INSTALLATION AND OPERATING INSTRUCTIONS HM Series
Contents
1. da dead demanding 12 50 OPERATING INSTRUCTIONS oi sccscsscccecesoscosascoscsnncensconnsansnsestosessasinensanscensenessadsenssensnceniss 12 5 4 FROST oeenn eisini 12 52 ENERGY SAVING TIPS 12 5 3 CONTROL SYSTEMS eee 13 clave moreso enemies demas panne yemanamerameeeannis 14 54 MAINTENANCE scccoisstiecnsssansinsavssevataevucnatunvenencassactardsvensntanicnialansvasasdesebouteuiniasesvanbants 14 60 GAS CONVERSION s sssesssesssossesssisssosssessssssssessoesssessoosstsssessosssonsSsos eesse isoosspri eoira s os5ses 15 61 BURNER CONVERSION 15 62 GAS PIPE SIZING TABLES Leren 16 70 TROUBLESHOOTING sc ssssssersssssseossssissssosusseosssosssessssssosssosscessss soesososssossssssre ssssssosssssess 16 E E E T 17 8 0 HM SERIES WIRING DIAGRAM essesersesesoseseseseososossesososeseseosososeesosososesessososossesosesssee 18 8 1 MODEL NAN 18 82 NPS Lapeer 18 9 0 AONE YEAR LIMITED VRV ae 19 Inst195 HM Series Hydronic Boiler V10_10 1 0 INTRODUCTION Congratulations on your purchase of Hurlcon Hydronic Boiler Correct installation and service of your new heating system and correct chemical maintenance of the water will ensure years of service The HM Series Boiler is compact lightweight and efficient gas fi2. N18 N10 N10 500 3 30 mm silver 0 78 kPa 1 9mm black 2 50 kPa 1 9 black 2 00 kPa Inst195 HM Series Hydronic Boiler V10_10 15 6 2 GAS PIPE SIZING TABLES Natural gas at 1 13 kPa gas meter pressure VICTORIA Maximum run of copper pipe with average number of fittings Model 20 mm 25 mm 32 mm 40 mm 50 mm HM 200 2m 8m 30 m 75m 320 m HM 250 6m 18m 45 220 m HM 300 4m 14m 35m 140 m HM 400 3m 8m 20m 90 m HM 500 1 6m 14m 60 m 1 25 gas meter pressure S A W A some areas N S W Maximum run of copper pipe with average number of fittings Model 20 mm 25 mm 32 mm 40 mm 50 mm HM 200 6m 25m 90 m 240 320 m HM 250 4m 18m 60 m 160 m 320 m HM 300 3m 14m 45m 110 m 320 m HM 400 2m 8m 25m 70m 300 m HM 500 6m 18m 45m 200 m 2 75 kPa gas meter pressure N S W some areas some new areas of Victoria Maximum run of copper pipe with average number of fittings Model 15mm 20 mm 25 32 200 4m 40 160 m 320 m HM 250 3m 25m 100 m 320 m HM 300 2m 20m 85 280 m HM 400 12m 50 m 160 m HM 500 8m 35 m 100 m 7 0 TROUBLESHOOTING BOILER WILL NOT LIGHT Possible cause Remedy Automatic ignition system fails Check water flow light indicator Pump not running Check pump and flow switch Pump air locked Air bleed
3. 8 0 HM SERIES WIRING DIAGRAM 8 1 MODEL 200 400 3 LED BOARD WH PUMP RUN BL WH ON TIMER SR BURNER BR 9 RESET an T F 15 2 BI WH D ee EP FN 18 B1 A p p ner M6 2 N her ok ted RD l 014 OR Q13 Gi Et PA PL vi SENSOR S sel DE PG Ge le 3 PIN PLUG FLOW SWITCH R n o i BR BL BR BROWN D WH WHITE RD RED ju D1 PL PURPLE BL BLUE _ g a On GND irs 7 VALVE
4. anti clockwise to decrease burner pressure Maximum inlet gas pressure is Natural Gas 3 5 kPa Propane Gas 3 5 kPa ULPG 3 5 kPa Nominal burner pressure is HM 250 HM 300 HM 400 Natural Gas kPa High Flame 0 82 0 82 0 75 Low Flame 0 10 0 10 0 10 Propane Gas kPa High Flame 2 50 2 50 2 50 Low Flame 0 80 0 80 0 80 ULPG kPa High Flame 2 00 2 00 2 00 Low Flame 0 80 0 80 0 80 Inst195 HM Series Hydronic Boiler V10 10 10 4 3 CHECKING MINIMUM GAS PRESSURE ONA RON Set up manometer Turn boiler OFF Remove screw from brass test point located on outlet side of gas valve burner manifold Connect manometer tube to test point Turn boiler ON and wait for main burner to ignite Press and hold EXIT button for 5 seconds Hand indicator lights Press and hold Decrease button to move gas ball valve to lowest setting Read gas pressure 4 4 ADJUSTING MINIMUM GAS PRESSURE Increasing minimum gas pressure Press Increase button until correct pressure 15 reached Release locking screw Move actuator to lowest setting Tighten locking screw Return to automatic operation by pressing EXIT for 5 seconds Decreasing minimum gas pressure PARKEN Inst195 HM Series Hydronic Boiler V10 10 Release locking screw Move actuator toward the maximum setting Tighten locking screw Press and hold Decrease button to move gas valve to lowest setting Repeat
5. Ready indicator off Room thermostat switches on Pump restarts burner ignites Water flow stopped by external control Flow switch de activates burner turns off and pump continues to run for preset time Flow indicator off Water flow is reinstated Flow switch reactivates burner re ignites Flow indicator on 5 4 MAINTENANCE It is recommended that the following items are professionally checked at least every six months and at the beginning of every heating season 1 Examine the balanced flue or indoor draught diverter Make sure there are no obstructions to the flow of air to or flue products from the appliance 2 Visually check the main burner and pilot flames If the flame appears yellow the burner should be cleaned by a qualified service technician 3 Keep the boiler area clear and free of combustibles and flammable liquids Chlorine should not be stored in the vicinity of the boiler Chlorine vapours when drawn through a boiler can rapidly cause corrosion of the heat exchanger 4 Keep the boiler area free from garden refuse and debris This will help prevent insects nesting in the unit and ensure extended life and reliability of your boiler Inst195 HM Series Hydronic Boiler V10_10 14 6 0 GAS CONVERSION 6 1 BURNER CONVERSION 1 Turn off gas supply to unit 2 Turn off power supply to pump and boiler 3 Remove front access door 4 Disco
6. is activated Standard settings are as follows Radiator amp Fan Coil System Set temp Dead zone High limit High Limit Automatic reset Manual Reset 80 C 5 C 85 C 90 1151195 HM Series Hydronic Boiler V10 10 13 OPERATION Sequence of events once the boiler has been correctly installed with the room thermostat and burner turned off Event Result Turn on electrical power to the boiler Controller powers up and completes test procedure Pump starts up Flow indicator on Turn on burner switch Turn on room thermostat Ignition sequence begins checks water flow high limit and flow temperature against set temperature Modulation valve adjusts gas rate Ready indicator on Burner lights Burner indicator on Water flow reaches set temperature Modulation valve has reduced gas flow to hold set temperature All indicators on Water flow temperature reaches set temperature plus 5 Burner turns off Burner indicator off Water flow temperature falls to set temperature Modulating gas valves starts to open Burner relights Burner indicator on Water flow temperature reaches 90 C High limit switch opens burner shuts down Pump continues to run for preset time Burner switch turned off Burner shuts down pump continues to run Ready indicator off Room thermostat switches off Burner shuts down pump continues to run for preset time
7. nipple 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 valves 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 larger size than the gas inlet connection Therefore 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 built in pressure regulator pressure test point is provided on the burner manifold On starting the boiler 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 3 8 PUMP SELECTION If a pump has not been supplied by your Dealer as part of this Boiler package it will be necessary to size the Pump in accordance with the following flow rate and pressure drop chart System pressure drop will need to be added to the corresponding boiler pressure drop FLOW RATES amp PRESSURE DRO
8. system amp pump bearing Flow switch open By pass to test Defective gas control Shut off gas supply and call for service Thermostat turned off Turn on Set temperature lower than water temperature Increase set temperature Water too hot fault condition displayed Refer to fault indication table High Limit Thermostat open Reset Insufficient water flow Check for too many valves turned off BOILER MAKING KNOCKING NOISES Possible cause Remedy Boiler operating after pump has shut off Shut off gas supply and call for service Heat exchanger scaled Shut off gas supply and call for service Inst195 HM Series Hydronic Boiler V10_10 16 If the boiler cannot be made to perform correctly please contact the Hurlcon Service Office closest to you For VICTORIA Phone 03 9765 9765 NEW SOUTH WALES Phone 02 9674 8544 QUEENSLAND Phone 07 3393 3233 SOUTH AUSTRALIA Phone 08 8345 5755 WEST AUSTRALIA Phone 08 9258 9322 For all other areas please contact our Victorian office Siemens RWF40 controller program standard settings To access press and hold PRG for 10 seconds Process data Parameter Display Actual Factory Settings Setting Setpoint 1 SP1 80 Setpoint 2 optional SP2 0 Digital Setpoint Shift optional Dsp 0 Outside Temperatur
9. 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 for a SPA or POOL Boiler 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 Inst195 HM Series Hydronic Boiler V10_10 3 2 0 HM MODELS AVAILABLE Model 250 300 400 Input MJ NG 240 288 350 Output kW 55 66 80 2 1 STANDARD EQUIPMENT HM MODELS Electronic control including PID control with auto tune Set point shift via building automation system Displays set and flow temperature Electronic ignition Safety devices e Built in flow switch Built in run on timer for pump Manual reset high limit e Reliable in high wind areas Built to last All copper double row heat exchanger e Bronze headers with brass sensor pockets e Fully powder coated steel cabinet e Powder coated flue terminal Efficiency e Hot surface intermittent pilot e Highly efficient stainless steel burners e Double row counter flow heat exchanger e Out door compensation ready just add outdoor sensor e Electronic gas modulation turn down 3 1 Ease of installation Fully plumbed ready to go All electrical pre wi
10. E G G PUMP ANE hj CONNECTION ev 2 5 5 x lt Red GN RWF40 CONTROLLER GAS VALVE 3 LED BOARD WH PUMP RUN BL 3 WH ON TIMER OR BURNER BR rvs e RESET T K e ab 5 GY 063 B9 WH bd Ed INT O e f ee l 1 Po M6 N TRANSFORMER L EL me fi aL RD 914 6 N og Gt vi SENSOR HI LIMIT ____ ce 3 PIN PLUG FLOW SWITCH x 9 BL BR BROWN 2 WH WHITE RD RED D1 PL PURPLE F on BL BLUE g GND 225 WH G zz BR 10 PUMP IGNITION CONNECTION MODULE lt o 2 S Leeee De lt ee 1 RWF40 CONTROLLER BL H e L Y1 Y2 gt MODGAS VALVE IGNITOR VALVE 1151195 HM Series Hydronic Boiler V10 10 18 9 0 ONE YEAR LIMITED WARRANTY GENERAL CONDITIONS Hurlcon cover your boiler with a limited 1 year warranty against defective materials and workmanship from the date of purchase plus 30 days to allow for installation The heat exchanger including headers are covered by a five year warranty plus 30 days to allow for installation Proof of purchase date must be
11. INSTALLATION AND OPERATING INSTRUCTIONS INSTALLATION AND OPERATING INSTRUCTIONS INSTALLATION AND OPERATING INSTRUCTIONS Melbourne 03 95542275 Coast 07 5552 2600 Perth 08 9350 2600 Sydney 02 9853 2100 Townsville 7 sales hurlconheating com au Brisbane 07 3308 5400 Adelaide 08 81 www hurlconheating com au INDEX 10 INTRODUCTION 3 LA NOTICE TO INS TALUS 3 20 HM MODELS AVAILABLE ci csssssssssssvsssvdscsossnsscnssonsssavevsascsis sntsasnsensdcussencsesehnsseesisatescsonctes 4 21 STANDARD EQUIPMENT HM MODELS 4 30 INSTALLATION arsen 5 Sak SAFETY RULES eee 5 3 2 BOILER 6 INDOOR INSTALLATION Lune 6 3 4 VENTILATION Air supply to the 7 3 9 ER NER 8 36 ELECTRICAL CONNECTION 8 3 7 GAS ninna aa ei 9 38 PUMP SELEG TION spes 9 40 5 10 STARTING BOILER 10 4 2 TESTING BURNER PRESSURE 10 43 CHECKING MINIMUM GAS 11 44 ADJUSTING MINIMUM GAS PRESSURE rnrvrvrervvnrrnrrsvnvenernrrrerrrnerrersenersensenenne 11 4 5 FLOW SWITCH
12. PS Boiler Model 250 300 400 Flow l s 1 33 1 59 2 13 10 Deg C Rise Boiler pressure drop kPa 1 90 2 50 5 10 Flow l s 0 89 1 06 1 42 15 Deg Rise Boiler pressure drop kPa 1 60 2 00 4 20 Flow 1 5 0 66 0 80 1 06 20 Deg C Rise Boiler pressure drop kPa 0 44 0 69 1 47 Inst195 HM Series Hydronic Boiler V10 10 4 0 COMMISSIONING 4 1 STARTING THE BOILER 1 Purge gas line of any air and wait five minutes for gas to clear 2 Plug three pin plug into suitable power point and switch on The READY indicator should light Digital controller should now operate and indicate water temperature 3 Pump should start the FLOW indicator should light 4 Turn Burner Switch ON 5 After a few seconds the burner should ignite Ignition will be confirmed by the BURNER indicator 6 If the burner fails to light check FLOW indicator is on Turn burner switch off then on to reset ignition system 4 2 TESTING BURNER PRESSURE 1 Set up manometer 2 Turn boiler OFF Remove screw from 7 brass test point located on outlet side of gas valve burner manifold 4 Connect manometer tube to test point 5 Turn boiler ON and wait for main burner to ignite and gas modulation to go to fully open 6 Once main burner has ignited the manometer must indicate the nominal burner pressure listed below 7 To adjust gas valve regulator remove regulator adjustment cap and using a screwdriver turn plastic bush clockwise to increase
13. cal dimension of any free ventilation opening shall be 6 mm The minimum free ventilation area provided by each opening shall be MODELS HM 200 250 300 400 500 AREA 65 000 80 000 100 000 130 000 160 000 The following diagram is provided as a guide only All flueing and installation work must be carried out by an authorized person Flueing 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 flueing materials in close proximity to combustible surfaces Approved gas amp termination cowl Bolted sleeve to connect flue Draft diverter purchased from Hurlcon Upper grille for fresh air ventilation Lower grille for fresh air ventilation 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 HM Boiler must be installed 450 mm above floor level Inst195 HM Series Hydronic Boiler V10_10 7 3 5 CLEARANCES The boiler must be installed at least 500 mm from any combustible surface Clearances must with 601 Clearances from non combustible surfaces are Front 500mm Both sid
14. conditions causing an inadequate water circulation Incorrect gas pressure or gas supply Incorrect or excessive flow rate of water Failing to correct bleed water system of air Chemical contamination of combustion air or use of chemical additives to the water No person is authorised to make any warranties on Hurlcon s behalf To place a service call contact your nearest Hurlcon office Inst195 HM Series Hydronic Boiler V10_10 19 INSTALLATION AND OPERATING INSTRUCTIONS INSTALLATION AND OPERATING INSTRUCTIONS Victoria Ph 03 9554 2275 Fax 03 9554 2272 HURLCON HEATING Pty Limited A B N 97 007 284 504 www hurlconheating com au email service hurlconheating com au Information and specifications subject to change without notice New South Wales Queensland South Australia Western Australia Gold Coast Townsville Ph 02 9853 2100 Ph 07 3308 5400 Ph 08 8152 7600 Ph 08 9350 2600 Ph 07 5552 2600 Ph 07 4750 3100 Fax 02 98532170 Fax 07 3308 5470 gt Fax 08 8152 7670 Fax 08 9350 2670 Fax 07 5552 2670 Fax 07 4750 3170 Inst195 HM Series Hydronic Boiler V10_10 20
15. e optional tA Predefinition of external setpoint SPE Parameter Level Parameter Display Factory Setting Limit value of limit comparator AL 0 Switching differential for limit comparator HySt 0 Proportional band Pb 1 20 Derivative time dt 30 Integral action time rt 120 Contact spacing db 2 Actuator running time tt 60 Switch on threshold burner stage II HyS1 2 Switch off threshold stage Il HyS2 0 Upper switch off threshold HyS3 4 Response threshold 0 Heating curve slope H 4 Parallel displacement P 0 access press and hold PRG for 10 seconds for second time Configuration Level Parameter Display Factory Setting Analog input 1 2 amp 3 setpoint changeover shift C111 9030 Limit comparator controller type setpoint 1 locking C112 0010 Unit address decimal place unit signal for out of range C113 0100 Measurement range start analog input 1 SCL 0 Measurement range end analog input 1 SCH 100 Measurement range start analog input 2 SCL2 0 Measurement range end analog input 2 SCH2 0 Lower setpoint limit SPL 50 Upper setpoint limit SPH 85 Actual value correction analog input 1 OFF1 0 Actual value correction analog input 2 OFF2 0 Actual value correction analog input 3 OFF3 0 Filter time constant for digital filter analog input 1 DF1 1 For OUTDOOR TEMP control refer to wiring diagram For NIGHT SETBACK connect D2 and Ground on RWF40 Inst195 HM Series Hydronic Boiler V10 10 17
16. es 500mm Rear 500mm Above 1500mm Combustible Surfaces 500mm Minimum Recommended service clearances 500mm on both sides and 1000 in front for component removal connections and servicing Boiler must be installed on a fireproof base 3 6 ELECTRICAL CONNECTION The boiler is supplied with standard 10 amp 3 pin plug for connection to 240V 10 amp GPO The boiler incorporates 240 24 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 240 volt power supply for the pump electrical connection which incorporates the pump run on timer terminal strip is provided for 24 volt room thermostat and the addition of an outdoor compensation sensor If the supply cord is damaged it must be replaced by the manufacturer or its service agent or similarly qualified person in order to avoid a hazard Electrical connections Connect circulator to these connections 240 Volts 5 Amps max Use relays for higher capacity or 3 phase pumps Field wiring of outdoor sensor by others Remove loop to connect room thermostat 24 VOLT The thermostat cannot be powered from this circuit dry contact must be provided Inst195 HM Series Hydronic Boiler V10 10 3 7 GAS CONNECTION The gas connection is on the left side of the boiler A 20 mm 25mm for HM 500 flare
17. floor because some gas 15 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 not store or use flammable liquid or chemicals near this appliance e not use aerosols in the vicinity of this gas appliance e 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 Inst195 HM Series Hydronic Boiler V10_10 5 3 2 BOILER DIMENSIONS MODEL DIM A DIM DIM DIM 200 640 175 405 515 250 710 175 405 315 1 300 273 200 410 540 DRAFT DIVERTER Bea INDOOR MODEL ONLY 400 910 250 515 710 500 1100 305 695 2110 I t 1 q 0 786 1 930 HM500 ONLY 5 1 4 260 y by GAS PIPE L i INLET 20
18. mm Le A oo 25mm HM500 ONLY 580 00 3 3 INDOOR INSTALLATION If the HM Boiler is to be installed indoors an indoor draught hood kit must be purchased from Hurlcon and installed on the HM Boiler to convert it to an indoor model Product code numbers for draught hoods Boiler model Indoor top model Flue size Part number HM 200 DH 20 175 mm 10966 HM 250 DH 25 175 mm 10964 HM 300 DH 30 200 mm 10967 HM 400 DH 40 250 mm 10965 HM 500 DH 50 300 mm 10968 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 Inst195 HM Series Hydronic Boiler V10_10 6 3 4 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 AGA 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 verti
19. nnect gas supply from gas valve 5 Remove the two Phillips head screws from the angle brackets at the end of the manifold tube securing burner assembly to combustion chamber 6 Disconnect wiring from gas valve 7 Remove drive motor form gas valve 8 Slide complete burner tray out through the access opening 9 Remove the four s s bolts securing the injector manifold to the burner tray 10 Remove burner injectors and replace with desired gas type injectors 11 Remove pilot burner and change pilot injector to desired gas type 12 Remove regulator screw cap from top of gas valve 13 Turn plastic plug anti clockwise until fully removed and withdraw spring 14 Insert spring for desired gas type and re install plastic plug 15 Re install burner assembly and reconnect gas supply 16 Check gas system for leaks 17 Commence lighting procedure as described above 18 Adjust burner pressure as described above Natural Gas Propane Gas ULPG Gas Injector Pilot Burner Injector Pilot Burner Injector Pilot Burner Model size Size pressure size size pressure size size pressure N18 N10 N10 200 3 30 mm silver 0 82 kPa 1 9mm black 2 50 kPa 1 9 black 2 00 kPa N18 N10 N10 250 3 30 mm silver 0 82 kPa 1 9mm black 2 50 kPa 1 9 black 2 00 kPa N18 N10 N10 300 3 30 mm silver 0 82 kPa 1 9mm black 2 50 kPa 1 9 black 2 00 kPa N18 N10 N10 400 3 30 mm silver 0 75 kPa 1 9 black 2 50 kPa 1 9 black 2 00
20. provided in order to substantiate warranty claim The warranty includes in field labour costs where the boiler is installed in a capital city metropolitan area Labour charges apply to boilers installed outside of these areas Any costs for transport of faulty or replacement parts removal or reinstallation are the owner s responsibility Hurlcon assumes no liability for consequential damages of any kind Like your motor vehicle your new boiler requires periodic service and maintenance to keep it operating in top condition and at maximum efficiency An annual service by one of our qualified service technicians is highly recommended LIMITATIONS All warranties only apply if the boiler is installed and operated in complete compliance with the installation and operating instructions The warranty shall not apply to any boilers or parts that have been subject to accident negligence alteration abuse or misuse ADDITIONAL WARRANTY EXCLUSIONS This warranty does not cover failures or malfunctions resulting from e Failure to properly install operate or maintain the boiler in accordance with our printed instructions provided e Abuse alteration accident fire flood and the like Examples of misuse or neglect include but are not limited to physical damage from external force not following installation instructions leaving door off for extended periods of time inappropriate application of the boiler etc Scaling freezing or other
21. red hydronic boiler It is equipped with features that take advantage of new technology developed exclusively by Hurlcon The Hurlcon 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 Hydronic Boiler is equipped with electronic ignition The electronic display tells at a glance the operational status of the boiler Note The appliance is not intended for use by young children or infirm person without supervision Please ensure that young children are supervised to ensure that they do not play with the appliance 1 1 NOTICE TO INSTALLERS This is a Floor Mounted External Hydronic Central Heating Boiler For use with Natural Gas or LP Gas as per the attached data label Australian Gas Association Tested AGA Approval No 6423 The information below is given to assist the installer with the installation of this range of HYDRONIC HM 200 500 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
22. red including three pin power supply Flow switch run on timer installed and wired Weather proof balanced flue external installation Terminal box for pump outdoor compensation and room thermostat Inst195 HM Series Hydronic Boiler V10_10 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 boiler should always be installed downstream of the pump The water connections are located on the left hand side of the boiler Right hand connection models are available by special order The inlet and outlet are clearly marked Water connections are 1 2 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 balanced flue terminal and is suitable for outdoor installation An internal model is available on request WARNING An approved pressure relief valve must be fitted to this boiler before operation 3 1 SAFETY RULES For your safety read before lighting This appliance is equipped with an ignition device which automatically lights the pilot Do not try to light the pilot by hand BEFORE OPERATING smell all around the appliance area for gas Be sure to smell next to the
23. s etc should be closed to stop the loss of warm air During the summer or while on vacation turn the boiler off Set up a regular program of preventative maintenance for the boiler each new heating season Check heat exchanger controls burner operation etc e If the heating system will not be used for a prolonged period turn the boiler off at the main gas valve and electrical power supply Inst195 HM Series Hydronic Boiler V10_10 12 5 3 CONTROL SYSTEMS DIGITAL CONTROLLER OPERATION DESCRIPTION The sophisticated digital thermostat controller provides display of water flow temperature set point temperature and operating status of the boiler TEMPERATURE DISPLAY The RED display indicates the flow water temperature from the boiler The GREEN display indicates the boiler water flow set temperature Flow Temp Set Point Temp QDO MOs Manual operation Control system ready Modulating valve closing Modulating valve opening Not used Limit Comparator Increase value button Decrease value button Program set button Program exit button The controller is set to Hurlcon factory default settings at the time of manufacture These settings are suitable for a wide range of applications but may require fine tuning depending on individual project specifications and characteristics A detailed Siemens RWF 40 product manual is available on request which details how all settings are made and the auto tune function
24. until correct minimum gas pressure 15 achieved Return to automatic operation by pressing EXIT for 5 seconds 11 4 5 FLOW SWITCH The Hurlcon Boiler has an inbuilt flow switch which allows the burner to operate only when the system is full of water and the circulating pump is operating NOTE The installed flow switch has no user adjustments Air in the system may stop the boiler from lighting 5 0 OPERATING INSTRUCTIONS e STOP Read the safety rules above Turn off electric power to appliance This appliance is equipped with an ignition device which automatically lights the pilot Do not try to light the pilot by hand Wait five minutes to clear out any gas If you then smell gas STOP Refer to instructions above Turn on power to appliance Turn Burner Switch ON The boiler will ignite in around 10 seconds If the appliance will not operate turn burner switch OFF for 5 seconds then ON again If the appliance still does not ignite call your service technician TO TURN GAS OFF TO APPLIANCE Turn off all electrical power to the appliance e Turn off gas tap in gas line prior to boiler 5 1 FROST PROTECTION If there is any possibility of the boiler being left cold during frost conditions an approved anti freeze should be added 5 2 ENERGY SAVING TIPS Make sure the ingress of cold air under doors and through gaps around windows is kept to a minimum All open fire chimneys evaporative air conditioning duct
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