Hamworthy UF150-1 Installation, Commissioning And Operating Instructions
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Hamworthy UF150-1 Installation, Commissioning And Operating Instructions

Upton series. floor standing, condensing , open flue, fully modulating, pre-mix, gas fired boilers for heating & domestic hot water installations
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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 I
2H
LPG Propane I
3P
IMPORTANT NOTE
THESE INSTRUCTIONS MUST BE READ AND
UNDERSTOOD BEFORE INSTALLING,
COMMISSIONING, OPERATING OR SERVICING
EQUIPMENT

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Graham Dring
February 12, 2025

Good Morning. Does the Hamworthy Upton UF 350 Boilers have any third party network capabilities for BMS systems such as Modbus or BACnet

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Summary of Contents for Hamworthy UF150-1

  • Page 1 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 I LPG Propane I...
  • Page 2 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.
  • Page 3 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 I LPG Propane I NOTE: THESE INSTRUCTIONS MUST BE READ AND UNDERSTOOD BEFORE INSTALLING, COMMISSIONING, OPERATING OR SERVICING EQUIPMENT.

  • Page 4: Table Of Contents

    User Instructions FAULT FINDING ..........................28 Safety Temperature Limiter (Limit Thermostat) Ignition Controller Water Flow Switch 10.0 SERVICING ............................30 11.0 REPLACEMENT OF FAILED COMPONENTS ................32 12.0 RECOMMENDED SPARES ......................34 Page HAMWORTHY HEATING LTD UPTON FLOOR STANDING SERIES 500001340/C...
  • Page 5 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 Page HAMWORTHY HEATING LTD UPTON FLOOR STANDING SERIES 500001340/C...
  • Page 6 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 Page HAMWORTHY HEATING LTD UPTON FLOOR STANDING SERIES 500001340/C...

  • Page 7: Introduction

    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.
  • Page 8 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...

  • Page 9: Supply And Delivery

    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.
  • Page 10 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 HAMWORTHY HEATING LTD UPTON FLOOR STANDING SERIES 500001340/C...

  • Page 11: Size And Space Requirements

    Flow & Return Flow R 2-11 Gas R 1 1/4-11 Return R 2-11 Relief Valve G3/4 Not supplied Flue O 130 58.5 Flue Drain Figure 3.1.1 - Dimensions and Clearances UF100 & 150 HAMWORTHY HEATING LTD UPTON FLOOR STANDING SERIES 500001340/C...
  • Page 12 57 Relief valve 1 Module high 173 Flow & Return Flow & Return Flow R 2-11 Gas R 1 1/4-11 Return R 2-11 Relief Valve G3/4 Flue O 130 Not supplied 58.5 Flue Drain HAMWORTHY HEATING LTD UPTON FLOOR STANDING SERIES 500001340/C...
  • Page 13 Flow & Return 1 Module high 173 Flow & Return Flow R 2-11 Gas R 1 1/4-11 Return R 2-11 Relief Valve G3/4 Flue O 130 Not supplied 58.5 Flue Drain 1127 HAMWORTHY HEATING LTD UPTON FLOOR STANDING SERIES 500001340/C...
  • Page 14 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.
  • Page 15 Condensate pipe O 34 Gas Manifold DN65 R3" System Safety Relief Valve G1.5" Pressurisation unit & Expansion Vessel Figure 3.2.2 – UF100 & UF150 2MW Primary circuit and Gas manifold pipe kit HAMWORTHY HEATING LTD UPTON FLOOR STANDING SERIES 500001340/C...
  • Page 16 Condensate pipe O 34 Gas Manifold DN65 R3" System Safety Relief Valve G1.5" Pressurisation unit & Expansion Vessel Figure 3.2.3 – UF200 & UF250 3MW Primary circuit and Gas manifold pipe kit HAMWORTHY HEATING LTD UPTON FLOOR STANDING SERIES 500001340/C...
  • Page 17 Condensate pipe O 34 Gas Manifold DN65 R3" System Safety Relief Valve G1.5" Pressurisation unit & Expansion Vessel Figure 3.2.4 – UF300 & UF350 2MW Primary circuit and Gas manifold pipe kit HAMWORTHY HEATING LTD UPTON FLOOR STANDING SERIES 500001340/C...
  • Page 18 Condensate pipe O 34 Gas Manifold DN65 R3" System Safety Relief Valve G1.5" Pressurisation unit & Expansion Vessel Figure 3.2.5 – UF300 & UF350 4MW Primary circuit and Gas manifold pipe kit HAMWORTHY HEATING LTD UPTON FLOOR STANDING SERIES 500001340/C...

  • Page 19: Site Location And Preparation

    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. M8 Lifting eye fixing positions. Figure 4.2 - Gas Connection Point Gas connection HAMWORTHY HEATING LTD UPTON FLOOR STANDING SERIES 500001340/C...

  • Page 20: Gas Supply

    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. HAMWORTHY HEATING LTD UPTON FLOOR STANDING SERIES 500001340/C...
  • Page 21 Maximum working water pressure is 5.3bar. • For minimum water pressure 0.5 bar - refer to Appendix E Safety Valve G¾” Flow water connection R2” Return water connection R2” Figure 4.4 - Water Connection Points HAMWORTHY HEATING LTD UPTON FLOOR STANDING SERIES 500001340/C...

  • Page 22: Condensate Connections

    • Condense is mildly acidic, typically pH3 - pH5. • Condense pipe work must be non-corrosive and not copper. Hamworthy recommend Polypropylene plastic waste pipe. • Condense may be discharged to a standard drain subject to National or Local regulations.

  • Page 23: Electrical Supply

    NOTE: The appliance must be isolated from the electrical supply if electric arc welding is carried out on connecting pipe work. FOR TYPICAL SCHEMATIC DETAILS SEE FIGURE 4.6 FOR DETAILED WIRING INSTRUCTIONS SEE FIGURES 9.3.1 Figure 4.6 - Navistem Electrical Connections HAMWORTHY HEATING LTD UPTON FLOOR STANDING SERIES 500001340/C...

  • Page 24: Boiler Assembly

    5.3 Flue Connection The Hamworthy Upton boiler is designed for use with open flue systems type B23p - Intake from ventilated plant room and discharge via horizontal/vertical flue. With the boiler in its desired location, engage the flue collector ducts into each other and position such that the spigots will fit into the respective flue sockets at the rear of the boiler.

  • Page 25: Sealed Systems

    Boilers must not be capable of isolation from the safety valve. Valves between boiler and safety valve to be three way type such that when boiler is isolated from the safety valve it is open to atmosphere. Hamworthy Heating Ltd recommend using the safety valve connection provided on the boiler.

  • Page 26: Checks Prior To Lighting

    4) System may be considered sound if over a period of 2 minutes any drop in pressure is less than 0.5 mbar (0.2" wg.). Note:- Allow a manometer stabilisation period of approximately 1 minute before each 2 minute check period. Following soundness tests close valve B and remove manometer connections and tighten test points. HAMWORTHY HEATING LTD UPTON FLOOR STANDING SERIES 500001340/C...

  • Page 27: Checks Prior To Lighting The Boiler

    Once the preliminary checks have been completed and the gas inlet pressure has been verified as correct, commissioning of the boiler modules may begin. Gas Isolation Valve On/Off Switch Fig 7.2.1 - On/Off switch HAMWORTHY HEATING LTD UPTON FLOOR STANDING SERIES 500001340/C...

  • Page 28: Initial Llghting

    Note: Should remedial work be carried out on a module, then the non-firing module must be electrically isolated so as to prevent accidental operation in the event that the installation is required for ongoing heating requirements. HAMWORTHY HEATING LTD UPTON FLOOR STANDING SERIES...
  • Page 29 Figure 8.3.1 - Operating phases HAMWORTHY HEATING LTD UPTON FLOOR STANDING SERIES 500001340/C...

  • Page 30: Ignition Controller Check

    NOTE: THIS DISTANCE MUST BE SET TO ENSURE ACCURATE ANALYSIS OF FLUE GASES. 3. Insert probe horizontally into the flue gas sample pipe until depth stop is met. Figure 8.5.2 - Insertion of Analyser Probe HAMWORTHY HEATING LTD UPTON FLOOR STANDING SERIES 500001340/C...
  • Page 31 To increase the CO level, turn the adjustment clockwise. Figure 8.6.5—Adjusting gas valve offset Fig 8.5.3 - Combustion settings (Note: readings taken with front cover removed and 155mm probe insertion CO = < 80 ppm*). HAMWORTHY HEATING LTD UPTON FLOOR STANDING SERIES 500001340/C...

  • Page 32: User Instructions

    CONTACT HAMWORTHY HEATING TECHNICAL DEPARTMENT FOR FURTHER DETAILS 7. Shut down the boiler and isolate from the electrical supply. Remove instrumentation and replace test points and plugs.
  • Page 33 Inlet gas pressure sensor - test point Return Overheat thermostat Pressure sensor HT spark generator Flue gas analyser test point Air filter Gas isolating valve Figure 8.5.4 - General Overview of Boiler Controls HAMWORTHY HEATING LTD UPTON FLOOR STANDING SERIES 500001340/C...

  • Page 34: Fault Finding

    Engineer. Should a fault code appear which cannot be reset, or a fault code repeatedly occurs, contact Hamworthy Heating for assistance. Do not continue to operate or use the boiler 9.1 Safety Temperature Limiter (Limit Thermostat) 1.
  • Page 35 Figure 9.3.1- Wiring Diagram HAMWORTHY HEATING LTD UPTON FLOOR STANDING SERIES 500001340/C...

  • Page 36: Servicing

    13) Check and clean air filter. Filter can be washed in 10.1 Regular servicing is recommended, preferably by clean water. a Hamworthy appointed person, and at least annually, to Re-assemble in reverse order taking care to inspect and ensure trouble free operation.
  • Page 37 UF100, UF150, UF300 & UF350 UF200 & UF250 3.5 ±1 66 ±0.25 3.5 ±1 66 ±0.25 SECTION A-A Figure 10.2.1 - Spark Electrode position SECTION D-D 100 ±0.25 SECTION C-C Figure 10.2.2 - Flame Probe position HAMWORTHY HEATING LTD UPTON FLOOR STANDING SERIES 500001340/C...

  • Page 38: Replacement Of Failed Components

    . Carefully disconnect all plug connections from the LMS, 11.5 Water Flow switch taking note of their location. The plugs are polarised to HAMWORTHY HEATING LTD UPTON FLOOR STANDING SERIES 500001340/C...

  • Page 39: Gas Data

    Disconnect display ribbon cable from PCB. available from Hamworthy Heating Ltd spares Refit ribbon cable to new display PCB and push the department.

  • Page 40: Recommended Spares

    SPARES ITEM PART No. ELECTRICAL ITEMS Navistem control - UF100-1 Nat Gas..........................179319 Navistem control - UF150-1 Nat Gas..........................179320 Navistem control - UF200-1 Nat Gas..........................179321 Navistem control - UF250-1 Nat Gas..........................179322 Navistem control - UF300-1 Nat Gas..........................179323 Navistem control - UF350-1 Nat Gas..........................
  • Page 41 39.6 49.4 Ignition Heat Input (Gross) 128.3 102.0 Gross Efficiency 100% Load 50/30°C 87.0 87.6 Gross Efficiency 30% Load 50/30°C 98.2 95.5 Noise Emission @ 1m (per module) dB (A) 59.7 58.5 HAMWORTHY HEATING LTD UPTON FLOOR STANDING SERIES 500001340/C...
  • Page 42 Standby heat loss Pstby kW 0.196 0.212 0.229 0.279 0.320 0.160 Emissions of nitrogen Nox mg/kWh oxides Nat Gas Emissions of nitrogen Nox mg/kWh 42.8 44.8 49.0 40.1 47.3 47.1 oxides LPG HAMWORTHY HEATING LTD UPTON FLOOR STANDING SERIES 500001340/C...
  • Page 43 NOTE: FOR BASIC TERMINATION DIAGRAM SEE FIGURE 4.6 FOR BOILER WIRING SCHEMATIC SEE FIGURE 9.3.1 FOR MULTIPLE BOILER WIRING SEE FIGURE B1.2 FOR CONTROL WIRING SEE FIGURE E1.3.1 TO E1.3.3 HAMWORTHY HEATING LTD UPTON FLOOR STANDING SERIES 500001340/C...
  • Page 44 All modules must be sequenced. Enable - will give On/Off control of the modules 0~10V - will give modulation control of each module Option 2 provides modulation control of up to 16 modules. HAMWORTHY HEATING LTD UPTON FLOOR STANDING SERIES 500001340/C...
  • Page 45 165.0 10.0 19873 90.0 170.0 15.0 15699 95.0 175.0 20.0 12488 100.0 180.0 25.0 10000 105.0 185.0 30.0 8059 110.0 190.0 35.0 6535 115.0 195.0 40.0 5330 120.0 200.0 45.0 4372 125.0 HAMWORTHY HEATING LTD UPTON FLOOR STANDING SERIES 500001340/C...

  • Page 46: Flue Data

    Any flue system with a horizontal section should have a maximum slope of 3° upwards in the direction of the exhaust gas flow. All joints should be such that any condensation is directed back down the slope to an open HAMWORTHY HEATING LTD UPTON FLOOR STANDING SERIES...
  • Page 47 Consideration must be given to the correct calculation of the required flue size. If in any doubt consult Hamworthy Heating Ltd who working in partnership with Midtherm Engineering Ltd can provide a comprehensive flue design and installation package.
  • Page 48 In addition to the above the stacked module arrangement flue boxes are supplied with a trap terminating in a 32mm i.d. connection, which should be connected in a similar manner to a drain. HAMWORTHY HEATING LTD UPTON FLOOR STANDING SERIES...
  • Page 49 The air supply should be free from contamination such as building dust and insulation fibres from lagging. To avoid unnecessary cleaning and servicing of the boiler modules, the boilers should not be fired whilst building work is being undertaken. HAMWORTHY HEATING LTD UPTON FLOOR STANDING SERIES 500001340/C...

  • Page 50: Water Data

    Flow Temperature Set Point (default setting) °C 80°C Maximum flow temperature setting °C 85°C Minimum flow temperature setting °C 30°C Figure E1.1 Hydraulic Resistance Hydraulic Resistance - Upton UF150 UF350 UF300 UF250 UF100 UF200 Flow Rate l/s HAMWORTHY HEATING LTD UPTON FLOOR STANDING SERIES 500001340/C...
  • Page 51 If boilers are run off time clock control a pump overrun (not Hamworthy Heating Ltd supply) should be fitted which must run for a minimum of 5 minutes on shutdown of the last boiler. This must be interlocked to the Navistem B3000 boiler control for frost protection.
  • Page 52 Maximum system hot working pressure, generally given in bar gauge. From the parameters given, Hamworthy Heating can size the pressurisation unit and also the expansion vessel. Care must be taken in sizing expansion vessels to ensure maximum acceptance factors are not exceeded.
  • Page 53 Hydraulic Schemes: For Single Boiler Installations Figure E 1.3.1 - Schematic 1 - External Time Clock Enabled Boiler Figure E 1.3.2 - Schematic 2 - Two Heating Circuits with DHW & Boiler Shunt Pump HAMWORTHY HEATING LTD UPTON FLOOR STANDING SERIES 500001340/C...
  • Page 54 Hydraulic Schemes: For Multiple Boiler Installations Figure E 1.3.3 - Schematic 3 - Master and Slave Sequence Control With Reverse Return Primary Figure E 1.3.4 - Schematic 4 - Reverse Return Primary Circuit HAMWORTHY HEATING LTD UPTON FLOOR STANDING SERIES 500001340/C...
  • Page 55 Figure E 1.3.5 - Schematic 5 - Primary Circuit With Individual Boiler Shunt Pumps Figure E 1.3.6 - Schematic 6 - Reverse Return Primary Circuit with Individual Motorised Boiler Isolation Note: Motorised valves can be either power open/power close or power open/spring return close. HAMWORTHY HEATING LTD UPTON FLOOR STANDING SERIES 500001340/C...
  • Page 56 The pump is defaulted to pump speed min 100% & pump speed max 100% to adjust these values you will need to do the following. On the HMI press OK, time and date will appear. • Press and hold the I button for 3-5 seconds HAMWORTHY HEATING LTD UPTON FLOOR STANDING SERIES 500001340/C...
  • Page 57 Use rotary knob to select line number 8314, Boiler return temp will be displayed on the screen. Optional extras required for this configuration: Hamworthy Flow and return manifold kit Boiler Parameter Settings: Individual Boiler Shunt Pumps (Relay Output QX1) Legend...
  • Page 58 To check operation of pumps, mixing valves & thermostats select: engineer – diagnostic consumers – parameters 8730 to 8779 Optional extras required for this configuration: 2x Heating circuit extension modules AGU2.55A109 Part number 563605669 HAMWORTHY HEATING LTD UPTON FLOOR STANDING SERIES 500001340/C...
  • Page 59 1st period off 2nd period on 2nd period off 3rd period on 3rd period off Configuration 5710 Heating circuit 1 External enable—e.g. Remote time clock Settings must be programmed to master boiler HAMWORTHY HEATING LTD UPTON FLOOR STANDING SERIES 500001340/C...
  • Page 60 Function valve 2 H1 800 (800 = 80°C) 5890 Relay output QX1 Boiler pump Q1 Note: Use H1 wiring connection for 0-10V analog input from B.M.S. Optional extras required for this configuration: None HAMWORTHY HEATING LTD UPTON FLOOR STANDING SERIES 500001340/C...
  • Page 61 LPB bus communication module OCI345—one per boiler module Part number 563605667 Note: 2x LPB bus communications modules are supplied with each Merley boiler sequence controller, therefore addi- tional modules are only required for boiler module 3 upwards. HAMWORTHY HEATING LTD UPTON FLOOR STANDING SERIES 500001340/C...
  • Page 62 USEFUL USER INFORMATION INSTALLER SITE ADDRESS BOILER TYPE BOILER SIZE(S) UNIT NO(S). SERIAL NO(S). FLUE HAMWORTHY HEATING LTD UPTON FLOOR STANDING SERIES 500001340/C...
  • Page 64 Wessex House, New Fields Business Park, Stinsford Road, Poole, Dorset, BH17 0NF Telephone: 01202 662500 Fax: 01202 662522 Email: service@hamworthy-heating.com Website: www.hamworthy-heating.com Hamworthy reserves the right to make changes and improvements which may necessitate alteration to the specification without prior notice.

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