Hamworthy Stratton mk3 User manual

Stratton mk3

40 - 70 kW Frame and Header Kits Manual

IMPORTANT NOTE

THESE INSTRUCTIONS MUST BE READ

AND UNDERSTOOD BEFORE INSTALLING,

COMMISSIONING, OPERATING OR

SERVICING EQUIPMENT

UIN 233246 A01

40 - 70 kW Frame and Header Kits Manual

Stratton mk3 40, 60 & 70 using both Natural Gas and Propane

This kit is suitable for the following boilers:

CONTENTS

1 Introduction.....................................................................3

2 General Description Of Systems...................................4

3 System Components......................................................6

4 Installation Procedure....................................................8

5 Installation Drawings For Boiler Systems..................14

6 Electrical Connections & Wiring Diagram..................17

7 Commissioning and Testing........................................18

IMPORTANT

THESE KITS CAN BE USED IN CONJUNCTION WITH

LOW LOSS HEADERS & PLATE HEAT EXCHANGERS

SUPPLIED AS PART OF THE OPTIONS RANGE

40 - 70 kW Frame and Header Kits Manual

1 INTRODUCTION

This technical data contains information for

dimensioning and assembly of a cascade system kit

for the Stratton mk3 ranges.

These 40-70kW kits are supplied with gas and

water header kits designed for use with a low loss

header system.

They are based around a 1 wide and 2 wide system

which can be combined to create up to a 6 wide

cascade, along with all the necessary mounting

holes to enable the tting of the header kits and

frame securing bolts.

This manual contains all the technical and

dimensional data required to install these kits.

GENERAL DESCRIPTION OF FRAME AND

HEADER KITS

These systems are adapted to incorporate the use

of low loss headers, plate heat exchangers and

optional sequencer control systems.

All these kits are supplied with the relevant

number of necessary parts needed to connect

these kits to the separately purchased appliances.

Boiler pumps are an accessory, and must be

selected for either low loss headers or plate heat

exchangers.

The ue congurations for the range of appliances using these system kits are C13, C33 & B23 (See appliance manual).

All headers and pipe work should be insulated in accordance with the Non Domestic Building Services Compliance Guide.

To ensure compliance with the maximum heat loss criteria, insulation thickness should be calculated according to BS EN

ISO 12241 using standardised assumptions.

40 - 70 kW Frame and Header Kits Manual

Available Rig

Congurations

Total Output

Required (KW)

Number of

boilers and

Frames

Footprint Size

WxDxH (mm)

Header Kit

Range Size

Prod No.

Single Frame Congurations 40 - 70 1 500 x 685 x 1418 DN50 232859

Twin Frame Congurations 80 - 140 2 1000 x 685 x 1418 DN50 232860

Triple Frame Congurations 120 - 210 3 1500 x 685 x 1418 DN50 232861

Quad Frame Congurations 160 - 280 4 2000 x 685 x 1418 DN50 232862

Five Frame Congurations 200 - 300 5* 2500 x 685 x 1418 DN50 232863

Six Frame Congurations 240 6** 3000 x 685 x 1418 DN50 232864

Available Appliances

kW Product No.

Stratton mk3 S 3 40 AA082635

Stratton mk3 S 3 60 AA082636

Stratton mk3 S 3 70 AA082637

Low Loss Header Accessories (Mixing Header)

DN50

232875

Note.

All boilers need to be sized in accordance to the total required heat load and the modulation capabilities of the appliances.

* Max 5 x 60 kW only

** Max 6 x 40 kW only

A one wide system is dened as tting one pipe kit with a single frame and one boiler.

A two wide system is two boilers on two separate frames bolted together with a pipe kit which serves the two wide system.

These one and two wide systems can be combined in any permutation to create up to a six wide cascade.

2.1 FRAME AND HEADER KIT DESIGN OPTIONS

2 GENERAL DESCRIPTION OF SYSTEMS

1. These water headers and pumps (accessory) are designed for use with a low loss header system (option), or plate heat

exchangers only (option).

2. Appliances are not provided with these kits and will be required to be purchased separately.

40 - 70 kW Frame and Header Kits Manual

2.2 MULTIPLE BOILER INSTALLATIONS

When sizing multiple appliance installations, the minimum and maximum system heat load requirements need to be matched to

the minimum and maximum appliance load capabilities.

These water header & pump kits are design to supply the optimum water ow around the appliance water circuit only and must

be used in conjunction with a suitably sized low loss header (mixing header) or plate heat exchanger.

2.3 HYDRONIC ISOLATION: LOW LOSS HEADER & PLATE HEAT EXCHANGER

A low loss header allows ow separation within a hydronic system.

This allows two ow circuits to operate with their own ow and pressure drop environments whilst e󰀨ectively transferring heat to

its adjoined water circuit.

This enables the modern high resistant, high e󰀩ciency boilers to operate under their optimum conditions, while the main heating

circuit operates to its own controlled optimum requirements.

2.4 OUTPUT CONTROL

All pumps (optional) controls should be designed to be wired to the appliance to allow a controlled pump over run.

If using an external pump control system the capability of a timed pump over run signal provided by the appliance must be

maintained at all times.

2.5 GAS SUPPLY

The water header kits are supplied with a 2” gas header, associated components and hoses to make the connection to the

appliance

Note: Test points are provided at each end of the 2” gas header. The test point nearest to the gas inlet is intended to be used as

the appliance inlet pressure point.

2.6 ASSEMBLY

The frames must be located in a suitable place that a󰀨ords a at and level oor area of suitable load bearing capacity. Care must

be taken when locating the frames that space is available for the servicing, installation and maintenance of the appliance and all

of the associated connections and equipment. (See Appliance manuals)

When using multiple frames they must be bolted together and secure to the oor.

2.7 SAFE HANDLING

Installation may require 2 or more operatives to move it to its installation site, remove it from its packaging base and during movement

into its installation location. Manoeuvring may include the use of a sack truck and involve lifting, pushing and pulling.

Caution should be exercised during these operations.

Operatives should be knowledgeable in handling techniques when performing these tasks and the following precautions should be

considered:

• Grip the boiler at the base.

• Be physically capable.

• Use personal protective equipment as appropriate, e.g. gloves, safety footwear.

During all manoeuvres and handling actions, every attempt should be made to ensure the following unless unavoidable and/or

the weight is light.

• Keep back straight.

• Avoid twisting at the waist.

• Avoid upper body/top heavy bending.

• Always grip with the palm of the hand.

• Use designated hand holds.

• Keep load as close to the body as possible.

• Always use assistance if required.

40 - 70 kW Frame and Header Kits Manual

• 2” gas header with inlet test points

• All the associated safety controls, pipes and ttings

required to connect the water and gas header to the

appliances are supplied. Di󰀨erent pumps are available as

options.

3.1 MAIN WATER HEADERS

The main water header consists of un-insulated water ow and

return pipes incorporating location and frame mounting brackets

sized to cater for the range of products available for use with

these kits.

The Single unit water header is a DN50 pipe system with

threaded connections. (Threaded anges are provided with

DN50 50 - 70 kW Low loss header kit).

3.2 GAS HEADER

The gas header consists of a 2” manifold tailored to t the two,

three or four unit versions available and is located in the cradle

incorporated in the water header bracket structure.

All the pipe work and connections are provided to connect the

header to the required appliance.

Test points are provided at each end of the 2” gas header. The

test point nearest to the gas inlet is intended to be used as the

appliance inlet pressure point.

3.3 LOW LOSS HEADERS (MIXING

HEADERS)

All variants of these kits (optional) must be tted to suitably sized low

loss header.

Note; Bespoke low loss headers may not be able to connect

directly to these headers due to the change in pitch and position

of the header pipe work used in these kits. (See frame t low loss

header)

Hamworthy recommend:- DN50 – 232875.

3.4 BOILER PUMP

Pump kits and External pump controls (sold separately) are

designed to provide the optimum ow around the appliance

water circuit ensuring the maximum ow rates are contained

within the design constrains of the appliance.

It is not recommended to t additional pumps directly to the

appliance circuit unless they have been designed to ensure the

maximum permissible appliance ow rate is not exceeded.

3.5 BOILER CONNECTION KITS

These boiler connections are un-insulated and contain the

following:

LEGEND

1. 1 ¼” x 1 ¼” x ¾” Tee

2. 3/4" Taper plug

3. 1 ¼” Male Parallel/Taper Hex Nipple

4. 1 ¼” x 1 ¼” x ½” Tee

5. Drain cock

6. Non return valve

7. Pump union

8. Pump inc. gaskets (optional)

Note. For boiler connection assembly, refer to Frame 4.4

3.6 FREE-STANDING FRAMES

The low height frames are designed to provide a compact

oor mounted structure capable of having any of the range of

appliances tted to them.

Incorporating all the required mountings and assembly systems

to bolt up to four frames together in a side by side format and

mount the relevant water and gas heater kits.

Provision is also provided to allow the frames to be bolted to the

oor.

Note: Floor mounting bolts are NOT provided.

3.7 INSTALLATION AREA AND

DIMENSIONS

Care must be taken to ensure adequate access for boiler /

cascade system installation and servicing.

A minimum of 450mm clearance must be provided from the

front of the installed boilers to facilitate boiler servicing.

Additional clearance must also be considered in the event of

boiler replacement.

Consideration to connecting heating ow and return pipework,

gas supply and condensate drainage must be given. Routing

of the condensate drain must be made to allow a minimum fall

of 1 in 20 away from the installed boilers, throughout its length.

Adequate room above the boilers must be provided to install

and service the boiler ue system. Further information with

respect to ue and condensate drain connection is provided in

the installation and servicing instructions provided within the

boilers packaging carton.

3 SYSTEM COMPONENTS

Note. Isolating Valves

are tted to water

header along with

exible connecting

pipes.

FLOW RETURN

40 - 70 kW Frame and Header Kits Manual

IMPORTANT POINTS

Before commencing installation:

If Wall mounting;

• Ensure wall is capable of supporting the weight of boilers to

be mounted

• Mark drill points of header using the frame as a guide.

• Mark height on to the wall from the oor to the top of the

boiler

• Ensure oor is at and level and is of suitable load bearing

capacity

If Frame mounting;

• The frames must stand on a at and level oor of suitable

load bearing capacity.

• If using a pipekit the header must be bolted to the frame

before the hoses are connected to the boiler.

MOUNTING FRAME MUST BE SECURED TO THE FLOOR

WITH BOLTS

These Installations refer to perpendicular wall and oor. If

walls are not perpendicular, it is recommended that a pipekit be

used.

Allowances must be made for installation where skirting boards

or other features are in place that may a󰀨ect the nominal

installation conditions.

40 - 70 kW Frame and Header Kits Manual

4 INSTALLATION PROCEDURE

4.1 WALL MOUNTED SIDE BY SIDE OPTION

Ensure wall is capable of supporting the weight of boilers to be mounted. Note. boiler weights can found in the boiler

Installation Instructions.

1. Cut the sides o󰀨 the cardboard wall mounting template/s (found in the boiler packaging) to create the 50mm side clearance

required.

2. Mark the height on to the wall from the oor to the top of the boiler as shown in Section 4.1.

3. Tape the template/s to the wall ensuring the 50mm side clearance per boiler requirement is adhered to.

4. Drill the required holes in the wall to t the wall mounting plate plugs. (See boiler Installation Instructions for details)

5. Screw the wall mounting plate(s) to the wall.

continued . . . . .

40 - 70 kW Frame and Header Kits Manual

4.1 WALL MOUNTED SIDE BY SIDE OPTION CONT'D............

1388 10

GAS

360

HEADER

505

All dimensions in mm

Careful consideration MUST be given to the installation tolerances. See Section 3.7.

if these are not adhered to, hoses may become kinked or connections may not t.

SIDE VIEW PLAN VIEW

40 - 70 kW Frame and Header Kits Manual

4.2 SIDE BY SIDE FRAME KIT MOUNTING PROCEDURE

1. Place the frame kit sections in the required position and bolt them together at the top and bottom with the bolts, nuts and

washers provided.

2. Drill and t the required oor bolt's (not provided) through the hole provided in the front of the frame feet. (Note, this must

be done before tting water headers)

IMPORTANT: MOUNTING FRAME MUST BE SECURED TO THE FLOOR WITH BOLTS

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