Hamworthy. Stratton Wall Hung. Stainless Steel Condensing Boilers Natural Gas or LPG Outputs 45kW to 100kW

Transcription

1 Hamworthy Stratton Wall Hung Stainless Steel Condensing Boilers Natural Gas or LPG Outputs 45kW to 100kW

2 Stratton Wall Hung, Pre-mix Gas Fired Modular Boilers The new Stratton boiler from Hamworthy brings together the design flexibility of a compact commercial wall hung modular boiler system with the reliability assurance of a stainless steel heat exchanger for long life and consistent high efficiency performance. Four models are available from 45kW to 100kW output (in condensing operation). Higher outputs can be achieved by combining multiple Stratton boiler modules together under the control of a Merley sequence controller (maximum 16 boilers). Hamworthy offer a range of standard horizontal mounting header and flue assembly kits, with kits for 1, 2, 3 or 4 boilers in series, to aid the designer and installer. All models feature an advanced pre-mix combustion system with fully modulating burner and intelligent microprocessor control to maximise efficiency and to keep CO 2 and NO X emissions to a minimum with all models achieving European Class 5 NO X rating. Consequently, the Stratton provides a safe, ultra clean, efficient and quiet commercial heating solution, or potable hot water solution if used with a Powerstock or equivalent calorifier. Designed for sealed system use and with installation to include a low loss header, each model is supplied optimised for natural gas and can be converted for LPG usage on-site. With flexibility of installation in mind, the Stratton can be installed with either a room sealed flue or a conventional open flue system in line with B23, C13, C33 or C53. Maximum output temperature is 80 C with no minimum return temperature and maximum working pressure of 4 barg. Durable stainless steel heat exchanger Accurate load matching Fully modulating for greater efficiency System design flexibility Burner controllable for maximum condensing operation BENEFITS The high efficiency condensing Stratton range of commercial modular boilers features a robust heat exchanger designed in stainless steel for corrosion resistance and long life. Options Single and multiple boiler controls Natural gas or propane Pipe kits and low loss header Flue header kits Range of flue components Stratton boiler modules with pipe kit and flue header kit 2

3 Specification Stratton Wall Hung Boiler Typical Layout Stainless steel condensing heat exchanger Cylindrical modulating premix burner Control panel with integrated burner controller Flue gas test point Hot water flow to heating circuit Condensate syphon Flue gas exhaust Fan-drawn combustion air inlet Automatic air vent Coiled stainless steel combustion heat exchanger Water pressure switch Air pressure switch Pump Fan Condensate drain Return from heating circuit Summary Stratton boilers feature an advanced pre-mix fan-drawn combustion system, with cylindrical burner and twin-coil counter-flow heat exchanger, managed by an integral intelligent microprocessor-based controller with energy saving features such as reduced start/stop cycling and modulation control. Combustion power can modulate from 100% down to 25% to closely align boiler operation with the prevailing demand. The correct gas/air ratio is held throughout the modulation range to ensure clean and efficient combustion is maintained, with burner power governed by the speed of the fan drawing the gas and air mixture to the burner. With a net efficiency of 109.3% and low emissions (NO X below 45mg/kWh, CO 2 maximum volume 8.6%), the compact and durable Stratton boilers, together with their range of pipe kits and flue accessories, make a very attractive proposition for specifiers, installers and users alike. All models are suitable for operation with room sealed flue systems or open flue systems allowing the designer greater flexibility in siting the boilers, which can be installed in almost any wall location within the building thanks to long permissible flue runs: up to 9m for concentric flues or longer with twin duct room-sealed flue systems and open flue systems. Stainless Steel Counter-flow Heat Exchanger The Stratton boiler features a stainless steel, counter-flow, radial heat exchanger with a co-axially mounted burner. The heat exchanger comprises a primary (combustion) coil coected, via a manifold, to a secondary (condensing) coil ruing directly above and parallel to the primary coil. Each coil is a spiral waterway made from 316L grade stainless steel for high resistance to corrosion and long life. Oval cross-section waterways improve heat transfer and save space, making the Stratton a powerful and responsive, yet highly compact boiler. The primary coil is directly heated by the cylindrical burner, which is mounted inside, and concentric with, the primary coil. The burner emits flames radially, giving an even heat distribution along the entire length of the coil, even at low modulation. The secondary coil is also heated by the combustion gases from the burner as they rise up to the flue exhaust. However, when condensing conditions prevail i.e. the flue gas temperature falls below 57 C, the secondary coil also recovers latent heat from the combustion gases as they condense around the coil, adding to the overall efficiency of the boiler and reducing heat losses through the flue. Any condensate formed in the process drains away via a condensate drain which includes a syphon trap to prevent any risk of escape of any combustion gases via the condensate drain. Primary Circulation An integral boiler pump circulates water for the heating circuit through the heat exchanger. Water circulates from secondary coil to primary coil, via a manifold which changes the direction of rotation of the flow, and then is output to the heating circuit, via a low loss header. Turbulent flow is maintained throughout the passage through the coils, maximising heat transfer. The controller ensures a short pump overrun is included after the burner is turned off to continue circulation and protect the heat exchanger from overheating. 3

4 Specification Stratton Wall Hung Boilers Circulation Pump Wilo Star pumps are used across the Stratton boiler range for the integral circulation pump with flow rates from 0.48l/s to 1.11l/s. Additional Heating System Pump(s) In addition to the integral boiler circulation pump, one or more pumps will be required for heating circulation and/ or Domestic Hot Water (DHW) circulation, which can be controlled (on/off) from the boiler controller; these pumps should be coected via a contactor. Ignition Safe and reliable automatic firing of the burner is ensured via spark-ignition and ionisation flame detection systems. Burner A small flame is held on the entire surface of the cylindrical burner combustion head. This ensures optimum combustion at any point in the modulation range of the boiler. The Gas Train Gas is supplied through a zero governor valve to precisely control the mixture of gas and air entering the burner as it modulates, to maintain the correct gas and air ratio for high combustion efficiency. Low Emissions All Stratton boilers achieve European Class 5 performance for NO X emissions, with emissions as low as 35mg/kWh. Efficiency Stratton condensing boilers achieve a full load efficiency of up to 88.5% gross (97.8% net) whilst at part load the efficiency rises to 98.9% gross (109.3% net). This equates to seasonal efficiencies of up to 96.9% gross, far exceeding the Building Regulations minimum seasonal efficiency requirements of 86% gross for new buildings and 82% gross for existing buildings, using natural gas. Electrical Details Supply 230V 50Hz Single Phase Wiring external to the boiler must be installed in accordance with I.E.T. regulations and any local regulations which apply. Pressure Relief Valve and Other Safety Equipment Each Stratton boiler is protected by a pressure relief valve set to 4 bar. Additional safety features designed to stop the boiler, or prevent it from starting, include a minimum water pressure switch set to 1 bar, a safety limit thermostat set to maximum 100 C, and water flow and air differential pressure switches to check there is sufficient water and air flow for boiler operation. Syphon Trap The Stratton features a condensate syphon trap to prevent the escape of flue gases out of the condensate drain pipe. Automatic Air Vent (AAV) An automatic air vent is included in the Stratton to automatically purge air in the heating circulation water. Pipe Kits with Low Loss Headers The boiler must be used with a low loss header arrangement to provide hydraulic separation from the heating circuit pump(s), to ensure secondary circuit conditions do not adversely affect flow through the boilers. To support the designers and installers, Hamworthy provide a choice of pipe kits with low loss headers for single and multiple boiler arrangements. The single boiler pipe kit includes a steel header which fits horizontally under the boiler, attaching to and supported by pre-formed flow and return steel pipework coections to the boiler. The header has R2 coections to the heating circuit flow and return, R1 coections for 1 diameter steel pipes to coect to the boiler, an Rc³ 8 coection pressure gauge, and R½ drain coection. For multiple boiler arrangements, ready-to-assemble, frame mounted pipe kits are available. These comprise a steel wall-mounted frame sized to suit the number of boilers it supports, together with a steel vertical low loss header, steel horizontal flow and return pipes, steel gas supply pipe, polypropylene condense discharge pipe, isolation ball valves and pre-formed copper coections to the boilers. All header pipework for the water side are DN80 PN6 sized steel pipe and flanges, and DN50 PN10 for gas pipework. For more information on low loss header and pipe kits refer to page 8 and 9. Note that drain valves, gauges and blanking plugs are not HHL supply. Wall Mounting The Stratton has been designed with ease of installation in mind. For single boiler applications the boiler, together with its individual low loss header, is simply mounted on a suitable non-flammable wall using fasteners (not HHL supply) to suit wall type through predrilled mounting holes and slots at the top of the boiler. For multiple boiler applications using pipe kits, these include a mounting frame. This is first assembled and then secured to the wall using appropriate fasteners for the wall type. Pipe headers and associated equipment are then fitted to the frame, followed by the boilers which are mounted on two studs per boiler at the top of the frame, and secured with M10 nuts. Flue Coections Each Stratton boiler has separate air and flue coections, although adapters are available for concentric flue coections. Polypropylene is used in flue pipe coections to resist the slightly acidic nature of the combustion gases and condensate. Flue coections at the boiler are 80mm dia. for STW45/STW60 and 100mm dia. for STW85/STW100. Air inlet coections are 80mm dia. for all Stratton models. Flue Components and Flue Header Kits Stratton boilers are suitable for flue systems designed in accordance with B23, C13, C33 and C53 schemes. Hamworthy offers flue components for all of these schemes, and also flue header kits to provide a shared B23 flue for two to four boilers, to complement the frame and pipe kits. For more information on flues refer to page 14 and 15. 4

5 Controls Overview Stratton Boilers Stratton boilers can be installed in a variety of configurations, from single boiler applications to multiple boilers, and controlled locally, or remotely via a building management system. Each boiler features an extremely versatile microprocessor based boiler control system that can be tailored to meet the exact needs of the heating system, and capable of integrating the boiler and other system components. Every Stratton boiler is equipped with the following control features as standard: Remote on/off control input (e.g. time clock control) Remote modulation input (0-10V analog input) External air temperature sensor input Volt free contacts Frost protection Pump overrun for internal pump LCD User Interface Local control and monitoring is carried out from the controller LCD user interface on the front of the boiler. Logical pushbutton operation provides access to set or monitor control parameters. Temperature Control All Stratton boilers are fitted with a manual reset limit thermostat set to 100 C. An electronic temperature control thermostat regulates the boiler flow temperature up to a maximum of 80 C. Stratton boilers also incorporate a return temperature sensor, which, in conjunction with the flow temperature sensor, governs the modulation set point of the boiler. Status Signalling All Stratton boilers are fitted with a multi-function clip-in module to provide two volt free, normally open contacts for remote status monitoring as standard. One indicates boiler normal run (boiler lit and no errors) when closed, the other indicates a general fault alarm when closed Volt DC Analog Input The standard multi-function clip-in module also provides a 0-10 volt DC analog signal interface to control the modulation level of the burner, or to set the flow temperature set point. The 0-10 volt signal can be used for remote coection of the boilers to a Building Management System, (BMS) to control remotely the temperature set point or boiler load setting. If this is used, then the 0-24V DC remote on/off control caot be used. Remote On/Off Control (Remote Timer) 24V DC signal and return coections are provided for remote on/off control, for example, by a remote timer, and require wiring to a volt-free contact switch at the remote controlling device. If not used, a link must remain across the 24V supply and return terminals. If this is used, then the 0-10V DC analog input control caot be used. LPB Bus Communications Module The optional Siemens LPB bus communication clip-in kit is used to coect the boiler control unit (Siemens LMU64) to the optional sequence control module. Each boiler in a modular installation requires a clip-in LPB bus communications module to communicate with the boiler sequence controller. External Air Temperature Sensor Stratton boilers can be supplied with an optional external air temperature sensor to exploit the full functionality of the boiler controls, and enable direct temperature compensation on the boiler, maximising the opportunity for condensing operation. When fitted with an external temperature sensor, the boiler s own thermostat is overridden and the flow temperature is controlled as a function of external temperature conditions. Using a range of adjustable compensation slopes built into the standard boiler controls, the flow temperature profile can be tailored to suit the needs of individual heating systems. For multiple boilers, the external temperature sensor should be used be used in conjunction with the optional Merley boiler sequence controller. Frost Protection When fitted with an external air temperature sensor the boiler control system features a two stage frost protection system. Stage one involves turning the integral boiler pump on should the external air temperature fall below 1.5 C. Stage two involves firing the boiler should the internal water temperature fall below 5 C. Whenever the boiler fires, the internal pump is automatically switched on. For further details of controls for single boilers refer to page 10 and for multiple boilers, please see page 11. Clip in modules on the LMU64 Boiler Management Unit 5

6 Technical Data Stratton Performance and General Data Information Module Size STW45 STW60 STW85 STW100 Energy Building Regulations seasonal efficiency gross (%) Boiler output 80/60 C kw Btu/h x 1000 Boiler output 50/30 C kw Btu/h x 1000 Boiler input (gross) maximum kw Btu/h x 1000 Boiler input (net) maximum kw Btu/h x 1000 Boiler output minimum kw 80/60 C Btu/h x Water temperature maximum C Water content (not including headers) litre Water Design flow 20 C Δt rise l/sec Residual pump 20 C Δt rise kpa m Water pressure maximum barg Gas Flue Water pressure minimum barg 1 Gas flow rate maximum, natural gas (G20) Gas inlet pressure nominal, natural gas (G20) Gas inlet pressure maximum, natural gas (G20) m 3 /h mbar 20 mbar 25 Gas flow rate nominal, LPG (G31) kg/h Gas inlet pressure, LPG (G31) mbar 37 Approximate flue gas 15 C, 8.8% CO 2, 80/60 C, NG. m 3 /h Flue gas temperature 80/60 C C NO X Emission (DAF) European Class 5 Pressure at flue 80/60 C mg/kwh Pa mbar Water flow/return coections inch G 1 G 1 G 1¼ G 1¼ Coection Gas inlet coection pipe thread inch G¾" Flue diameter (I/D) nominal mm Air inlet diameter (I/D) nominal mm 80 Condensate trap coection(s) (O/D) mm 25 Power consumption maximum W Supply voltage nominal 230V 1Ph 50Hz 6 Misc Boiler module ruing current Amps Approximate shipping weight including packaging kg Boiler weight (dry) kg Noise 1m Max db(a) Min db(a) Note: All measurements are with G20 natural gas unless otherwise stated

7 Dimensional Details Stratton Boiler Dimensions and Clearances Front of Boiler A D C R Gland hole x 6 Gas Safety valve Flow Return Cold inlet View on underside Safety relief valve Condensate discharge pipe Front View Side View B Air inlet 80 dia. Hole 12 dia. Slot 35 x 12 dia. To suit M10 wall fixing screws 600 min clearance CRS 125 Wall Fixing Detail Plan View All dimensions in mm Stratton Model Ref. STW45/STW60 STW85/STW100 Flue coection height/mm A Flue coection diameter/mm B Boiler depth D Flue Type B23 C13/C33 C53 Stratton Model STW45 STW60 STW85 STW100 STW45 STW60 STW85 STW100 STW45 STW60 STW85 STW100 Flue pipework diameter/mm / /150 80/80 100/100 Min. clearance/mm Ref. C

8 Pipe and Header Kits Single and Multiple Stratton Boilers Single Boiler Pipe Kit with Low Loss Header For individual Stratton boiler operation a simple kit is available with a square section low loss header coected to and supported by flow and return steel pipes which coect to the underside of the boiler. The kit includes: n n Steel header unit with steel pipe coections to boiler n n Brass adapters G 1½ to 1, and G 1½ to 1¼ with EPDM seals to suit all boiler model coections n n 2 heating circuit coections n n Pre-fitted foam insulation n n Dial pressure gauge (4 bar) ndrain n valve n n Coection for an expansion vessel on the return (angled) pipe With this pipe kit the boiler is directly mounted to the wall, and so the mountings studs must take into account the weight of the boiler and the universal header. Multiple Boiler Pipe Kits with Frame and Header For multiple Stratton boiler systems Hamworthy offer a range of wall-mounted pipe kits, available for combinations of two, three or four boilers. Each kit includes: n n Steel wall-mounting frame assembly n n 150mm dia. vertical low loss header with pressure gauge and automatic air vent n n 80mm dia. flow and return header pipes with DN80 PN6 flanges n n Gas header pipe with isolation valve, and DN50 PN10 flanges n n Condensate drain pipe with Tee n n Isolating valves (flow) and three port valve (return) n n Copper coections from flow and return header pipes to boiler The flow and return header pipe lengths, valves and coection quantities etc. vary between kits to suit the number of boilers. The result is a neat and compact easy-to-install solution, with all the necessary parts supplied, requiring only hook-up to water gas and electrical supplies, and to the heating circuit. The kits are sized to suit 45kW/60kW or 85kW/100kW boilers, sharing the same dimension headers, but with different length copper coections to the boiler, as the 85kW and 100kW boilers are deeper than the 45kW and 60kW boilers. Note that the wall-mounting frames have no floor-bearing capability. Single Boiler and Low Loss Header Kit Dimensions/mm R2" 83 Return coection * Minimum Height All dimensions in mm Mountings, 2 x 12 dia. holes, 405 between centres for M10 fixings plus 2 x 12 dia. x 15 horizontal slots for alternative mounting points R2" Flow coection B 110* Single Boiler Referenced Dimensions/mm Ref. STW45/STW60 STW85/STW100 Boiler depth A Flue height B Pipe kits (with frames) and B23 flue header kits for two (left) and three (right) Stratton boilers A 269 * Header dimensions include a nominal 20mm depth of insulation 1800 Hole centr

9 Dimensional Details Stratton Pipe Kits and Flue Header Kits 390 C dia. D Hole centres 419 Holes 12 dia. Clearance 15 dia F H G E * L 18+4* M All dimensions in mm *4mm gasket width Pipe kit (with frame) and B23 flue header kit for four Stratton boilers, with dimensions The flue header kits are for B23 scheme open flue systems only and are separate from the pipe kits. See Flue Design section on page 15. Dimensions of Boiler Modules with Multiple Boiler Pipe Kits and Flue Header Kits/mm Output Power of Stratton Modules Models STW45 STW60 STW85 STW100 Number of Boilers Ref C 507 D 160 E F G H L M 1527** 2077** 2631** C 532 D 200 E F G H L M 1527** 2077** 2631** **Includes 4mm per gasket and 18mm for blank flange widths Boiler Model STW45 STW60 STW85 STW100 Number of boilers Output Power C Output Power C

10 Control Details Stratton Wall Hung Single Boilers The control options for single Stratton wall hung boilers are different to those for multiple boilers. Please refer to page 11 for controls on multiple boilers. All controls functions are managed via the boiler management unit Siemens LMU64. Using a combination of options, the level of control is expandable for up to two heating circuits and one domestic hot water cylinder. A circulation pump overrun timer is incorporated within the boiler LMU. Programmable Room Sensor A Stratton single boiler system can be fitted with a single programmable room sensor, which should be located in the first heating zone. This room thermostat allows heating circuit management to be based on both the internal and external air temperature. The boiler will manage the heating circuit pump via a contactor according to the program requirements of the programmable room unit. Features: Individual 7 day program with auto summer / winter hour change for heating circuit 1, heating circuit 2 and DHW 3 periods per day per time program Constant or variable temperature flow Compensated flow temperature based on external and room air temperatures Optimised start / stop based on external and room air temperatures Building frost protection based on room air temperature Summer shutdown based on external air temperature Holiday period with frost protection Reduced temperature, night set back for non occupancy hours n n Daily pump exercise function to prevent any risk of pump sticking after prolonged idle period Programme lock to prevent tampering Individual temperature settings for each zone To achieve full functionality an external air sensor must be fitted. Options for a Single Boiler only Programmable room sensor External air sensor 2nd heating circuit clip-in relay kit DHW cylinder sensor kit External Air Sensor An optional external air temperature sensor may be wired directly to the boiler to exploit the direct weather compensation functionality of the boiler controls. This sensor may be coected to the control scheme and should ideally be positioned on an external wall with northerly aspect. 2nd Heating Circuit Clip-in Relay Kit To control a second heating circuit, an additional clip-in relay kit is required for fitting directly to the LMU. The kit comprises a relay and water temperature sensor complete with pocket. This kit provides outputs for a pump and mixing valve. Mixing valve allows second heating circuit to operate at a different temperature set-point to heating circuit 1 Second heating circuit should operate at the same or lower temperature than circuit 1, e.g. underfloor heating Programmed via the programmable room sensor Compensated flow based on external air temp and using a curve separate to that of heating circuit 1 owing to mixing valve Optimised start/stop based on external air temperature Frost protection based on water temperature in second heating circuit For the second heating circuit, the boiler will manage the circuit pump and/ or mixing valve via contactors, according to the program requirements of the programmable room sensor and the water temperature sensor. Only one programmable room sensor may be coected, therefore the second heating circuit management is derived from time control and external air temperature measurement. DHW Cylinder Sensor Kit This kit is for a domestic hot water (DHW) circuit directly controlled from the boiler, but programmed via the programmable room sensor, and features: Immersion sensor complete with pocket DHW cylinder sensor and pump output directly from boiler LMU Frost protection based on stored water temperature Reduced storage temperature for non-occupancy hours Anti-Legionella function For the DHW cylinder circuit, the boiler will manage the primary coil pump according to the program requirements of the programmable room unit and the DHW cylinder sensor. 10

11 Control Details Stratton Wall Hung Multiple Boilers The control options for multiple Stratton wall hung boilers are different to those for single boilers. Please refer to page 10 for controls on single boilers. Sequence Controller LPB Bus For use with multiple boilers, the optional Merley sequence controller can control up to 16 boilers. Communication between the boilers and sequence controller is facilitated via the LPB bus. Merley is the latest generation boiler sequence controller for multiple boiler installations. Using the Siemens controls platform, Hamworthy boilers can be controlled to share the load between boiler modules to maximise efficiency and system performance. Merley wall mounted sequence controller As a standalone device with autonomous control of the boilers, the controller can be extended to sequence control the boilers and also to manage a complete heating circuit as well as a domestic hot water (DHW) cylinder. A range of room and external air temperature sensors, including wireless options, ensures comfort levels within the building are maintained. When integrated with a building management system (BMS), the Merley operates only as a boiler sequence controller, receiving the required operating temperature from the building management system via a 0 to 10 volt analog signal. Each sequence control system is supplied with a smart digital interface display allowing the user to monitor the current operating status of the boilers, and also the building where the Merley is used to control a heating zone and hot water cylinder. Full details of the Merley sequence controller are provided in publication, , available to download at or request a printed copy, Tel: Options for Multiple Boilers only Boiler sequencing cascade controller LPB bus communications clip-in module Choice of room sensors External air sensor Hard wired or wireless controls DHW cylinder sensor kit The Merley boiler sequence controller can be supplied within a dedicated housing for wall mounting or as a loose kit for integrating within a plant room control panel. Wall Mounted Controller Merley sequence controllers are available factory assembled within a robust steel enclosure suitable for wall mounting, with the digital interface display pre-mounted to the housing door. The sequence controller is mounted to a DIN rail attached to the panel back plate assembly, with electrical trunking to simplify routing for site cables to the appropriate wiring terminations. A cable gland plate is located on the underside of the control panel with 6 loose cable glands supplied for fitting on site. Loose Kit Controller For installations where the sequence controller will be integrated within an existing or new plant room control panel, the Merley sequence controller can be supplied in loose kit form. A suitable space must be allocated within the plant room control panel for mounting the sequence controller to the back plate and for mounting the digital display to the control panel door. Boiler Sequence Control Strategies The Merley sequence controller can be configured to sequence boilers in traditional cascade mode or in unison mode. Cascade Control Steps a boiler module on at its lowest rate and then modulates it to its maximum rate, before switching on the next boiler module to match the system load. Maintains the lowest number of boiler modules in operation for a given heat load. This control strategy is particularly suited to boilers operating in constant temperature systems where there is no great efficiency advantage to be gained from operating boilers at part load. Unison Control Steps each boiler module on in turn at its lowest rate, and then modulates all boiler modules simultaneously to higher rates to match the system load. This method of sequencing can offer higher operating efficiencies, taking advantage of the higher part load efficiencies available at low firing rates. This control strategy is particularly suited to condensing boilers operating in variable temperature systems where low water temperatures and part load boiler operation allows optimum boiler operating efficiency to be achieved. Hamworthy generally recommends the use of the unison control strategy as it offers the greatest overall fuel efficiencies. 11

12 Application & System Data Stratton Boilers Gas Supply Pipes Supply pipes must be fitted in accordance with BS6891 or IGE/UP/2 as appropriate. Pipework must be of adequate diameter for the length of run, and must not be of a smaller diameter than the boiler s gas coections. For gas pipe sizing calculations refer to Chartered Institute of Building Services Engineers (CIBSE) Guide C. The complete installations must be purged and tested for soundness as described in BS6891 or IGE/UP/1 and IGE/UP/1A as appropriate. Water Flow Requirements The Stratton boiler is designed as a rapid response, low water content unit, to run continuously with maximum reliability. Care should be taken in the initial design and layout to ensure adequate water flow through the boiler(s) having due regard for the influence of the control system. The primary circuit design should be such that secondary circuit conditions caot have an influence over reliable operation of the boilers. System Feed Water Quality Modern heating systems often contain a diverse mix of metals which, when combined with supply water of varying chemical composition, can lead to corrosion. It is therefore important to treat water to ensure the long term satisfactory operation of the boilers and heating system. Hamworthy recommend a water treatment specialist is appointed to undertake analysis of the water and to recommend suitable cleaning and dosing regimes, to ensure the quality of the system and make-up water remains within the following tolerances throughout the life of the installation: Water Properties Acidity level Concentration of dissolved oxygen Chlorides (Cl) Calcium Carbonate (CaCO 3 ) Permitted Levels 8.2<pH<9.5 <0.1 mg/l <50 mg/l <100mg/l (initial fill) <10mg/l (top up) Water Filter A coarse filter and dirt separator must be fitted in the return pipework to remove suspended particles, and suitable air separation must be provided at high points in the circuit. Condensate Discharge Natural gas boilers typically produce condensate at a rate of 13 litres per hour per 100kW input energy when operating in condensing mode. Although the condensate produced is mildly acidic (typical ph~3.5), normally it can be disposed of through the drainage system. If in any doubt about local regulations, check with the local water authority. The Stratton boilers are equipped with a polypropylene syphon drain coection to which plastic polypropylene piping, with glued sealed joints should be coected, to dispose of the condensate. The condense discharge pipe should have a minimum fall of 3 to drain, and should discharge via tundish arrangement. To prevent any risk of freezing in winter, the condense pipe should be insulated and/or routed internal to the building where possible. General Ventilation Requirements An adequate supply of fresh air for combustion and ventilation must be provided in accordance with BS5440 for boiler installations less than 70kW net rated input (Stratton models STW45 and STW60), and in accordance with BS6644 for boiler installations greater than 70kW net rated input (Stratton models STW85 and STW100, or multiple Stratton boiler combinations). When Stratton boilers are installed as room sealed units the air supply is for ventilation only. Boiler House Temperatures Additional requirement of BS6644 for multiple boiler installations requires that the air supplied for boiler house ventilation shall be such that the maximum temperatures within the boiler house do not exceed: At floor level, 25 C (or 100mm above floor level) At mid-level, 32 C (1.5m above floor level) At ceiling height, 40 C (or 100mm below ceiling height) Ventilation Grille Openings High and low level ventilation grilles shall be positioned as high and as low as practicably possible. Low level grills will be located within 1metre of floor level for Natural Gas. High level grilles are recommended to be positioned within 15% of the boiler room height from the ceiling. High and low ventilation grilles shall communicate with the same room or internal space where compartment ventilation is used. Where ventilation grilles communicate directly with outside air they shall be positioned on the same wall. Air Supply The air supply should be free from contamination such as building dust and insulation fibres from lagging. To avoid uecessary cleaning and servicing of the boiler modules, the boilers should not be fired whilst building work is being undertaken. Where a boiler installation is to operate throughout the summer months, e.g. for domestic hot water production for more than 50% of the time, then additional ventilation allowances are required. Refer to BS6644 for more information. 12

13 Electrical Details Stratton Boiler Coections The following electrical coections are provided on each boiler: Supply live neutral and earth Heating circuit pump output DHW circuit pump output Optional programmable room sensor Remote on/off control input Optional external air temperature sensor n n Optional DHW cylinder temperature sensor With alternative wiring options for either: n n 0-10V analog controls n n BMS input signal for remote signalling n n Boiler general fault signal output to BMS n n Boiler normal run signal output to BMS Or n n 0-10V analog controls n n Powered supply for remote signalling n n Powered boiler general fault signal output n n Powered boiler normal run signal output Electrical Supply An independent isolator and fused electrical supply is recommended for each boiler. Supply is 230 volt, 50Hz, single phase. Wiring to the boiler must be installed in accordance with the latest IET regulations and any local regulations which apply. Wiring external to the boiler must be installed in accordance with IET 7671:2008 (2011), wiring regulations. Wiring must be completed in heat resistant 3-core cable (size 1.0mm 2 c.s.a.). External fuses should be rated 6 amps for each boiler. To prevent drawing excessive current (>1 amp) through the boiler control panel, it is recommended that external pumps are coected via contactors. Electrical Coections Separate entry points are provided in the boiler for power and signal cables, with gland plates fitted in the bottom of the boiler frame to accept these cables. Two termination strips are provided for all external coections inside the font cover. Access to the gland plates and termination strips is made by lifting and then tipping forward the black panel which retains the controller. Status Signalling Volt free contacts are provided to indicate the following operating conditions n n Boiler normal run n n Boiler general fault L N K1 N K3 N OT OT RT+ RT M B9 M B3 X51-01 X52-01 X52-02 X V Analog input Ground Supply 230V 1Ph 50Hz fused 6 amps Heating circuit pump output maximum 1A or via contactor DHW circuit pump output maximum 1A or via contactor BMS input signal for remote signalling Optional programmable room sensor Remote on/off input signal (remove link) Optional external air temperature sensor Optional DHW cylinder temperature sensor Boiler fault signal output to BMS Boiler run signal output to BMS OR X51-01 X52-01 X52-02 X52-03 L N L N L N 0-10V Analog input Ground Powered supply for remote signalling Boiler fault signal output powered Boiler run signal output powered Powered output contacts rated 230V ~ 50Hz, maximum 1A 0-10 Volt DC Analog Input A 0-10 volt DC analog signal interface is provided to control the boiler from an external Building Management System (BMS). If using this interface, remove the link on the remote on/off terminals. The interface can be configured to control the boiler according to either power requirement or temperature requirement. Remote On/Off Facilitating control from an external source the remote on/off circuit is powered at 24V DC and requires a volt-free contact device, such as a relay in a remote timer to enable/disable operation. The boiler will operate using its own internal temperature regulation controls in remote on/off operation mode. Optional Sensors and Sensor Cables The following optional sensors are listed below together with their maximum cable length in metres. n n DHW sensor, maximum cable length 10m n n External sensor, maximum cable length 40m n n Ambient thermostat, maximum cable length 40m n n Ambient sensor, maximum cable length 50m 13

14 Flue Design Stratton Boilers Single Wall Flue Systems B23 and B23 Headers, C13, C33 and C53 Stratton boilers are suitable for flue systems designed in accordance with B23, C13, C33 or C53 schemes. Hamworthy offers flue components to suit these flue schemes for single boilers, and also B23 flue header kits for multiple boilers. All flue systems must be installed in accordance with the 3rd edition of the Clean Air Act Memorandum Piping, elbows and terminals for all Stratton boilers are a single-wall polypropylene construction (not UV stabilised, except for terminals) with EPDM joint seal, so therefore only suitable for internal use. Where flue systems must be run or be located externally, please contact our technical team for further assistance. B23 terminal only is stainless steel. Flue coections at the boiler are 80mm dia. for STW45/ STW60 and 100mm dia. for STW85/STW100. Air inlet coections are 80mm dia. for all Stratton models. Pipework is available in different diameters to suit the flue scheme and design requirements. Single wall individual or concentric pipe is available in standard lengths of 1m and 0.5m. Telescopic pipe and 90 or 45 elbows are also available to reach the desired termination point. Other optional accessories are available and include support brackets and roof flashing. To simplify the flue ordering process, Hamworthy have a flue order form available for you to call off all your flue component requirements. To request a Stratton flue system order form, telephone or sales@hamworthy-heating.com and state which flue system you are plaing to use. C53 Room Sealed, Twin Pipe Flue Individual Boiler with Horizontal Air Inlet and Vertical Flue Terminal (Diagram 4) The C53 standard terminal kit includes a horizontal air inlet terminal with 90 elbow and vertical flue terminal. Additional lengths and elbows can be used to extend the standard kit to the required length see graphs opposite. Flat or pitched roof flashing are available. C53 Flue details air and flue pipe Stratton Model Flue Dia. Equivalent Length (m) (mm) 45 Elbow 45 Elbow STW45 & STW STW85 & STW Diagram 4 C53 Shaded items included in standard terminal kits. 450 C53 Maximum Flue and Air Duct Lengths: Stratton STW45 Length (linear) of flue duct/m (80mm Dia.) Length (linear) of flue duct/m (80mm Dia.) 18 Maximum length of ducts 16 for G20 Natural Gas Maximum length of ducts for G31 LPG (Propane) Maximum length (linear) of air duct/m (80mm Dia.) C53 Maximum Flue and Air Duct Lengths: Stratton STW60 Length (linear) of flue duct/m (100mm Dia.) Maximum length of ducts for G20 Natural Gas Maximum length of ducts for G31 LPG (Propane) Maximum length (linear) of air duct/m (80mm Dia.) C53 Maximum Flue and Air Duct Lengths: Stratton STW85/100 Maximum length of ducts for G31 LPG (Propane) Maximum length of ducts for G20 Natural Gas Maximum length (linear) of air duct/m (100mm Dia.) B23 Open Flue Multiple Boiler Systems with Horizontal Terminal (<150 kw only), Vertical Terminal or Existing Chimney B23 open flue header kits for 2, 3 or 4 boilers are available (see illustrations on page 8 and 9) and comprise all components for boiler flue outlet coection to the header including a condensate drain. Onward pipework, elbows and vertical discharge are not included in the header kits. Header pipework diameters and dimensions are shown on page 9. Maximum length of flue pipe run (not HHL supply) after header depends on overall maximum power of the multiple boiler system and the diameter of the common flue. 14

15 Flue Design Stratton Boilers Single Wall Flue Systems B23 and B23 Headers, C13, C33 and C53 Diagram 2 C mm/m fall to boiler C33 Room Sealed, Concentric, Vertical Balanced Flue (Diagram 3) Individual Boiler (Roof) The C33 standard terminal kit includes the concentric coection kit and terminal. Additional concentric lengths and elbows can be used to extend the standard kit to the required length. Flat and pitched roof flashings are available mm Max Shaded items included in standard terminal kits. C13 Room Sealed, Concentric, Horizontal Balanced Flue Individual Boiler (Diagram 2) The C13 standard terminal kit includes the concentric coection kit, elbow and terminal with wall plates. This kit can be fitted in left hand, right hand or rear orientation. Additional concentric lengths and elbows can be used to extend the standard kit to the required length. Diagram 3 C33 Shaded items included in standard terminal kits. 800mm Max 30mm/m fall to C13 and C33 Maximum Flue Length for Single Boilers Equivalent Length (m) Stratton Model Flue Dia. (mm) Max Flue Length (m) 45 Elbow 90 Elbow STW45 & STW60 80/ STW85 & STW / B23 Open Flue Individual Boiler with Vertical Terminal or Existing Chimney (Diagram 1) All B23 flue installations must use the correct boiler coection kit that includes expansion adaptors to increase the boiler flue coection to the required diameter for the flue system as well as the boiler air inlet filter. The B23 flue terminal kits are manufactured in stainless steel including flue terminal, 1.5m pipe, adaptor for polypropylene pipe and either a flat or pitched roof flashing. For 110 and 125mm diameter flue systems the terminal diameter is 130mm, and for 160mm diameter flue systems only the terminal diameter is 180mm. Additional lengths and elbows can be used to extend the flue system to the required terminal position. Diagram 1 B23 } } } Flue terminal kit Intercoecting pipework Boiler coection kit - Expansion adapter and air inlet filter (shaded items) B23 Maximum Flue Length for Single Boilers Stratton Model STW45 STW60 STW85 STW100 Flue Adaptor (boiler coection to flue pipe) Dia. (mm) Max Flue 80/60 C (m) Max Flue 53/30 C (m) NA NA Equivalent Length 90 & 45 Elbow (m)

16 Hamworthy Heating Accreditations Customer Service Centre Hamworthy Heating Limited Fleets Corner, Poole, Dorset BH17 0HH ISO 9001 Quality Management System ISO Environmental Management System OHSAS Health & Safety Management System The printed version of this brochure is produced using environmentally friendly print solutions in partnership with our suppliers Telephone: Web: Hamworthy reserves the right to make changes and improvements which may necessitate alteration to the specification without prior notice B