up connectors are factory fitted and tested The whole is shrink wrapped for security and
basic protection. Refer to Kit instructions 500005162
Model H mm W mm D mm Weight (kg)
UF100-1922 1000 1200 152
UF200-21536 1000 1200 286
UF300-32150 1000 1200 420
UF150-1922 1000 1200 177
UF300-21536 1000 1200 336
UF450-32150 1000 1200 495
UF200-1922 1000 1200 220
UF400-21536 1000 1200 422
UF600-32150 1000 1200 624
UF250-1922 1000 1200 247
UF500-21536 1000 1200 476
UF750-32150 1000 1200 705
UF300-1922 1000 1400 287
UF600-21536 1000 1400 551
UF900-32150 1000 1400 815
UF350-1922 1000 1400 310
UF700-21536 1000 1400 597
UF1050-32150 1000 1400 884
Flue manifold 700 500 500 11

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UPTON FLOOR STANDING SERIES 500001340/C
1800
Minimum clearances
700
1450
2200
50
20
2017
582
1990 Flue
380 Flue 754
940
76
Drain
120
114Drain 206Flue
323
Gas
338
Return
741 Flow
1551 Gas
1566 Return
1969 Flow
341
Flue
91 Flue
155 Flue
58.5Gas
173 Flow & Return
Flow R 2-11
Return R 2-11
Gas R 1 1/4-11
Flue O130
Flue O200
Relief Valve G3/4
Not supplied
350Flow & Return
624Gas
400 400
1300
750 750
Minimum boiler to boiler spacing
3 Modules high
2 Modules high
1 Module high 57 Relief valve
866
614
175
789
1376 Flue
1403
234 Drain
937 Gas
977 Return
1380 Flow
Figure 3.1.1 - Dimensions and Clearances UF100 & 150
3.0 SIZE AND SPACE REQUIREMENTS
3.1 The Upton boiler range has been designed to utilise minimum floor space, therefore it is important that the plant room
has sufficient ceiling height to allow for installation and connection to the flue system allowing for sufficient access at sides
and behind boiler for pipe work connections. See Figure 3.1

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UPTON FLOOR STANDING SERIES 500001340/C
Figure 3.1.2 - Dimensions and Clearances UF200 & 250
Minimum boiler to boiler spacing
400
400
1300
1800
Minimum clearances
700 50
1450
2200
750 750
940
20
614
789
76
Drain
58.5Gas
57 Relief valve
173 Flow & Return
Relief Valve G3/4
Not supplied
341
Flue
582
120
323
Gas
338
Return
741 Flow
624Gas
350Flow & Return
206Flue
114Drain
Flow R 2-11
Return R 2-11
Flue O130
Gas R 1 1/4-11
1 Module high
2 Modules high
3 Modules high
Flue O250
1034 Flue
866
175
381 Flue 942
2017
1990 Flue
155 Flue
1551 Gas
1566 Return
1969 Flow
1403
234 Drain
937 Gas
952 Return
1355 Flow
1376 Flue

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UPTON FLOOR STANDING SERIES 500001340/C
Figure 3.1.3 - Dimensions and Clearances UF300 & 350
1300
Minimum boiler to boiler spacing
Minimum clearances
400
400
1800
700 50
1450
2200
750 750
1 Module high
2 Modules high
3 Modules high
Flue O300
2017 Flow
2080 Flue
381 Flue 1128
1403
234 Drain
954 Gas
952 Return
1355 Flow
1466 Flue
155Flue
1551 Gas
1549 Return
1969 Flow
Flue O130
Gas R 1 1/4-11
Flow R 2-11
Return R 2-11
624Gas
350Flow & Return
741 Flow
338
Return
323
Gas
120
582
206Flue 114Drain
865
789
614
175
20
1127
76
Drain
341
Flue
58.5Gas
173 Flow & Return
39 Relief valve
1220 Flue
Relief Valve G3/4
Not supplied
UF350 = 100
UF300 = 155
UF350 = 450
UF300 = 381
UF350 = 2118 UF300 = 2080
UF350 = 1504 UF300 = 1466

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UPTON FLOOR STANDING SERIES 500001340/C
3.2 The Hamworthy Heating Ltd pipe work kit is designed to provide a complete primary circuit system for two and three
high stacked modules. Multiple stacked units can be connected together to provide large output arrays. See the following
pages for the size and number of modules that can be connected together. There is no pipe work kit option for single
boilers modules. The basic kit consists of a flow and return manifold to which can be fitted a combined low loss header
and dirt air separator, blanking flanges and a secondary manifold for three heating circuits.
• The flow and return manifold is supplied with matched primary circuit pumps, isolating valves, gas manifold,
condensate drain and boiler safety relief valves. An automatic air vents is fitted to the top of the flow header and
the vertical flow and return manifold have connection points for flushing the system, plus drain and air bleed valves.
Flexible hoses connect the manifold to the flow and return ports on the boilers. Non return valves on the pump
supply prevent reverse flow through non firing modules.
• The combined low loss header and dirt air separator has an adjustable support stand, sensor pockets in the flow
and return ports to control the mixed flow temperature, automatic air vent and drain valve for sludge removal. The
low loss header can be fitted to either the side of the flow and return pipe kit using the flanged pipes supplied.
• Blanking flanges for the flow and return headers are provide with connection points for system safety relief valve in
the top flange and for an expansion vessel and/ or pressurisation unit in the lower flange.
• The secondary circuit manifold allows for up to three separate heating circuits to be connected to the low loss
header. Fixing bolts and gaskets are provided with the manifold.
Figure 3.2.1 – Primary circuit and Gas manifold pipe kit
Secondary
circuit manifold
Combined low loss header
and dirt air separator
Flow and return manifold kit Blanking flange
Gas manifold

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UPTON FLOOR STANDING SERIES 500001340/C
Flow & Return DN100 PN16
Condensate pipe O34
Gas ManifoldDN65
G1.5" Pressurisation unit
& Expansion Vessel
R3" System SafetyRelief Valve
2253
1943
1643
187
1029
668 400
1658
1348
144
76
1985
1230
7501006573
804
349
236
Figure 3.2.2 – UF100 & UF150 2MW Primary circuit and Gas manifold pipe kit
UF100 & UF150 DN100 2MW Primary circuit and Gas
manifold pipe kit
The pumps are sized to allow 12 modules in two or
three high stacks to be connected together to form the
primary circuit.

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UPTON FLOOR STANDING SERIES 500001340/C
Figure 3.2.3 – UF200 & UF250 3MW Primary circuit and Gas manifold pipe kit
Flow & Return DN150 PN16
Condensate pipe O34
Gas ManifoldDN65
R3" System SafetyRelief Valve
G1.5" Pressurisation unit
& Expansion Vessel
773 1006 750
174 1388
1753
76
668 400
1029
2314
1948
1643
184
347
2342
1399
805
325
UF200 & UF250 DN150 3MW Primary circuit and Gas
manifold pipe kit
The pumps are sized to allow 12 modules in two or
three high stacks to be connected together to form the
primary circuit.

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UPTON FLOOR STANDING SERIES 500001340/C
Figure 3.2.4 – UF300 & UF350 2MW Primary circuit and Gas manifold pipe kit
Flow & Return DN150 PN16
Condensate pipe O34
Gas ManifoldDN65
R3" System SafetyRelief Valve
G1.5" Pressurisation unit
& Expansion Vessel
805
347
2314
1948
1753
174 1388
76
668 400
184
7501006773
2528
1399
1029 1643
325
UF300 & UF350 DN150 2MW Primary circuit and Gas
manifold pipe kit
The pumps are sized to allow 6 modules in two or
three high stacks to be connected together to form the
primary circuit.

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UPTON FLOOR STANDING SERIES 500001340/C
Figure 3.2.5 – UF300 & UF350 4MW Primary circuit and Gas manifold pipe kit
Flow & Return DN200 PN16
Condensate pipe O34
Gas ManifoldDN65
G1.5" Pressurisation unit
& Expansion Vessel
1753
209 1326
76
668 400
2408
1643
184
7501006873
802
347
2527
1399
1029
391
210
R3" System SafetyRelief Valve
1981
UF300 & UF350 DN200 4MW Primary circuit and Gas
manifold pipe kit
The pumps are sized to allow 12 modules in two or
three high stacks to be connected together to form the
primary circuit.

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UPTON FLOOR STANDING SERIES 500001340/C
4.0 SITE LOCATION AND PREPARATION
4.1 Site Location.
• In the event that the boiler cannot be moved on a pallet truck, the four M8 bolts retaining the top cover can be
replaced with M8 lifting eyes and using suitable lifting slings hoisted into position.
IMPORTANT: lifting of single modules only is permitted by using the M8 lifting eye fixing positions provided.
DO NOT LIFT THE BOILER BY THE CASING PANELS!
• The floor or plinth for the boilers and pipe work kit 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 and pipe work kit where used.
• The floor or plinth must be fireproof in accordance with BS 6644.
• The plant room must have sufficient space for installation of boilers, pipe work, pumps controls, flues ventilation,
access and servicing and other items of plant.
Figure 4.2 - Gas Connection Point
Gas connection
M8 Lifting eye fixing positions.
Boiler Model UF100/150 UF200/250 UF300/350 UF300/350
Stack size 3 high 2 high 3 high 2 high 3 high 2 high 3 high 2 high
Number of modules 12 12 612
Maximum output @ 20°C ΔTMW 1.8 3.0 2.0 4.0
Maximum pressure bar 6
Minimum pressure bar 1.0 1.2 1.5 1.5
Maximum flow rate Kg/s 21.5 35.8 25.1 50.2
Weights
Flow and return manifold kit kg 207 156 282 212 317 235 351 270
Low loss header and pipe work kg 131 124 336 325 336 325 438 416
Secondary circuit manifold kit kg 59 106 106 158
Blanking flanges kit kg 15 28 28 43
Water content
Flow and return manifold l36 27 65 50 65 50 87 73
Low loss header and pipe work l40 34 100 88 100 88 169 148
Figure 3.3 - Pipe Kit Data

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UPTON FLOOR STANDING SERIES 500001340/C
4.2 Gas Supply.
• Gas supply pipes must be in accordance with BS 6891 or IGE/UP/2
• Gas supply connections to the boiler must not be smaller than the connection on the boiler - R1¼” all models.
• 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.
• Boiler inlet gas pressure; nominal 20mbar (minimum 17.5mbar) for Natural Gas or nominal 37 mbar (minimum
25mbar) for LPG dynamic at the connection to the boiler.
• Boiler house gas isolation valve must be clearly identified and installed close to the entrance / exit.
4.3 Flue System
• Flue termination, routing and construction must comply with the requirements of the Clean Air Act 1993, BS 6644,
BS 5440 and IGE/UP/10 where applicable.
• Upton boilers installed in modular format with a common flue, must use the manifold provided with the boiler prior to
any connection to the flue system which must be suitable for condensing application.
• Upton boilers are suitable for open flue (type B23P) installation, drawing combustion air from the plant room. The
maximum number of modules firing into a common chimney is 8. The flue system must be designed to limit the max.
suction to 100Pa (negative), measured at the flue sample point of the base module in the boiler stack. This condition
must be checked hot and with all boilers firing, the max. pressure at the flue sample point should not exceed those
stated in Appendix C Fig C1 - Flue data.
• Any stabiliser fitted must be in or close to the vertical chimney.
• Due to the low flue gas temperature, (~50°C) condensation will occur in the flue, flue materials must be non-
corrosive and utilise fully sealing joints.
• Flue construction is recommended of a twin wall, insulated type to maintain buoyancy within the flue.
• Adequate facilities must be provided for draining the flue condensation.
• Horizontal flue runs must be kept as short as possible and be inclined at minimum 3° (50mm/m) towards the boiler.
For maximum equivalent flue lengths, refer to Appendix C.
• Any flue must be self-supporting and separable from the boiler for servicing requirements.
• Note: Due to high thermal efficiency of the Upton boiler and the resultant low flue gas temperatures there will be
visible pluming of the flue gases at the flue termination. This is likely even when the boiler is not operating at
condensing temperatures.
• Fan dilution - the design must provide for the use of balancing and trim dampers, and their location and
operation must be such that the constraints detailed above can be met. Care must be taken to ensure that
the fan performance is matched to deliver the appropriate dilution, whilst ensuring that excessive suction is
not applied to the boilers. If in doubt, refer to HHL Technical.
• Fan assist - the use of fan assist is not recommended as the boilers have sufficient fan performance to drive
the system. If in doubt, refer to HHL Technical.