Hurlcon H120S Manuale utente

Hurlcon Gas Fired

Hot Water Boiler

H120 & H150 S & B Models

INSTALLATION AND OPERATING INSTRUCTIONS

HURLCON Manufacturing & Sales Pty. Ltd. A.B.N. 97 007 284 504

48 Hanna Street, Noble Park, VICTORIA. 3174

Telephone: (03) 9554 2200 Facsimile: (03) 9554 2270

www.hurlcon.com.au email: service@hurlcon.com.au

Information and specifications subject to change without notice.

Rev 136-1105

H120 –H150 Hot Water Boilers page 2

INSTALLATION AND OPERATING INSTRUCTIONS...........................................................1

1.0 INTRODUCTION ...............................................................................................................3

1.1 NOTICE TO INSTALLERS .....................................................................................3

2.0 MODELS AVAILABLE ....................................................................................................4

2.1 STANDARD EQUIPMENT......................................................................................4

3.0 INSTALLATION ...............................................................................................................5

3.1 SAFETY RULES......................................................................................................5

3.2 GUIDE TO INSTALLATION...................................................................................6

3.3 CLEARANCES ........................................................................................................7

3.4 ELECTRICAL CONNECTION................................................................................7

3.5 BOILER DIMENSIONS...........................................................................................8

3.6 INDOOR INSTALLATION......................................................................................8

3.7 VENTILATION – AIR SUPPLY TO THE BOILER.................................................9

3.8 HEATING PIPE SIZE & LAYOUT........................................................................10

3.9 SIZING OF PRESSURE VESSEL..........................................................................10

4.0 COMMISSIONING .........................................................................................................11

4.1 STARTING BOILER..............................................................................................11

4.2 TESTING BURNER PRESSURE...........................................................................11

4.3 FLOW SWITCH.....................................................................................................11

4.4 GENUS IV 3 BUTTON CONTROLLER…………………………………………...12

5.0 OPERATING INSTRUCTIONS .....................................................................................12

5.1 ENERGY SAVING TIPS........................................................................................13

5.2 MAINTENANCE ...................................................................................................13

5.3 CONTROL SYSTEMS...........................................................................................13

6.0 GAS CONVERSION........................................................................................................15

6.1 BURNER CONVERSION ......................................................................................15

6.2 GAS – COMPONENT INFORMATION ................................................................16

6.3 GAS PIPE SIZING TABLES..................................................................................16

7.0 TROUBLESHOOTING...................................................................................................17

8.0 H120 – H150 WIRING DIAGRAM.................................................................................18

8.1 MODEL H120 – H150 WITH HEATSAVER ........................................................ 18

9.0 ONE YEAR LIMITED WARRANTY.............................................................................19

H120 –H150 Hot Water Boilers page 3

1.0

INTRODUCTION

Congratulations on your purchase of a Hurlcon H120 - H150 Series Hot Water Boiler. Correct

installation and service of your new heating system and correct chemical maintenance of the water

will ensure years of service. The H120 - H150 Series Boiler is a compact lightweight and efficient

gas fired hot water boiler. It is equipped with features that take advantage of new technology

developed exclusively by Hurlcon.

The Hurlcon Boiler is a floor mounted atmospheric boiler with a built in balanced flue for outdoor

installation. The power output is controlled by an integrated electronic controller to maintain the set

point water temperature over a wide load range. In addition, the Hurlcon Boiler is equipped with

electronic ignition. The electronic display tells at a glance the operational status of the boiler.

1.1 NOTICE TO INSTALLERS

This is a Floor Mounted - External – Hot Water Boiler

For use with Natural Gas or LP Gas as per the attached data label.

The information below is given to assist the installer with the installation of this range of H120 –

H150 Boilers. Please read it carefully in order to make the installation as easy as possible and to

ensure the system works well and conforms to the necessary government regulations.

PLEASE READ THESE INSTRUCTIONS BEFORE STARTING THE INSTALLATION.

It is important that this boiler is installed and serviced as detailed in these instructions by an

AUTHORISED person.

This boiler is to be installed and serviced to the requirements of the

Local Building, Gas, Water and Electricity Authorities.

These instructions are to be held by the owner / user after installation.

This boiler must not be used as a SPA or POOL Heater

This appliance must be installed in accordance with the installation instructions, local gas fitting

regulations, the AGA Installation Code AG 601 and any other relevant statutory authorities.

Refer to data plate for details of gas type, gas consumption and burner pressure.

H120 –H150 Hot Water Boilers page 4

2.0 MODELS AVAILABLE

Details Model

120S & 120B Model

150S & 150B

Height 900 900

Length 510 640

Width 390

Gas input 105 MJ 144 MJ

Gas type Natural & L P Gas

Nom output 24 kW (82,000Btu) 35 kW (119,000Btu)

Ignition system Electronic Ignition

Heat exchanger/burner All copper/stainless steel

Boiler Thermostat digital Electronic Genus 1V

Pressure relief 300kPa (3 Bar)

Expansion vessel 7 litre diaphragm (~60lt system)*

Circulator In line Centrifugal Pump*

Hi limit Thermostat 100

C manual reset

Run on timer Electronic temperature and time based.

Pressure reduction valve 1 Bar pre-set *

Packed weight 50kg 60kg

2.1 STANDARD EQUIPMENT

Electronic control including.

•Displays set and flow temperature.

•Electronic ignition

Safety devices

•Built in flow switch

•Built in run on timer

•Manual reset high limit

Built to last

•All copper double row heat exchanger

•Stainless steel burners

•Fully powder coated steel cabinet

•Powder coated flue terminal

Efficiency

•Hot surface ignition

•Highly efficient stainless steel burners

Ease of installation

•Fully plumbed ready to go, including circulator*, expansion tank*, pressure reduction valve*

& 1” flow – return isolation valves.

•All electrical pre wired including three pin power supply.

(* not supplied with ‘B’ model boiler)

H120 –H150 Hot Water Boilers page 5

3.0 INSTALLATION

THIS APPLIANCE MUST BE INSTALLED BY AN AUTHORISED PERSON.

Refer to boiler data plate for specifications of gas type, gas consumption, burner pressure and water

pressure.

This appliance must be installed in accordance with local regulations and A.G.A. Installation Code

AG 601.

The flow and return connections are located on the rear of the boiler. The flow and return

connections are clearly marked and the connections are 1” BSP FI.

The Hurlcon Boiler is fitted with a built in flow switch and will not start unless full of water and the

pump is operating.

The Hurlcon Boiler incorporates a balanced flue terminal and is suitable for outdoor installation. An

internal model is available on request.

3.1 SAFETY RULES

For your safety – read before lighting

This appliance is equipped with an ignition device, which automatically lights the burner. Do not

try to light the burner by hand.

BEFORE OPERATING smell all around the appliance area for gas. Be sure to smell next to the

floor because some gas is heavier than air and will settle on the floor.

Safety

WHAT TO DO IF YOU SMELL GAS

•Do not try to light any gas appliance.

•Do not touch any electrical switch.

•Turn off the gas supply at the gas meter.

•Immediately call your gas supplier or licensed gas fitter.

NOTE. Some gases are heavier than air and it may be necessary to smell for leaks at

floor level.

House keeping

•Do not store or use flammable liquids or chemicals near this appliance.

•Do not use aerosols in the vicinity of this gas appliance.

•Keep this appliance free of debris.

WARNING:

Should overheating occur or the gas supply fail to shut off, turn off the manual gas control valve

to the appliance.

Do not use this boiler if any part has been under water.

H120 –H150 Hot Water Boilers page 6

3.2 GUIDE TO INSTALLATION

Location of Flue Terminals – An extract from AG 601

Minimum Clearances Required For Balanced Flue Terminals or The Terminals Of Outdoor

Appliances.

openable

window

door

See note 3

See note 2

T = Flue terminal

I = Mechanical air inlet M = Gas meter

P = Electricity meter

or fuse box Shading indicates prohibited

areas for flue terminals

MIN. CLEARANCE

(mm)

A Below eaves, balconies and other projections

Appliances up to 50 MJ/h input 300

Appliances over 50 MJ/h input 500

B From the ground, above a balcony or other surface 300

C From a return wall or external corner 500

D From a gas meter (M) 1000

E From an electricity meter or fuse box (P) 500

F From a drain pipe or soil pipe 150

G Horizontally from any building structure (unless appliance approved 500

for closer installation) or obstruction facing a terminal

H From any other flue terminal, cowl, or combustion air intake 500

I Horizontally from an openable window, door, non-mechanical air inlet, or any

other opening into a building with the exception of sub-floor ventilation 500

Appliances up to 150 MJ/h input 500

Appliances over 150 MJ/h input (natural draught) 1500

Appliances over 200 MJ/h input 1500

All fan-assisted flue appliances, in direction of discharge 1500

K From a mechanical air inlet, including a spa blower 1500

N Vertically below an openable window, non-mechanical air inlet, or any other

opening into a building with the exception of sub-floor ventilation See table

CLEARANCE ‘n’ (mm)

Space heaters All other appliances

Up to 50 MJ/h

input Up to 50 MJ/h

input Over 50 MJ/h &

up 150 MJ/h Over 150 MJ/h

input

150 500 1000 1500

NOTES:

1 All distances are measured to the nearest part of the terminal.

2 Prohibited area below electricity meter or fuse box extends to ground level.

3 See Clause 5.13.6.6 for restrictions on a flue terminal under a covered area.

4 See Appendix J, Figures J1(a) and J2(a), for clearances required from a flue terminal to an LP Gas cylinder.

A flue terminal is considered to be a source of ignition.

The above information is part of AG 601 FIGURE 5.3 as supplied by the AGA and is provided as an indication of the

correct clearances only. Please refer to the latest issue of AG 601.

Deleted:

H120 –H150 Hot Water Boilers page 7

3.3 CLEARANCES

The boiler must be installed at least 500mm from any combustible surface. Clearances must comply

with AG 601.

Clearances from non combustible surfaces are:

Front 500mm

Both sides 500mm

Rear 80mm

Above 1500mm

Combustible Surfaces 500mm Minimum

Boiler must be installed on a fireproof base.

3.4 ELECTRICAL CONNECTION

The boiler is supplied with a standard 10 amp 3 pin plug for connection to a 240V 10 amp GPO.

The boiler incorporates a 240/24 VAC transformer which supplies power to the control circuit only

and must not be used for any additional equipment. All equipment connected to mains power

should be protected by an RCD circuit breaker. The boiler has a 240 volt power supply for the pump

electrical connection which incorporates the pump run on feature. A terminal strip is provided for a

24 volt room thermostat.

To enable temperature set-back, cut the blue wire loop at the 4 way connector attached to the control

board. Extend the blue wires to a remote switch or timer with volts free contacts. With contacts

closed, Set 1 is enabled. With contacts open, Set is enabled.

If the supply cord is damaged, it must be replaced by the manufacturer or its service agent or a

similarly qualified person in order to avoid a hazard.

3.4.1 GAS CONNECTION

A ¾”BSP FI is provided for gas line connection. An approved manual shut off valve must be

installed in the gas fitting line before the boiler so that the gas can be turned off and the boiler

removed for servicing if required. The gas shut off valve should be sized the same as the gas fitting

line to prevent excessive pressure drop in the gas pipe.

The gas fitting line should be installed by an authorised person and comply with local regulations

and A.G.A. code AG 601. The gas line from the meter will usually be of a larger size than the gas

inlet connection. Therefore a reduction to the boiler connection fitting will be necessary. The

reduction should be as close to the boiler as possible.

Before using the boiler, test all connections for gas leaks using soapy water.

The boiler gas valve has a built in pressure regulator with a ⅛” pressure test point provided. On

starting the boiler, a manometer must be used and burner pressure checked against the boiler data

plate. The gas valve regulator may need adjustment to correct manifold pressure. Incorrect burner

pressure may void warranty.

H120 –H150 Hot Water Boilers page 8

3.5 BOILER DIMENSIONS

3.6 INDOOR INSTALLATION

If the H120 - 150 Boiler is to be installed indoors, an indoor draught hood kit must be purchased

from Hurlcon and installed on the Boiler to convert it to an indoor model.

Product code numbers for draught hoods are:

Boiler model Indoor top model Flue size Part number

H120 DH 12 125 mm 10134

H150 DH 15 150mm 10970

A flue no smaller than the draught diverter diameter must be installed and terminated with an

approved gas flue cowl (not a Chinaman’s hat) 600mm above any roofline that is within 1.5 metres

horizontally from the flue.

105 130 130 390

H120 – 510

H150 - 640

Front Side Controls

Side Plumbing

900

Flow & Return 1” FI

Cold feed ½” FI

Gas inlet ¾” FI

H120 –H150 Hot Water Boilers page 9

3.7 VENTILATION – AIR SUPPLY TO THE BOILER

When installing the boiler indoors, it is imperative that an adequate supply of fresh air is provided

for combustion. Failure to provide adequate ventilation voids all warranties and may be a danger to

persons or property. Please refer to AG 601 for full details.

Two permanent openings shall be provided directly to outside. The openings shall be located to

ensure the distance between the top of the upper opening and the ceiling of the room or enclosure,

and the distance between the bottom of the lower opening and the floor of the room or enclosure

does not exceed 5% of the height of the room or enclosure.

The minimum vertical dimension of any free ventilation opening shall be 6 mm.

The minimum free ventilation area provided by each opening shall be:

MODELS H120 H150

AREA mm

35,000 50,000

The following diagram is provided as a guide only. All fluing and installation work must be carried

out by an authorized person. Fluing must conform to local regulations and to A.G.A. installation

code AG 601. Care must be taken to provide the correct ventilation and correct fluing materials in

close proximity to combustible surfaces.

A Hurlcon indoor draught diverter must be fitted to unit in accordance with Hurlcon’s

Instructions and Installation Codes before the boiler can be enclosed.

Do not install spa blowers in the same room as a gas boiler. This is potentially dangerous to

spa users.

Do not store chemicals or fuel in the same room as the gas boiler. This may cause fire or

explosion.

When installing in a garage the H120 – 150 Boiler must be installed 450 mm above floor level.

1500

600

Upper grille for fresh

air ventilation

Lower grille for fresh

air ventilation

Approved gas

termination cowl

Bolted

sleeve to

connect flue

Draft diverter

purchased

from Hurlcon

H120 –H150 Hot Water Boilers page 10

3.8 HEATING PIPE SIZE & LAYOUT

•The flow & return connection sizes of 1”BSP on the boiler are not necessarily the correct

pipe sizes for the heating system. It is important that the pipe sizes are correctly calculated

before installation.

•Hurlcon recommend a two pipe system with the pipes sized according to the flow

requirements and length of runs with a maximum water velocity of 1.5 M/s.

•Reference The Institute of Plumbing Australia. - “SELECTION & SIZING OF COPPER

TUBES FOR PIPING SYSTEMS”.

Nominal flow capacities

Model Output Flow rates DT pd min Pipe dia F & R length

120 24 kW 0.38 l/s 15

°C 8 kPa 20 mm 6.0 m

150 35 kW 0.53 l/s 15

°C 14 kPa 25 mm 4.5 m

Notes

1. An automatic heating bypass valve should be fitted to maintain adequate flow rate through the

boiler when thermostatic valves are fitted and or when the majority of radiators are required to be

turned off for long periods of time.

2. Any pipe work that is in an unheated area such as under the floor or in the ceiling space should be

suitably insulated to prevent heat loss and possible freezing of the pipes.

3. The pipe work should be graded to facilitate the elimination of air at the highest point and the

draining of the system at the lowest point. Provide air bleeds and drains at these points.

3.9 SIZING OF PRESSURE VESSEL

If the total water capacity of the heating

system is greater than 60 litres then an

additional pressure vessel should be fitted.

An approximate figure can be calculated

from the following table. An additional

tank can be fitted at a convenient location

on the system if required.

Item Capacity

litres per

Therma rad Radiators 0.70 kW

Thermaboard single 0.22 metre

Thermaboard double 0.44 metre

Copper tube 25 mm 0.44 metre

Copper tube 20 mm 0.23 metre

Copper tube 15 mm 0.10 metre

Typical two pipe system

Hydronic Boiler

Return

Radiator/Heat emitter

Flow

Bypass valve

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