Hamworthy 563216020 User guide

Chesil - Electronic
Pressurisation Unit
Equipment For Commercial/Light Industrial
Central Heating Installations.
Installation, Commissioning
and Servicing Instructions
IMPORTANT NOTE
THESE INSTRUCTIONS MUST BE READ
AND UNDERSTOOD BEFORE INSTALLING,
COMMISSIONING, OPERATING OR
SERVICING EQUIPMENT

HAMWORTHY HEATING LTD
CHESIL-ELECTRONIC 500001181/K
i
NOTE: THESE INSTRUCTIONS MUST BE READ AND UNDERSTOOD BEFORE
INSTALLING, COMMISSIONING, OPERATING OR SERVICING EQUIPMENT.
THE CHESIL - ELECTRONIC PRESSURISATION UNITS ARE INTENDED FOR USE ONLY
IN COMMERCIAL/LIGHT INDUSTRIAL APPLICATIONS.
THESE PRESSURISATION UNITS COMPLY WITH THE ESSENTIAL REQUIREMENTS OF THE MACHINERY DIRECTIVE 89/392/EEC
AMENDED BY 91/368/EEC, THE LOW VOLTAGE DIRECTIVE 2006/95/EC AND THE ELECTROMAGNETIC COMPATIBILITY DIRECTIVE
2004/108/EC.
PUBLICATION NO. 500001181
ISSUE ‘K’
FEBRUARY 2015
Chesil
Pressurisation Units
(Electronic Control)
Installation, Commissioning
and Servicing Instructions

HAMWORTHY HEATING LTD
CHESIL-ELECTRONIC 500001181/K
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CONTENTS PAGE
1.0 INTRODUCTION ................................................................................................................................1
2.0 TECHNICAL DATA............................................................................................................................1
3.0 SEALED SYSTEM FUNCTION..........................................................................................................2
3.1 Terminology........................................................................................................................................2
3.2 Application ..........................................................................................................................................3
4.0 OPERATION OF THE PRESSURISATION UNIT..............................................................................4
4.1 Unit Operation.....................................................................................................................................4
5.0 GENERAL REQUIREMENTS ............................................................................................................4
5.1 Related Documents............................................................................................................................4
5.2 Mains Water Connections...................................................................................................................5
5.3 Expansion Vessels .............................................................................................................................5
5.4 Safety Relief Valve .............................................................................................................................5
6.0 INSTALLATION..................................................................................................................................6
6.1 Location ..............................................................................................................................................6
6.2 Pipework Connections........................................................................................................................6
6.3 Electrical Connection..........................................................................................................................8
6.4 Electrical Connection To The User Terminals....................................................................................8
6.5 Operation of the Controller .................................................................................................................8
6.6 Trouble Shooting ................................................................................................................................8
6.7 Standard Menu Display ......................................................................................................................8
6.8 Maintenance Menu Display ................................................................................................................8
6.9 Alarms...............................................................................................................................................10
6.10 Factory Default Settings ...................................................................................................................11
7.0 COMMISSIONING............................................................................................................................12
7.1 Mechanical Installation .................................................................................................................... 12
7.2 System Flushing ...............................................................................................................................12
7.3 Electrical Installation.........................................................................................................................12
7.4 System Expansion Vessel................................................................................................................12
7.5 Initial Setting of Unit..........................................................................................................................13
7.6 Filling the Unit...................................................................................................................................13
7.7 Pump Spindle Access Hole………………………………………………………………………………...14
8.0 FAULT FINDING ..............................................................................................................................15
9.0 SERVICING SCHEDULE.................................................................................................................16
9.1 6 Monthly ..........................................................................................................................................16
9.2 12 Monthly ........................................................................................................................................16
9.3 4 Yearly.............................................................................................................................................16
10.0 SERVICING AND REPLACEMENT OF COMPONENTS................................................................17
10.1 Hamworthy Heating Recommended Spares....................................................................................17
10.2 Pump Replacement..........................................................................................................................17
10.3 Pressure Sensor Replacement.........................................................................................................18
10.4 Replacement Of Control Box Assembly On Wall Mounted Unit.......................................................18
10.5 Replacement Of Controls PCB Wall Mount & Floor Standing Units ................................................19
10.6 Replacement Of Display PCB Wall Mount Unit................................................................................19
10.7 Replacement Of Display PCB Floor Standing Unit .........................................................................20
10.8 Low Water Level Switch Replacement.............................................................................................20
10.9 Inlet Valve Replacement...................................................................................................................21
10.10 Non-Return Valve Replacement ......................................................................................................21
11.0 Frost Protection Kit (optional accessory kit) ....................................................................................22
APPENDIX ‘A’ – Diagrams, drawings and Data................................................................................................23

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FIGURES PAGE
Figure 1 Part Numbers...................................................................................................................................... 1
Figure 2 Basic Overall Dimensions................................................................................................................... 1
Figure 3 Technical Data.................................................................................................................................... 2
Figure 4 Typical System Schematic Layout...................................................................................................... 3
Figure 5 Expansion Vessel Operation.............................................................................................................. 3
Figure 6 Schematic Layout .............................................................................................................................. 4
Figure 7 Hamworthy Heating Expansion Vessels ............................................................................................ 5
Figure 8 Recommended Clearance Dimensions.............................................................................................. 6
Figure 9 Wall Mounting Bracket Dimension ..................................................................................................... 6
Figure 10 Wall Mounting Pipework Dimensions................................................................................................. 7
Figure 11 Floor Standing Pipework Dimensions ............................................................................................... 7
Figure 12 Restrictor Inserts ...…….....………………………………………………………………………………..13
Figure 13 Changing Restrictor Inserts ………………………………………………………………………...…….13
Figure 14 Float Adjustment ...………....…………………………………………………………………………...…13
Figure 15 Priming Screw ...………....……………………………………………………………………………...13
Figure 17 Fault Finding Guide.......................................................................................................................... 15
Figure 18 Pump Removal................................................................................................................................. 17
Figure 19 Pump Removal................................................................................................................................. 17
Figure 20 Pump Removal................................................................................................................................. 17
Figure 21 Pressure Sensor .............................................................................................................................. 18
Figure 22 Location Of Sensor........................................................................................................................... 18
Figure 23 Control Box....................................................................................................................................... 18
Figure 24 Controller Terminals......................................................................................................................... 18
Figure 25 Main Control PCB............................................................................................................................. 19
Figure 26 Display PCB ..................................................................................................................................... 19
Figure 27 Location Of Display PCB On Floor Standing Unit............................................................................ 20
Figure 28 Removal Of Inclined Panel............................................................................................................... 20
Figure 29 Disassembly Of Display PCB Enclosure ......................................................................................... 20
Figure 30 Assembly Of Display PCB In Enclosure........................................................................................... 20
Figure 31 Level Switch In Tank ........................................................................................................................ 21
Figure 32 Level Switch Supplied As Spare.. .................................................................................................... 21
Figure 33 Non-Return Valve Assembly ............................................................................................................ 21
Figure 34 Non-Return Valve Fitting Location On Pump................................................................................... 21
Figure 35 Frost Protection Kit (Optional).......................................................................................................... 22
Figure 36 Frost Protection Kit Installed (Optional)............................................................................................ 22
Figure A1 Frost Protection Kit Wiring Diagram................................................................................................. 23
Figure A2 Main Wiring Diagram........................................................................................................................ 24
Figure A3 Heating System Calculation Sheet................................................................................................... 25

HAMWORTHY HEATING LTD 1
CHESIL-ELECTRONIC 500001181/K
1.0 INTRODUCTION
The WSE, FSE & FTE models in the Hamworthy Chesil range of pressurisation unit are designed to maintain the
minimum pressure requirement of modern low/medium temperature, sealed central heating systems. The
pressurisation units also provide replacement water for losses from the system.
Note! The pressurisation units are not to be used to fill the system from empty.
Figure 1 - Part Numbers
The Chesil units are housed in a powder coated steel cabinet with removable cover. Housed in the cabinet is a
pump, connecting pipe-work and pressure sensor. This sensor is connected to an electronic controller housed in a
moisture proof enclosure. The controller switches the pump on or off to maintain the user defined pressure in the
sealed system. In the top of the cabinet is the header tank, with a float valve to be connected to the water mains.
The pump draws the make up water pressurising the system from this tank. In the wall mounted unit the user
interface for the controller is accessed through the cut out in the front cover. On the floor mounted units the user
interface is mounted within the inclined control panel at the top of the unit.
A ‘Frost Protection’ kit is available as an optional extra Pt. No. 563605663 -see page 22 for details.
2.0 TECHNICAL DATA
All screw threads used in the Chesil units conform to ISO 7/1 or ISO 228/1 for pipe threads where applicable &
ISO 262 for all general screw threads.
The basic overall dimensions of the unit are shown in Figure 2 below. Performance and General Data is shown in
Figure 3 (overleaf).
Figure 2 - Basic Dimensions
WALL MOUNTED WSE MODEL FLOOR STANDING FSE & FTE MODELS
Model Description HHL Part Number
WSE Wall Mount / Single Pump / Electronic Control 563216016
FSE Floor Mount / Single Pump / Electronic Control 563216020
FTE Floor Mount / Twin Pump / Electronic Control 563216021
385
382
280
280
780
600

HAMWORTHY HEATING LTD 2
CHESIL-ELECTRONIC 500001181/K
Figure 3 - Technical Data
Floor Standing Wall Mounted
Hamworthy Heating Part Number 563216020 563216021 563216016
Weight (empty) kg 23 29 21
Weight (full) kg 30.6 36.6 28.6
Tank capacity litres 7.6
Minimum cold fill pressure bar 0.5
Maximum cold fill pressure bar 3.4
Maximum operating pressure bar 7.0
Maximum Flow Rate l/min 6
Maximum water flow rate @
maximum cold fill pressure l/min 0.1
Factory Pre-set Values
Cold fill pressure bar 1.8
System low pressure alarm bar 1.3
System high pressure alarm bar 3.6
To suit system conditions
Maximum water flow temp °C 82
Maximum static height m 16.5
Minimum system operating pressure bar 0.7
Maximum system operating pressure bar 7.0
Safety relief valve setting (Not HHL supply) bar 4.0
Min. pressure differential bar 0.2
Electrical Data
Alarm Relay Contact Rating 13A 230V AC
Electrical Supply 230V AC 50Hz 1Ph
Start current amps 9
Run current amps 2.8
Backflow prevention air gap requirement Type AF
3.0 SEALED SYSTEM FUNCTION
Figure 4 shows the layout of a typical sealed system.
3.1 Terminology
Expansion Vessel Charge Pressure:
 The gas pressure in the expansion vessel with water connection open to atmosphere.
System Cold Fill Pressure:
 The water pressure in the system that the pressurisation unit is set to maintain.

HAMWORTHY HEATING LTD 3
CHESIL-ELECTRONIC 500001181/K
Figure 5- Expansion Vessel Operation
Figure 4 - Typical System Schematic Layout
3.2 Application
The system expansion vessel charge pressure is set 0.1 bar below the cold fill pressure. Before operation of the
boiler, with the system at cold fill pressure the expansion vessel is empty . As the system heats up the expanded
volume is absorbed by the expansion vessel. A small pressure rise occurs which is accommodated by the vessel.
When the system cools the pressure drops. If there has been some fluid loss the pressurisation provides
replacement.
1. Diaphragm position at the cold fill / charge pressure. The vessel is empty of system fluid.
2. Diaphragm position at the hot working pressure. The system volume has expanded due to the temperature
rise. The gas in the vessel is compressed. Acceptance factor = 0.35 maximum (recommended).
3. Diaphragm position at high system pressure. The boiler system is shut down by the system pressure
switch on.
4. Diaphragm at the safety valve lift pressure. Caused by boiler temperature limiter failure for example.
Acceptance factor = 0.5 maximum (recommended).

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4.1 Unit Operation.
The system pressure is continuously sensed by the pressure sensor in the pipe that connects to the heating
system. This is linked electrically to the PU electronic controller, which converts the signal from the sensor to a
pressure. The electronic controller checks this pressure against the user defined pressures to switch the
pressurisation pump on and off, and activate low or high pressure alarm relays if reached. The controller can also
determine the volume of water pumped into the system and compare this against user defined volumes to trigger
a general alarm relay. The controller also records the total run time of the pump(s) (if the unit is fitted with a back-
up pump), a user defined minimum run time can be set to stop the pump hunting when the on and off pressures
are close together. The user can predefine the electronics to alternate between pumps (in a twin pump unit) to
ensure that both pumps are operational. For small systems the user can select that the unit fills the heating
system from empty. For commercial systems Hamworthy Heating Ltd recommends that this ‘fill-function’ is only
used near the end of filling the system which should be filled with a suitable device such as an RPZ valve.
5.0 GENERAL REQUIREMENTS
5.1 Related Documents.
Pressure Systems and Transportable Gas Containers Regulations 1989.
It is the law that pressure system appliances are installed by competent persons in accordance with the above
regulations. Failure to install appliances correctly could lead to prosecution. It is in your own interest and that of
safety, to ensure that this law is complied with.
The installation of the pressurisation unit and expansion vessel MUST be in accordance with the relevant
requirements of the Pressure System Regulations, Building Regulations, IEE Regulations and the bylaws of the
local water undertaking.
It should also be in accordance with any requirements of the local authority and the relevant recommendations of
the following documents:-
Applicable standards and documents are:
BS 7074 Application, selection and installation of expansion vessels and ancillary equipment for sealed water systems.
BS 6644 Installation of Gas Fired Hot Water Boilers 60 kW to 2 MW
BS 6880 Parts 1,2&3: Code of practice for low temperature hot water heating systems of output greater than 45 kW.
BS 6759 Part 1 (ISO 4126): Specification for safety valves for steam and hot water.
BS EN 60335-1: Safety of household and similar electrical appliances
4.0 OPERATION OF THE PRESSURISATION UNIT
Figure 6 - Schematic Layout

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5.2 Mains Water Connections.
It is a requirement of the Water Supply (Water Fittings) Regulations 1999 that the system is filled using an RPZ
(Reduced Pressure Zone) valve with integral Type BA air gap. Information regarding the application, use and
maintenance requirements for RPZ valves with Type BA air gap is available from WRAS. It is also advisable to
contact the local water utility company to verify notification requirements for the use of these valves.
With the electronic model of Chesil pressurisation unit it is not always necessary to use an RPZ valve for system
filling as the units have a Fill function suitable for small systems to a maximum of 200 litres. Where this fill function
is used it is not necessary to have a quick fill loop using an RPZ valve.
5.3 Expansion Vessels.
System expansion vessels must be constructed to BS4814 or BS6144.
The required expansion vessel size is detailed in the contract documents. If in any doubt contact Hamworthy
Heating Limited for comprehensive system sizing information. Hamworthy Heating Ltd supply the ‘Burstock’ range
of suitable expansion vessels, details are shown below. A calculation sheet which can be used to determine a
suitable volume for an expansion vessel can be found in the Appendix.
Figure 7 - Hamworthy Heating Expansion Vessels—’Burstock’
Note: 25 litre expansion vessels are supplied complete with wall mounting bracket
5.4 Safety Relief Valve.
Must comply with BS6759 part 1, and be sized and installed in accordance with BS6644 & BS7074.
SALES REF NO. HAMWORTHY PART
NO.
TYPE TOTAL VOL.
LITRES
CONNECTION
DETAILS
WT
kgs
HOT WATER
APPLICATIONS -
EPDM DIAPHRAGM
(0-100°C MAX)
PV25W (kit) 563605641 VERTICAL 25 G3/4” 4.7
PV60W 5327120094 VERTICAL 60 G1” 14
PV80W 5327120095 VERTICAL 80 G1” 16
PV100W 532712096 VERTICAL 100 G1” 19
PV200W 532712088 VERTICAL 200 G1 1/4” 40
PV300W 532712089 VERTICAL 300 G1 1/4” 54
PV400W 532712090 VERTICAL 400 G1 1/4” 70
PV500W 532712091 VERTICAL 500 G1 1/4” 79
PV800W 532712092 VERTICAL 800 G1 1/2” 195
PV1000W 532712093 VERTICAL 1000 G1 1/2” 228