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METROSE-E

Cast iron sectionalfuel oil/gas boilers

06/12/01 - 94862839 - 8555-4428A

Hartley & Sugden

Assembly,Installation and maintenance

instructions

This product complies with the requirements of the following European directives and standards :

- 90.396 CEE Gas device Directive Relevant standard : EN 303.1 / EN 303.2 / EN 304.

- 73.23 CEE Low voltage Directive Relevant standard : EN 60.335.1.

- 89.336 CEE Electromagnetic Compatibility DirectiveRelevant standard : EN 50.081.1 / EN 50.082.1 / EN 55.014

CONTENTS

1. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.1 Technical specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2 Main dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

2. INSTALLING THE BOILER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62.1 Boiler location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62.2 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

3. ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

4. HYDRAULIC CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74.1 Dimensional information required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74.2 Important recommendations for connecting the boiler to the heating circuit . . . . . . . . . . . . . . . . . . . . . 74.3 Filling the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84.4 Sludge removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

5. CHIMNEY CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95.1 Flue size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95.2 Connecting to the flue . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

6. FUEL-OIL OR GAS CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

7. ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

8. MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108.1 Sweeping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108.2 Cleaning the casing material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138.3 Precautions required in the case of long boiler stops (one or more years) . . . . . . . . . . . . . . . . . . . . . 138.4 Precautions required if the heating is stopped when there is a risk of freezing . . . . . . . . . . . . . . . . . . 13

9. BURNER MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

10. SYSTEM MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1310.1 Water level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1310.2 Draining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

11. IDENTIFICATION PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

12. SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

CONFORMITY / MARKING

2

3

The boilers of the METROSE-E range are pressurisedhot water boilers designed for connecting to a flue pipewhich require a separate automatic fuel-oil or gas burner. The useful power of METROSE-E boilers is between 348 and 1450 kW.

METROSE-EBoiler with standard control panel designed to be connec-ted to the electrical cabinet.

30

0

I

0

I

8555N039

Warning :The boiler shall be assembled and ins-talled by a qualified professional only.Strict compliance with these assembly,installation and maintenance instructionsis a precondition for the correct opera-tion of the boiler.

1. GENERAL

4

Maximum operating pressure : 6 barMaximum operating temperature : 100°CMaximum safety temperature of boiler : 120°C(as per TRD 702)

Boiler thermostat setting : 30 - 85° CSafety thermostat setting : 110° C

TYPE OF METROSE E E E E E E E E E E E E E E E E E E EBOILER 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

Useful efficiency kW 348 406 464 522 580 638 696 754 812 870 928 986 1044 1102 1160 1218 1276 1334 1392to to to to to to to to to to to to to to to to to to to406 464 522 580 638 696 754 812 870 928 986 1044 1102 1160 1218 1276 1334 1392 1450

PowerkW 387 451 516 580 644 709 773 838 902 967 1031 1096 1160 1224 1289 1353 1418 1482 1547

to to to to to to to to to to to to to to to to to to toinput451 516 580 644 709 773 838 902 967 1031 1096 1160 1224 1289 1353 1418 1482 1547 1611

Number of sections 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

Water capacity l 389 427 465 503 541 579 617 655 693 731 769 807 845 905 943 981 1019 1057 1095

Water ∆T=10K mbar 18 22 28.4 34.8 42 50 57.6 67.2 77.6 26.2 30.2 35.8 41.4 48.0 53.6 59.2 64.8 71.6 78.4resistance ∆T=15K mbar 8 9,9 12.6 15.5 18.7 22.4 25.8 30 34.7 11.7 13.5 14.0 18.5 21.5 24 26.5 29 32 35(1) ∆T=20K mbar 4.5 5.5 7.1 8.7 10.5 12.5 14.4 16.8 19.4 6.5 7.6 9.0 10.4 12.0 13.4 14.8 16.2 17.9 19.6

Water ∆T=11°C m3/h 31.7 36.3 40.8 45.3 49.9 54.4 58.9 63.5 68.0 72.6 77.1 81.6 88.2 90.7 96.2 99.8 104.3 108.8 113.4flow ∆T=20°C m3/h 17.5 20.0 22.4 24.9 27.4 29.9 32.4 34.9 37.4 39.9 42.4 44.9 47.4 49.9 52.4 54.9 57.4 59.8 62.4(4) minimal m3/h 7.8 8.9 10.0 11.1 12.2 13.3 14.4 15.5 16.6 17.7 18.8 20.0 21.1 22.2 23.3 24.4 25.5 26.6 27.7

Pressure in thefurnace for nozzle mbar 1.7 1.75 1.8 1.9 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.85 3 3.1 3.2 3.3 3.4 3.5pressure = 0

Flue gas temperatureminus room K <190 <190 <190 <190 <190 <190 <190 <190 <190 <190 <190 <190 <190 <190 <190 <190 <190 <190 <190temperature (1)(3)

Mass flue gas Fuel oil kg/h 690 790 890 980 1080 1180 1280 1380 1480 1580 1670 1770 1870 1970 2070 2170 2260 2360 2460flow rate

Gas kg/h 720 830 930 1030 1140 1240 1340 1450 1550 1650 1760 1860 1960 2070 2170 2270 2380 2480 2580(1) (2)

Combustion chamber :- Recorded Diameter mm 614 614 614 614 614 614 614 614 614 614 614 614 614 614 614 614 614 614 614- Equivalent Diameter mm 694 694 694 694 694 694 694 694 694 694 694 694 694 694 694 694 694 694 694- Depth mm 706 817 928 1039 1150 1261 1372 1483 1594 1705 1816 1927 2038 2189 2300 2411 2522 2633 2744

- Volume m3 0.28 0.32 0.36 0.40 0.45 0.49 0.53 0.57 0.61 0.65 0.70 0.74 0.78 0.84 0.88 0.92 0.96 1.00 1.05

Loss on stoppage*∆T=30K % 0.11 0.10 0.09 0.09 0.08 0.08 0.08 0.08 0.07 0.07 0.07 0.07 0.07 0.07 0.06 0.06 0.06 0.06 0.06

Shipped weight kg 1852 2046 2237 2412 2601 2810 3000 3171 3364 3561 3756 3955 4124 4343 4538 4734 4930 5107 5297

* Loss on stoppage : total heat emission when the burneris off as a percentage of the nominal input power whenthe difference between the mean boiler temperatureand the room temperature is 30 K.

(1) Nominal operation (top boiler power)(2) CO2= 13.1 to 13.5% with fuel oil and

9.5% with natural gas.(3) Boiler temperature : 80°C

Room temperature : 20°C(4) After the burner stoppage a pump overun of 5 minutes

minimum is required.

1.1 Technical specifications

Min

. hei

ght f

or s

wee

ping

= 8

50F

low

det

ecto

r

1566

543

496

370

Ø F

815

1080

200

420

616

20

791

565

17,5

1670

3/4"

140

370

208

208

240

Max

.50

0M

ax. 7

00B

urne

r ce

nter

line

610

U BM

HK

Ø E

LG

130

A

D

T

Ø E

30022

310

0C

741

1172

30

0I

0I

Har

tley

& S

ug

den

5

1.2 Main dimensions

METROSE-E

ME

TR

OS

E-E

78

910

1112

1314

1516

1718

1920

2122

2324

25

A (

mm

)89

710

0811

1912

3013

4114

5215

6316

7417

8518

9620

0721

1822

2923

8024

9126

0227

1328

2429

35

B (

mm

) 96

710

7810

7813

0013

0015

2215

2217

4417

4419

6619

6621

8821

8824

5024

5026

7226

7228

9428

94

C (

mm

)14

8814

8814

8814

8814

8814

8814

8814

8814

8814

8814

8815

0415

0415

0415

0415

0415

0415

0415

04

D (

mm

)24

021

121

223

323

425

525

621

718

818

921

023

625

720

820

923

023

125

225

3

ø E

(wel

d)

139.

713

9.7

139.

713

9.7

139.

713

9.7

139.

713

9.7

139.

713

9.7

139.

715

915

915

915

915

915

915

915

9

ø F

(m

m)

300

300

300

350

350

350

350

400

400

400

400

400

400

400

**

**

*

G (

mm

)-

--

--

--

-15

015

037

037

037

065

065

065

098

098

098

0

H (

mm

)21

-8-7

1415

3637

-2-3

1-3

0-9

-813

-36

-35

-14

-13

89

K**

(m

m)

334

526

2748

4910

-19

-18

34

25-2

4-2

3-2

-120

21

L (

mm

)13

0514

4515

5516

4517

5518

4519

5521

0522

4523

5524

4525

5526

4528

4529

5530

4531

5532

4533

55

M (

mm

)24

826

531

924

329

722

127

525

932

426

932

126

529

926

932

426

932

424

930

3

T (

mm

)70

681

792

810

3911

5012

6113

7214

8315

9417

0518

1619

2720

3821

8923

0024

1125

2226

3327

44

U (m

m)

1355

.514

66.5

1577

.516

88.5

1799

.519

10.5

2021

.521

32.5

2243

.523

54.5

2465

.525

76.5

2687

.528

38.5

2949

.530

60.5

3171

.532

82.5

3393

.5

8555

N25

1-G

B

* P

lain

pla

te,

req

uir

es

cutt

ing

. M

axi

mu

m c

ut-

ou

t50

0 x

700

mm

G =

Leng

th r

equi

red

for

clea

ring

the

wat

er d

istr

ibut

ing

tube

**

Dim

en

sio

n r

ep

rese

ntin

g t

he

en

d o

f th

e 1

00

mm

long

chi

mne

y co

nnec

tion

No

ta:

with

mo

de

ls E

21

, E

22

, E

23

, E

24

an

d

E 2

5, a

pla

in p

late

whi

ch m

ust

be c

ut o

ut is

sup

-pl

ied

with

out

the

100

mm

chi

mne

y co

nnec

tion.

The

siz

es a

re g

iven

in m

m.

6

B

L

MC

A'

A

0,85

mm

ini

0,281 m

1,56

6 m

1,172 m

0,10

4 m

2

1

D mini

The METROSE-E boiler should be positioned on a fire-proof base which is level and flat. Also ensure that thefloor can support the flooded weight of the boiler whenit is fitted for operation. If the boiler location is not deter-mined precisely, leave enough space around the boilerto facilitate monitoring and maintenance operations.

The ventilation shall comply with applicable regulations,particularly codes of practice.

METROSE E 7 E 8 E 9 E 10 E 11 E 12 E 13 E 14 E 15 E 16 E 17 E 18 E 19 E 20 E 21 E 22 E 23 E 24 E 25

L 1305 1445 1555 1645 1755 1845 1955 2105 2245 2355 2445 2555 2645 2845 2955 3045 3155 3245 3355

M 248 265 319 243 297 221 275 259 324 269 321 265 299 269 324 269 324 249 303

C min. 300 300 300 300 300 300 300 300 436 436 656 656 656 936 936 936 1266 1266 1266

D min. - - - - - - - - 136 136 356 356 356 636 636 636 966 966 966

8259N004 A (GB)

8555N252

2. INSTALLING THE BOILER

2.1 Boiler location

2.2 Ventilation

1. Straight connection (not supplied)2. Angled connection (not supplied)

(1) In order to facilitate subsequent work on the boiler(replacing the water distributing tube etc.) use a flanged connection from the boiler to the system,making sure you comply with minimum clearancedimension D.

Please note : remember that boilers installed in orclose to rooms in which the atmosphere is polluted withchlorine or fluorine compounds may be subject to highcorrosion.

For example : hairdressing salons, industrial premises (solvents), cooling equipment, etc.Boiler installed in such locations shall not be coveredby the warranty.

If A = 1.2 m (door opening side), A' = 0.5 mIf A = 0.5 m, A' = 1.2 m (door opening side) : adaptthe dimensions on the basis of the dimensions of theburner when the door is open. B = 1.5 m : adapt the dimensions on the basis of thedimensions of the burner.

Boiler body

(1)

7

4. HYDRAULIC CONNECTIONS

4.1 Dimensional information required

8555N253

C10

80m

m200mm

H*

D


C (mm) 1488 1488 1488 1488 1488 1488 1488 1488 1488 1488 1488 1504 1504 1504 1504 1504 1504 1504 1504

D (mm) 240 211 212 233 234 255 256 217 188 189 210 236 257 208 209 230 231 252 253

H (mm) 21 -8 -7 14 15 36 37 -2 -31 -30 -9 -8 13 -36 -35 -14 -13 8 9

4.2 Important recommendations for connecting the boiler to the heating circuit

The installation shall be made in keeping with applicableregulations and codes of practice and the recommen-dations contained in these instructions.

The safety valve shall be connected to the boiler withoutany valve or stop valve between the boiler and the safetyvalve.

The heating system shall be designed and installed ina way as to prevent the water from the heating circuitand any substances added to it from flowing back intothe drinking water circuit located before it. The instal-lation shall not be directly connected to the drinkingwater system.

Note : After the burner stoppage a pump overun of 5minutes minimum is required.

3. ASSEMBLY

See the separate yellow booklet in the middle of theseinstructions.

Draining outlet3/4” tap

Heating return- 7 to 17 sections : 139.7 - 5”- 18 to 25 sections : 159 - 6”requires welding

Heating return- 7 to 17 sections : 139.7 - 5”- 18 to 25 sections : 159 - 6”requires welding

* dimension without connection(see figure on page 4, connection1 or 2)

Filling shall be performed with a low flow rate from alow point in the boiler room in order to ensure that allthe air in the boiler is bled from the high point of thesystem. Always stop the pump before filling.

VERY IMPORTANT :Instructions for starting up the boiler for the firsttime after the system is fully or partly drained :

If all the air is not bled naturally to an expansion vesselwhich opens out onto the air, the system must includemanual bleeder valves, in addition to automatic bleedervalves with the capability to bleed the system by them-selves when it is operating. The manual bleeder valvesare used to bleed all the high points of the system andto make sure that the filled system is free of air beforethe burner is turned on.

8

586mm

150mm

4.3 Filling the system

8555N254

4.4 Sludge removal

A tapped ø 2" hole with a plug has been provided onthe bottom of the front of the boiler. Fit a quarter-turnvalve on the opening to remove the sludge.

Sludge removal leads to the draining of large quantitiesof water, so remember to refill the system after the operation.

Note : never replace a boiler in an existing systemwithout carefully rinsing the system first.Install a sludge decanting pot on the returnpipe, very close to the boiler.

2” tapped sludgeremoval hole

9

815mm

586mm586mmK

The high-performance features of modern boilers andtheir use in specific conditions as a result of the advancein burner technology (e.g. first-stage or low modulation range operation) lead to very low flue gas temperatures(less than 160°C).

This requires :

- the use of flue pipes designed to enable the flow ofcondensates which may result from such operatingmodes, in order to prevent damage to the chimney;

- the installation of a draining tee at the foot of the chimney.

The use of a draught moderator is recommended as well.

8555N255

Refer to applicable regulations while determining the sizeof the flue. Please note that METROSE-E boilers have pressurised and tight furnaces and that the pressure atthe nozzle must not exceed 0 mbar, unless special sea-ling precautions have been taken, for instance in orderto connect a static condenser/regenerator.

5.2 Connecting to the flue

5. CHIMNEY CONNECTION

5.1 Flue size


ø F(mm) 300 300 300 350 350 350 350 400 400 400 400 400 400 400plain plain plain plain plainplate plate plate plate plate

K (mm) 33 4 5 26 27 48 49 10 -19 -18 3 4 25 -24 -23* -2* -1* 20* 21*

The connection shall be removable, and offer minimumload losses, i.e. it must be as short as possible with nosudden change in section.

Its diameter shall always be at least equal to that ofthe boiler outlet, i.e. :- ø 300 mm for 7-9 sections- ø 350 mm for 10-13 sections- ø 400 mm for 14-20 sections.

- Boilers with 21-25 sections are supplied with a plainplate. The maximum cut-out dimensions are 500 x 700 mm.

Fit a measuring point (ø 10 mm hole) on the flue, inorder to adjust the burner (combustion check).

* Dimension representing the end of the 100 mm long chimney connection.

Note : with models E 21, E 22, E 23, E 24 and E 25 a plain plate which requires cutting out is supplied without the 100 mm long chimney connection.

F ø chimneyconnection

10

6. FUEL-OIL OR GAS CONNECTIONS

Refer to the instructions supplied with the burner.

7. ELECTRICAL CONNECTIONSRefer to the instructions supplied with the control panelof the boiler.

8. MAINTENANCE

8.1 Sweeping

The operations described below shall onlybe performed with the boiler and power supply off.

The boiler will only operate efficiently if the exchangesurfaces are kept clean.

The boiler should be cleaned as soon as required andas the chimney, at least once a year or more, depen-ding upon applicable regulations and specific needs.

1

2

3

4

3

8555N173A

1

8555N172A

2

- Turn off the power to the boiler.- Remove the upper front panel.- Remove the retaining upper front crosspiece and then

the lower left and right-hand front panels.- Remove the lower front panel.

- Unfasten the wing nuts and remove the four sweeping doors.

11

- Remove the left and right-hand casing covers.- Remove the top insulating material.

8555N257

4

23

191

8555N258

5

8555N259

6

- Unfasten the nuts up to the stop.- Push in the handles of the sweeping covers.- Remove the sweeping covers.

- Brush the vertical plates.- Put back the sweeping covers, insulating material and

casing covers by reversing the procedure above.

Note : chemical sweeping is recommended for suchboilers.

- Put the baffle plates back in place.Interlock them with each other while fitting them intothe flue ways.

- Close the upper sweeping doors.

0

I

3

8555N256

- Remove the baffle plates from the upper flue ways.- Carefully sweep the four flue ways with the brush sup-

plied for that purpose.- Brush the baffle plates as well.- If possible, use a vacuum cleaner.

- Unscrew the eight closing nuts and open the furnacedoor.

These screws must not be unfastened inany event.

12

2

1

8555N171

9

8555N176

10

- Remove the lower rear panels.- Remove the lower rear crosspiece.- Remove the lower insulating material on the rear.

- Unfasten the wing nuts and remove the lower left and right-hand sweeping doors.

- Remove any soot deposit with a scraper or a vacuum cleaner.

- Open the lower sweeping cover of the flue gas box (two H 10 nuts + ø 10 washers).

- Remove the soot.- Put back the sweeping cover and doors.- Put back the lower insulating material, the crosspiece

and panels by reversing the removal procedure.

8555N260

8

- Brush out the inside of the furnace.- Clean the soot accumulated in the furnace and lower

flue ways with a vacuum cleaner. - Close the lower sweeping doors.- Put back the front casing panels by reversing the

removal procedure.

19

7

8555N185

13

8.2 Cleaning the casing material

Use a soapy solution and a sponge only. Rinse with cleanwater and dry with chamois leather or a soft cloth.

8.3 Precautions required in the case of long boiler stops(one or several years)

The boiler and the chimney must be swept carefully.Close all the doors of the boiler to prevent air from cir-culating inside the boiler.

We advise removing the pipe which connects the boilerto the chimney and to close off the nozzle with a cover.

We recommend the use of a correctly dosed antifreezeagent to prevent the heating circuit from freezing. If thiscannot be done, drain the system completely.

8.4 Precautions required if the heating is stopped when there is a risk of freezing

9. BURNER MAINTENANCERefer to the instructions supplied with the burner.

10. SYSTEM MAINTENANCE

10.1 Water level

Regularly check the level of water in the system andtop up if required, taking care that cold water is notadded suddenly into the boiler when it is hot.

This operation should be required only a few times ineach heating season, with very low quantities of water.Otherwise, look for the leak and repair it.

10.2 Draining

We advise you against draining the system unless it isabsolutely necessary.

14

11. IDENTIFICATION PLATE

The identification plate fixed on the side of the boilerduring installation is used to identify the boiler correctly.It also provides the main specifications of the boiler.

(1) 00 = 2000,01 = 2001, ...

Hartley & Sugden Halifax U.K.

XX - XX

8555N261

12. SPARE PARTSRefer to the following page.

Type of boiler

Year (1)

Week

Date of manufacture

Unit serial no.

44

2119

3839

2a

22

4347

37

20

2928

31

52

16

30a

46

46

40

39

39

46

39

40

15

4613

11

33

45

60

61

63

30

25

2321

37 24

38

6

14 36

7

1012

8

41 42

17

189

5

4

35

15

3449

321

2127

26

48

32

SON

DE A

PLON

GEU

R

200201

62

Spare parts METROSE-E cast iron sectional hot water boilers

8555N192

Note : while ordering spare parts, do not forget to provide the code number given in the list opposite the part reference.

BOILER BODY

HARTLEY & SUGDEN, Atlas Works, Gibbet Street, Halifax HX1 4 DBTel.: 01422 355651 • Fax: 01422 359636

e-mail: [email protected]

15

METROSE-E cast iron sectional hot water boilers

71

70

INSULATION

8555N198

16

89103

91

89

90

95

113

85

9784

114

110

99

84

100

92

93

116

86

102

96

10598

88

116

112

110

94

100

10183

82

88

104

81

80

87

104

103

80

106

114108

111 115107

8555N191

CASING


17

BOILER BODY + ACCESSORIES

Frame

1 8259-8953 Complete frame, 7 sections

1 8259-8954 Complete frame, 8, 9 sections









Body + accessories

2 8555-5505 Complete rear section

3 9495-0140 3/4" plug, no. 290

4 8259-8948 Normal intermediate section

5 8259-8949 Special intermediate section

6 9495-0110 1/2" plug, no. 290

7 8500-0027 1/2" pocket

8 9758-1286 Spring for pocket

9 8259-8950 Complete front section

10 8006-0212 Painted nipple 148.62 ø

11 9430-5027 Putty for nipple (300 g)

12 9508-6032 Silicone-coated fibreglass seal

13 9428-5095 Silicone filler tube (310 ml)

14 8015-8927 Assembly rod, 12 ø - 300 long




15 9754-0120 Spring for assembly rod

16 8015-8902 Complete indicator with frame

17 8015-7700 Sight glass + gaskets

18 8015-8907 Assembly rod, 14 ø - 910 long, 7 sections



















19 8006-8906 Plain square flange + gasket

20 8006-8907 Square flange with 2" tapped hole + gasket

21 9501-4155 222 x 170 x 4 gasket

22 8112-0028 2" plug

23 8008-8904Flange with outlet piece + gasket

for 7 - 17 sections

23 8008-8905Flange with outlet piece + gasket

for 18 - 25 sections

24 8008-8922 Nozzle + gasket

25 8802-4731 Flow switch 7 sections


25 8802-4736 Flow switch 9 - 16 sections

25 8802-4738 Flow switch 10 - 17 sections














26 8008-8908Flange with return piece + gasket

for 7 - 17 sections

26 8008-8909Flange with return piece + gasket

for 18 to 25 sections

27 8008-8924 Diaphragm + gasket

28 8228-8905 Complete articulation of furnace plate

29 9757-0424 Plain furnace door

30 9755-0235 Furnace door guard

31 9755-0236 Furnace door insulation

32 8008-8915 Furnace plate hinge

33 8555-8592 Bag of screws for furnace door

34 8555-5528 Flue gas outlet + braid

35 8208-0010 Cast-iron cleaning cover

Ref. Code no. DESCRIPTION Ref. Code no. DESCRIPTION


18

36 9504-6115 15 ø Thermocord gasket

37 8555-5508 400 ø connection plate + gasket



37 8555-5509 Plain connection plate +gasket

38 9508-6041 15 x 9 adhesive gasket

39 8555-5514 Left-hand sweeping door + braid

40 8555-5541 Right-hand sweeping door + braid

41 8555-5510 N1 sweeping cover + braid




45 8555-8593 Bag of screws for sweeping door

46 9508-6032 Silicone-coated fibreglass seal

47 8555-5515 Complete lock

48 8259-0010 Upper baffle

49 8008-8910 Distributing tube + gasket for 15 and 16 sections

49 8008-8911 Distributing tube + gasket for 17 to 19 sections

49 8555-5502 Distributing tube + gasket for 20 to 22 sections

49 8555-5503 Distributing tube + gasket for 23 and 24 sections

49 8555-5504 Distributing tube + gasket for 25 sections

52 9434-5102 Retouching spray paint - anthracite grey

52 9434-5104 Retouching spray paint - ivory

Cleaning tools

60 9696-8026 Brush for plate

61 8013-8703 Metal brush + 1300 long rod for 7 to 10 sections

61 8013-8704 Metal brush + 1800 long rod for 11 to 15 sections

62 8015-8716 Metal brush + 1300 long rod + extension for 16 to 22 sections

62 8015-8723 Metal brush + 1800 long rod + extension for 23 to 25 sections

63 9750-5103 1200 long scraper

63 9750-5106 1500 long scraper

63 9750-5108 1800 long scraper

INSULATING MATERIAL

Insulating material for body

70 8555-5516 Complete insulating material for body, 7 sections

70 8555-5517 Complete insulating material for body, 8 and 9 sections











Insulating material for sweeping covers

71 8555-5529 Complete insulating material for sweeping covers, 7 sections

71 8555-5530 Complete insulating material for sweeping covers, 8 and 9 sections







71 8555-5537 Complete insulating material for sweeping covers, 20 sectionss




BOILER CASING

80 8555-8008 1225 long rail

80 8555-8009 1365 long rail

80 8555-8010 1475 long rail

80 8555-8011 1565 long rail

80 8555-8012 1675 long rail

80 8555-8013 1765 long rail

80 8555-8014 1875 long rail

80 8555-8015 2025 long rail

80 8555-8016 2165 long rail

80 8555-8017 2275 long rail

80 8555-8018 2365 long rail

81 8555-8021 1246 long supplementary rail

82 8555-8035 1260 long left-hand cable channel











83 8555-8048 1260 long right-hand cable channel







19




83 8555-8056 2200 long right-hand cable channe



84 8555-8080 1196 long additional cable channel

85 8555-8066 1131 long central upper plate











86 8555-8079 1196 long additional central plate

Common parts

87 8259-8014 Lower front crosspiece

88 8555-8515 Fastening bracket for front side pane

89 8259-8818 Complete lower front side panel

90 8555-8516 Complete upper front panel

91 8555-8517 Complete lower front panel

92 8555-8518 Upper rear panel

93 8259-8021 Lower left-hand rear panel

94 8259-8022 Lower right-hand rear panel

95 8259-0518 Panel for furnace door

96 8555-8519 Control panel trim

97 8555-8520 Rear cover for standard control panel

98 8555-8521 Control panel bracket

99 8259-8055 Lower rear crosspiece

100 8555-8522 Upper crosspiece

101 8555-8526 Intermediate upper crosspiece

102 8555-8082 Joining central plate

103 8555-8523 Lower tab of rail

104 8555-8022 Upper bracket

105 8555-0526 Upper front crosspiece

106 9532-0780 Ring

107 9775-8859 Rapid nut

108 8555-8525 Fasteners for common parts

Front side casing

110 8555-8502 800 long front side panel



111 8555-8514 Fasteners for front side panel

112 8555-8507 800 long right-hand upper front plate for sweeping



112 8555-8510 800 long left-hand upper front plate for sweeping



Rear side casing

114 8555-8500 400 long rear side panel

114 8555-8501 600 long rear side panel

115 8555-8513 Fasteners for rear side panel

116 8555-8505 400 long upper rear plate for sweeping

116 8555-8506 600 long upper rear plate for sweeping

STANDARD CONTROL PANEL - FA3

Refer to the specific list in the instructions

for control panel

OPTIONAL FEATURES

200 9536-2215 135 mm long dip sensor, BP 42

201 9536-5186 R 1/2 pocket, 120 mm long


11/00


20

Hartley & SugdenHartley & Sugden follows a policy of continual improvement, and reserves the right to change specification without notice.

Hartley & Sugden, Atlas Works, Gibbet Street, Halifax HX1 4DB Tel: 01422 355651 Fax: 01422 359636

Servicing company :Fitter :

AD

HS

01

m1

METROSE-E boiler Number of sectionsFrame (dimensions depend upon model)Rear sectionNormal intermediate sectionSpecial intermediate sectionFront sectionSet of assembly rods + cleaning tools(contents depend upon model)

Standard accessory kit1 package

(contents depend upon model)

Additional accessory kit1 package

(contents depend upon model) **

Plain furnace plateFlue gas connection plate ø 300with opening ø 350

ø 400Plain flue gas connection plateFlue gas boxDistributing tube fitting *

7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 11 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 12 3 4 5 6 7 8 9 10 11 12 13 14 14 15 16 17 18 193 3 3 3 3 3 3 3 3 3 3 3 3 4 4 4 4 4 41 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

FA FA FA FA FA FA FA FA FA FA FA FA FA FA FA FA FA FA FA42 43 44 45 46 47 48 49 50*51*52*53*54* 55 56 57 58 59 60FA FA FA FA FA FA FA FA FA FA FA FA FA FA FA FA FA FA FA61 62 63 64 65 66 67** 68** 69 70 71 72 73 74 75 76 77 78 791 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 11 1 1

1 1 1 11 1 1 1 1 1 1

1 1 1 1 11 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

* * * * * 1 1 1 1 1 1

METROSE-E boiler Number of sectionsBaffle plates Package CM 22

Package CM 23

ASSEMBLY OF METROSE-E BOILERS

� Boiler body + accessories

- Boilers supplied with an assembled body :

Packaging : Before starting to assemble the boiler, refer to the tablebelow to check if you have received all the packagesrequired.

Refer to the applicable price list for any optionalfeatures used.

- Boilers supplied with an unassembled body :

METROSE-E boiler Number of sectionsAssembled boiler body (contents depend upon model)Cleaning tool kit (contents depend upon model)

7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 251 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 11 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

� Baffle plates

7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 251 1 1 1 1 1 1 1

1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2

METROSE-E boiler Number of sectionsBox with technical documents 1 Package

� Technical documents

7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

* The distributing tube fitting for METROSE-E boilers with 15 -19 sections is included in the accessory package.** The diaphragm fitting for METROSE-E boilers with 13 and 14 sections is included in the additional accessory kit package.

06/12/01 - FM8555-4428A

Important : Assemble the boiler in theorder given by the numbers of each figure,in compliance with all the instructions.

8555

-743

785

55-7

438

8555

-743

985

55-7

440

8555

-744

185

55-7

442

8555

-744

385

55-7

444

8555

-744

585

55-7

446

8555

-744

785

55-7

448

8555

-744

985

55-7

450

8555

-745

185

55-

-745

285

55-

-745

385

55-

-745

485

55-

-745

5

m2

METROSE-E boiler Number of sectionsCasing fittings Package FA 136

Package FA 137Package FA 7Package FA 8Package FA 9Package FA 10Package FA 11

7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 251 1 1 1 1 1 1 1 1 1 1

1 1 1 1 1 1 1 11 1

1 1 1 1 1 1 1 1 11 1 1 1 1 1 1 1

1 1 1 2 2 2 2 1 2 2 1 11 1 2 2 2 1 1 2 3 3 2 2 3 3

� Casing fittings

METROSE-E boiler Number of sectionsBody insulating material Package FA 30

Package FA 31Package FA 32Package FA 33Package FA 34Package FA 35Package FA 36Package FA 37Package FA 38Package FA 39Package FA 40Package FA 41

7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 251

1 11

1 11 1

11 1

1 11

1 11 1

1

� Body insulating material

METROSE-E boiler Number of sectionsStandard control panel Package FA 30 1

7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

� Control panel

METROSE-E boiler Number of sectionsFurnace plate with165, 186, 210, 240, or 295 ø holeConnecting plate with 300 øopening or plain connecting plateSet of anti-vibration studs 8208-7757

8208-77588208-77598208-7760

7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

1 1 11 1 1 1 1 1 1

1 1 1 11 1 1 1 1

� Accessories available as an option *

* Refer to the applicable price list for the other optional features (control units etc.) which may be used with these boilers.

METROSE-E boiler Number of sectionsPackage FA 16Package FA 17Package FA 18Package FA 19Package FA 20Package FA 21Package FA 22Package FA 23Package FA 24Package FA 25Package FA 26Package FA 27

7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 251 1 1 1 1 1 1 1

1 11 1

1 11 1

1 11 1

1 11 1

11

1

� Variable casing parts

m3

� If the boiler is supplied with an assembledbody, start assembly from figure 29.

Sectiontype :

E 7 1 2 3 1E 8 1 3 3 1E 9 1 4 3 1E 10 1 5 3 1E 11 1 6 3 1E 12 1 7 3 1E 13 1 8 3 1E 14 1 9 3 1E 15 1 10 3 1E 16 1 11 3 1E 17 1 12 3 1E 18 1 13 3 1E 19 1 14 3 1E 20 1 14 4 1E 21 1 15 4 1E 22 1 16 4 1E 23 1 17 4 1E 24 1 18 4 1E 25 1 19 4 1

104

8228-0004 8228-0001 8228-0002 8228-0003

104111 151

Tools required :

- JD-TE or JD-TE Plus assembly tool (+ extension forMETROSE-E 22 or larger)- Flat screwdriver- No. 2 Pozidriv screwdriver- 10, 13, 17 and 19 mm spanners

- 2 mm tubular box spanner- 27 mm tubular box spanner- electric screwdriver + No. 2 Philips bit- Stanley knife- Silicone filler (supplied)

� Assemble the boiler body from the rear tothe front :

- assemble the rear section,- assemble all the normal intermediate sections,- assemble all the special intermediate sections,- assemble the front section.

The number of sections of each type isprovided in the table below :

RearNormal

Intermediate

Special

intermediateFront

m4

� Place the frame on the floor, taking care to note theTOP and FRONT positions. � Fit the fastening brackets as shown, depending onthe type of boiler (one ø 12x40 screw, 19 mm spanner).

� Carefully insert the thermocord in the grooves of thesection and retain it in place with a few drops of silico-ne filler (every 30 cm approximately).Note : do not pull on the seal while inserting it.Otherwise, you may stretch it and reduce its thickness.

8555N042

8555N076 8555N005

8555N001

DESSUS

-O

BEN

- TOP

DE

SS

US

-O

BE

N- T

OP

DE

SS

US

-O

BE

N- T

OP

DESSUS

-O

BEN

- TOP

FRONTVORN

AVANT

FRONTVORN

AVANT

FRONTVORN

AVANT

FRONTVORN

AVANT

19

1 2

3 4

� Clean all the openings in the section with a brush.Remove any deposit on the bottom of the section.

� Establish the location of the frame on the basis of the opening direction of the furnace door and the length ofthe burner. Leave enough clearance at the rear of the boiler for water connections (see § 4.1 of the instructions)and the distributing tube (see § 2 of the instructions andfig. 23 in this booklet). � Fit the rear section on the frame, behind the fasteningbrackets (see detailed drawing) and prop it up. � Insert the lower assembly rods in the holes of the rearsection and the fastening brackets of the frame, in orderto position the rear section correctly according to the frame.

Boilers with7, 8, 10, 12, 14, 16,18, 20, 22 and 24 sections

Boilers with9, 11, 13, 15, 17, 19,21, 23 and 25 sections

TOP

TOP

BOTTOM

BOTTOM

7, 8, 10, 12, 14, 16,18, 20, 22 and 24 sections

9, 11, 13, 15, 17, 19,21, 23 and 25 sections

m5

� Place the first normal intermediate section, makingsure that it is turned in the right direction, i.e. with theflattening groove against the thermocord.� For safety, insert a lateral assembly rod (supplied)in the holes of the two sections.� Push the section gently and simultaneously onto bothnipples of the rear section with a hammer and a pieceof wood positioned in line with the bores.

� Assemble the remaining intermediate sections oneby one, to the procedure stated in figures 3, 4, 5, 6, 7and 8.

First assemble the normal intermediate sections,then the special ones (see page 3 of this booklet).

Leave the assembly tool in place.

� Clean the bores and nipples withdiluent. Remove any traces of rust-protective paint so that the surface is perfectly smooth. Coat with the lubricant supplied with the sections.

8555N003

8555N005

� Put the assembly tool in position. Tighten gradually so as to bring together the upperand lower connections evenly and simultaneously.

8555N006

8555N007

5 7

8 9

8555N004

6

ARRIÈ

RE

DESSUS

- OBEN

- TOP

AVANT

AR

RIÈR

E

DESSU

S- O

BEN- TO

P

AVANT

� Gently push in the two nipples.

Rearsection

Intermediatesection

m6

10

� Put in place the upper assembly rods in the two frontand rear lugs. � Mount the two crosspieces (supplied in package FA136 / FA137) with their bends turned backwards andfasten them to the rods with an expansion spring, a nutand a washer. � Remove the assembly tool.

8555N008

Fitting the upper and lower assembly rods

8555N009

11

8555N090

� Trim off any projecting ends of the thermocords the sweeping covers.

� On the lower assembly rods, fit the following at eachend in the given order : an expansion spring, a washerand a nut (the holes of the front lugs must be alignedwith the holes of the frame brackets as the assemblyrods are used to make the boiler body integral with theframe). � Stop tightening as soon as the gap between the springspires is equal to about 2 mm.

12

REAR FRONT

2 mm

2 mm2 mm

m7

Assembling the side assembly rods

lg.520 mmlg.420 mm

lg.420 mmlg.520 mm

520 mm

385 mm

385 mm

300 mm

420 mm

420 mm

420 mm

385 mm

420 mm

520 mm300 mm

A

A

C

CB

B

lg.520 mmlg.420 mm

lg.420 mmlg.520 mm

lg.520 mm

lg.385 mm

lg.300 mm

lg.420 mm

lg.420 mm

lg.420 mm

lg.385 mm

lg.420 mm

lg.520 mmlg.300 mm

A

A

AE

AE

E

E

C

C

C

C

C

D

D

D

D

CB

B

B B

B B

B

B

lg.385 mm

lg.385 mm

1 mm

1 mm

1 mm

B

A

C

D

B

A

C

D

1 mm AE

8555N115A

� The side assembly rods must be assembled fromthe rear to the front.� The rods must be inserted in the holes stated inthe diagrams (the lugs of the sections in which theassembly rods are to be inserted have two holes).

� Place the expansion spring and washer on the rearof each rod.Stop tightening the nuts as soon as the gap betweenthe spires of the springs is about 1 mm.

METROSE E 7

METROSE E 8

METROSE E 9

m8

8555N116A

E

E

A

A

B

B

B

B

B

B

lg.520 mmlg.420 mm

lg.420 mm

lg.520 mmlg.420 mm

lg.420 mm

lg.520 mmlg.520 mm

lg.420 mm

lg.520 mmlg.520 mm

lg.420 mm

lg.520 mmlg.420 mm

lg.420 mmlg.300 mm

lg.520 mmlg.420 mm

lg.420 mmlg.300 mm

DE

E

D

D

D

D

DC

C

C

C

C

C

C

C

1 mm

1 mm

1 mm

B

A

C

D

B

A

C

D

1 mm AE

METROSE E 10

METROSE E 12

METROSE E 11

m9

8555N117A

B

B

B

B

B

B

A

A

A

A

A

A

lg.520 mmlg.520 mm

lg.420 mmlg.300 mm

lg.520 mmlg.520 mm

lg.420 mmlg.300 mm

lg.520 mmlg.520 mm

lg.420 mmlg.420 mm

lg.520 mmlg.520 mm

lg.420 mmlg.420 mm

lg.520 mmlg.520 mm

lg.420 mmlg.520 mm

lg.520 mmlg.520 mm

lg.420 mmlg.520 mm

C

C

C

C

C

C

C

C

C

C

C

C

D

D

D

D

D

D

1 mm

1 mm

1 mm

B

A

C

D

B

A

C

D

METROSE E 13

METROSE E 14

METROSE E 15

m10

B

B

B

B

B

B

E

E

E

E

E

E

lg.520 mmlg.520 mmlg.300 mm

lg.420 mmlg.420 mm

lg.420 mm


lg.420 mm


lg.420 mm


lg.420 mmlg.420 mm


lg.420 mmlg.420 mm


lg.420 mmlg.420 mm

lg.420 mm

C

C

C

C

C

C

C

C

C

C

C

C

D

D

D

D

D

D

D

D

D

D

D

D

1 mm

1 mm

B

C

D

B

C

D

1 mm AE

8555N118A

METROSE E 16

METROSE E 17

METROSE E 18

m11

B

B

B

B

B

B

E

A

A

A

A

E


lg.420 mmlg.520 mm

lg 520 mmlg.520 mmlg.520 mm

lg.420 mmlg.520 mm









C

C

C

C

C

C C

C

C

C

C

C

C

C

C

C

D

D

D

D

D

D

D

D

DD

D

D

1 mm 1 mm

1 mm

BA C DBA C D

1 mm

AE

8555N119A

METROSE E 19

METROSE E 20

METROSE E 21

m12

8555N120A

A

A

E

E

B

B

B

B

lg.520 mmlg.520 mmlg.420 mmlg.420 mm


lg.520 mmlg.520 mmlg.420 mmlg.420 mm



lg.385 mm lg.520 mm


lg.385 mmlg.520 mm

lg.520 mm

lg.520 mm

C

C

C C C

CCC

C C

CC

D

D

DD

D D D

D

D

D

1 mm 1 mm

1 mm

BA C DBA C D

1 mm

AE

METROSE E 23

METROSE E 22

m13

8555N121A

E

E

E

E

B

B

B

B



lg.520 mmlg.520 mm

lg.520 mm

lg.520 mmlg.420 mm



lg.385 mmlg.520 mm

lg.520 mmlg.520 mm

lg.520 mm

lg.520 mmlg.420 mm

lg.385 mmlg.520 mm

lg.520 mm

lg.520 mm

D

D

D

D

D

D

D D

DD

D

D

C

C

C

C

C

C

C C

CC

C

C

1 mm 1 mm

1 mm

BA C DBA C D

1 mm

AE

METROSE E 25

METROSE E 24

m14

8555N012

8555N011

� Put the baffle plates into place in the upper front flueways, taking care to interlock them with each otherbefore fitting them.

Boiler E 7 - 9 E 10 - 14 E 15 - 19 E 20 - 25

Total numberof baffle 2 4 6 8plates

Package no. CM 22 CM 23CM 22

2xCM 23+ CM 23

� Clean off the protective varnish on the ground sur-faces with diluent. � The covers are numbered from 1 to 4, and must befitted with a thermocord ➀. The length of the thermocord depends upon the coverand is given below.

Type Thermocordlength

1 1335 mm

2 1110 mm

3 890 mm

4 665 mm

1

2

34

Cover n° 1 n° 2 n° 3 n° 4model

Type of Number of sweeping covers per typeboiler FRONT REAR

E 7 2 2E 8 2 2E 9 2 2E 10 2 2 2E 11 2 4E 12 2 2 2E 13 2 4E 14 2 6E 15 2 4 2E 16 2 4 2E 17 2 6E 18 2 2 6E 19 2 6 2E 20 2 6 2E 21 2 8E 22 2 6 2 2E 23 2 6 4E 24 2 8 2E 25 2 10

� Place the two no. 1 sweeping covers (with the handlesturned outward) on either side of the boiler startingfrom the front. Distribute the other covers evenly.

Each cover is fitted with a system whereby it can only be mounted with the handles turned outward.

� Fit the two locks of each cover between the sec-tions.� Push the cover towards the outside of the boiler, tothe “closed” position ➂.� Fasten the two brass nuts of each cover ➃.

Assembling the baffle plates

14 Assembling the sweeping covers

13

Handles turnedoutward

FRONT

REAR

19

m15

� Insert the thermocord in the sealing groove on eachside and hold it in place with a few drops of siliconefiller.

8555N013

15

� Insert the thermocord in the sealing groove of thetwo lower flue ways, on the rear and front of the boiler. � Put the four trap doors on the lower flue ways andfasten with the wing nuts.

8555N014

Putting in place the lower trap doors

Front and rear

16

17 18

� Put the furnace door insulating material in place andretain it with the four 3.94 x 25.4 SIM screws

� Place the furnace door on the floor and fasten thearticulation onto the door with three HM 12 screws.

8259N022

8259N023

� Fix the furnace door hinge on the right or left-hand sideof the front section by means of three H 12 x 25 screws.

8555N091

Installing the hinge of the furnace door

Refractory felt Rigid refractory plate

Two 3.94x25.4 SIM screws Two 3.94x25.4 SIM screws

7

m16

1

21

� Fit the door onto the hinge by inserting the pin ➀.

8555N101

2

� Close the furnace door on the 8 studs and fastenwith 8 washers and nuts ➁.

8555N092

� Fit the two doors of the upper flue ways (wing nuts). � Fit the plain flange onto the upper connection of thefront section (using four H 18 nuts), with the 170 x 222gasket in between (first soak the gasket in warm water). � Fit the flange with the sludge removal hole onto thelower connection of the front section (hole in the lowerpart of the flange) using four H 18 nuts, with the gasket in between (soak in warm water first).

8555N097

Flame inspection window

The flame inspection window is fitted with a 1/4" tap-ped hole for ventilation (optional) : - if a ventilation system is used, connect the hole to theone provided for that purpose before the burnercombustion head.

8555N179

19 20

m17

L

� E 7 - E 12 :Fit the boiler return flange with a ø 170 x 222 gasketin between (first soak the gasket in warm water), usingfour H 18 nuts. � E 13 - E 14 :Fit the water balancing diaphragm with the notches vertical onto the boiler return with a ø 170 x 222 gasketin between (first soak the gasket in warm water).Fit the heating return flange with a ø 170 x 222 gasketin between and fix it with four H 18 nuts.

� E 15 - E 25 :Fit the water balancing tube onto the boiler return witha ø170 x 222 gasket in between (first soak the gasketin warm water), using four H 18 nuts.Fit the heating return flange with a ø 170 x 222 gasketin between (first soak the gasket in warm water) andfix it with four H 18 nuts.

8555N099

Assembling the return flange on boilers E 7 - 25

Boiler Ltype (mm)

E 15, 16 380E 17 - 19 600E 20 - 22 880E 23 - 25 1210

22

� E 07 - 15 :Place the nozzle turned outside from the boiler with a ø 170 x 222 gasket in between (first soak the seal in warm water).Assemble the flange with angled piece so that the angleis turned upward, with a ø 170 x 222 gasket in between(first soak the gasket in warm water) and fasten withfour H 18 nuts.� E 16 - 25 :Assemble the flange with angled piece so that the angleis turned upward, with a ø 170 x 222 gasket in between(first soak the gasket in warm water) and fasten withfour H 18 nuts.

23

Carefully insert the ø15 gasket in the groove of the rear section and hold it in place with a few drops of silicone.

8555N162

Fitting the boiler outlet flange 24

Fitting the boiler outlet flange

8555N103

E 7 - E 12Pakage FA 42 to FA 47

Pakage FA 67 : 13 sectionsFA 68 : 14 sections

E 13 - E 14Pakage FA 48 : 13 sectionsFA 49 : 14 sections




m18

25 26

� Put the flat adhesive seal in place on the flue gas box.� Put the sweeping cover in place and fasten with two H 10 nuts and 10 ø washers.

� The flue gas outlet is fastened to the rear by meansof six studs, washers and ø 12 nuts.

8555N164

8555N163

� First adapt the steel connecting plate to the chimneyconnection flue. Then fasten that plate or the plate witha connecting piece supplied as an option with ten H 10nuts and ø 10 washers.

Hydraulic tightness check

After assembling the body, the fitter shall run awatertightness check with pressure equal to 1.3times the operating pressure.

8555N165

27 28

8555N177

Assembling the flow switch

Number Flow switchof codes

sections nos.

7 8802-47318 8802-47349 8802-4736

10 8802-473811 8802-474012 8802-474213 8802-474314 8802-474515 8802-474616 8802-473617 8802-473818 8802-475219 8802-475320 8802-475421 8802-475522 8802-475623 8802-475724 8802-475825 8802-4759

Before assembling the flue gas box, grease all bolts, studs and screws with high-temperature grease (not supplied).

m19

29

8555N181

� Put the baffle plates in place in the upper front flueways, taking care to interlock them with each otherbefore fitting them.

Boiler E 7 - 9 E 10 - 14 E 15 - 19 E 20 - 25

Total numberof baffle 2 4 6 8plates

Package no. CM 22 CM 23CM 22

2xCM 23+ CM 23

Assembling the baffle plates (for boilers supplied with an assembled body only)In boilers supplied with an unassembled body, the baffle plates are already in place.

� Mount the two crosspieces and fasten them onto therods with an expansion spring, a nut and a washer.

Assembling the upper crosspieces (package FA 136 or FA 137)

(for boilers supplied with an assembled body only)In boilers supplied with an unassembled

body, the crosspieces are already in place (see figure 12)

30

8555N010

� Assemble the pocket for the thermostats and ther-mometer in :- the third special intermediate section - 150 mm wide,

1/2" hole (E 7 - 19)or- the fourth special intermediate section - 150 mm wide,

1/2" hole (E 20 - 25).

� Plug the two (E 7 - 19) or three (E 20 - 25) free 1/2"holes in the special intermediate sections.

Assembling the pocket31

8555N188

REARFRONT

FRONT

REAR FRONT

FRONT

E 7 - E 19

E 20 - E 25

2 mm

2 mm

m20

� Place the cable channels so that their bevelled endis to the front. � Fasten with two H 8 x 16 screws + L8 washers in thethird hole starting from the front and opposite the special nut.� Fasten at the rear with two H8 x 16 screws + L8washers opposite the oblong holes and special nut.

AVANT

32 Assembling the cable channels (7 -17 sections)

8555N108(GB)

33 Assembling the top insulating material (7 - 17 sections)

8555N186(GB)

� Put in place the 600 mm wide (packages FA 30 - 36)top insulating material on the body of the boiler.

1

3

2

2

3

34

8555N112

� Assemble the intermediate piece on the assemblyrods by fitting one slotted side onto one rod and usingthe flexibility of the other rod. � Place the two cable channels so that their bevelledend is to the front.� Fasten the channels to the front crosspiece with twoH 8 x 16 screws + L8 washers in the third hole startingfrom the front and opposite the special nut.� Fasten the cable channels on the intermediate pie-ce with two H8 x 16 screws + L8 washers.

Assembling the cable channels and crosspieces (18 - 25 sections)

A

35 Assembling the additional cable channels (18 - 25 sections)

8555N113

� Align the two additional cable channels with the twoothers.� Fasten them to the intermediate piece and the rearcrosspieces with four H 8 x 16 screws and L8 washers.

No. of 7, 8, 9 10 11, 12 13, 14 15, 16 17sections

Length 1200 1500 1600 1800 2100 2200(mm)

No. of 18 19 20 21 22 23 24 25sect.A 2510 2600 2800 2910 3000 3110 3200 3310(mm)

REAR

FRONT

m21

� Put in place the two 600 mm wide (packages FA 37 - 41) pieces of insulating material on the bodyof the boiler.

� Push the insulating material under the front andrear crosspieces.

36Assembling the top insulating material

(18 - 25 sections)

8555N187

37

8555N114

� Fasten the positioning brackets (package FA136or FA137) onto the right and left-hand upper bossesof the front section with two H 8x16 screws and twoserrated washers (13 mm spanner).

Assembling the casing positioning brackets

No.of 18 19 20 21 22 23 24 25sect.

Length 2 x 2 x 2 x 2 x 2 x 2 x 2 x 2 x(mm) 1200 1200 1300 1400 1400 1500 1500 1600

80

90

m22

1

Assembling the lower rail support brackets

� Fasten the lower rail support brackets using H8 x 16screws.

Note : for the assembly direction, see the drawings below.

8555N129

Assembly direction of lower rail support brackets(seen from the top of the frame)

9 sections7, 8, 10 sections

11, 13, 15, 17 sections

Note : two lower rail support brackets and two upper rail brackets are left unused with 7, 8, 9 and 10 sections.

12, 14, 16 sections

FrontRearFrontRear

FrontRearFrontRear

Railsupport brackets




Frame

Frame

Left-hand side

Right-hand side

Left-hand side

Right-hand side

Left-hand side

Right-hand side

Left-hand side

Right-hand side

Frame

Frame

38

8555N182-GB

Example : E 7

38a

38b

m23

18, 20 sections

19, 21 sections

22, 24 sections

23, 25 sections

FrontRear

FrontRear

FrontRear

FrontRear

Rail support brackets


Frame

Left-hand side

Right-hand side

Left-hand side

Right-hand side

Left-hand side

Right-hand side

Left-hand side

Right-hand side





Frame

Frame

Frame

Note: two lower rail support brackets and two upper rail brackets are left unused with 18, 19, 20 and 21 sections.

8555N184-GB

38c

38d

m24

8555N130(GB)

� Fasten the lower rail with H 8x30 screws and L8washers.� The other rail support brackets are fastened oppositethe holes provided on the lower rail.

Length required while assembling the two-piecerails (boilers with 18 - 25 sections) (see fig. 42)

39

40

3 1

❷

❷

❷

4

� Fix the fastening bracket of the upper rails (packa-ge FA136 or FA137) on the upper lug ➀ (these brackets must be vertically aligned with the lowerrail support brackets).Fit the bracket onto the stub ➁.� Fasten with H 10x50 screws and serrated washersand H10 nuts ➂.

� Assemble the Rapid nut on the top of the bracket �with the tapped shaft on the inside.

8555N189

Assembling the fastening brackets of the upper and lower rails

FRONT

Impe

rativ

e al

ignm

ent

m25

41

Type ofboiler FRONT REAR

Side insulating material(length in mm)

E 7 1200E 8 1200E 9 1200E 10 600 400 400E 11 1200 400E 12 1200 600E 13 1200 600E 14 1200 600E 15 1200 400 400E 16 1200 400 600E 17 1200 400 600E 18 1200 1200E 19 1200 1200E 20 1200 400 400 600E 21 1200 400 1200E 22 1200 400 1200E 23 1200 600 1200E 24 1200 600 1200E 25 1200 400 400 1200

1

2

3

Installing the insulating material

� Place the side insulating material against the posi-tioning bracket ➀ and cut it so that it is flush with theupper lug on which the rail fastening bracket is fixed,along a 220 mm length ➁.

� ➂ Push the insulating material in behind the lugand the rail fastening bracket.

� Distribute the insulating material evenly so that youhave the same side insulating material on either sideof the boiler.� Cut the material similarly along the fastening brackets.

8555N128

Length required while assembling the two-piece rails (boilers with 18 - 25 sections) (see table below).

7 - 17 sections� Fix the upper rail with H8 x 30 screws and L8washers (the first hole from the front end of the railmust be opposite the first fastening bracket, and simi-larly with the other brackets).� Push the insulating material behind the lower railand underneath the boiler.� Join the pieces of insulating material to each otherwith the clips.

18 - 25 sections� Fix the upper rail with H8 x 30 screws and L8washers (the first hole from the front end of the railmust be opposite the first fastening bracket, and simi-larly with the other brackets).� Fix the additional upper and lower rails, makingsure you comply with dimension A (see table below).� Push the insulating material behind the lower railand underneath the boiler. Join the pieces of insula-ting material to each other with the clips.

A

8555N138

42

Number 18 19 20 21 22 23 24 25of sectionsA 2500 2615 2765 2875 2965 3075 3165 3275(mm)

Example : E 16

FRONT

FRONT

REAR

220

90

m26

43

1

2

4

5

23

8555N143

Assembling the side casing panels

Type of Front Rear

boiler Side panelsLength in mm

E 7 800 400E 8 940 400E 9 1050 400E 10 940 600E 11 1050 600E 12 940 400 400E 13 1050 400 400E 14 800 600 600E 15 940 600 600E 16 1050 600 600E 17 940 600 400 400E 18 1050 600 400 400E 19 940 600 600 400E 20 940 600 600 600E 21 1050 600 600 600E 22 940 600 600 400 400E 23 1050 600 600 400 400E 24 940 600 600 600 400E 25 1050 600 600 600 400

400 mm long panel in Package FA 10600 mm long panel in Package FA 11800 mm long panel in Package FA 7900 mm long panel in Package FA 8

1050 mm long panel in Package FA 9

1

2 8555N149

� Put the furnace door panel in place (package FA136or FA137) and fasten with two ø 3.94 x 12.7 tappingscrews. The furnace door panel may be cut in two atthe micro-joints.

� Fit two Rapid nuts in the bottom of the front sidepanels.

� Fix the casing support lower crosspiece (packa-ge FA136 or FA137) by means of two H 6x20 screwsand two serrated washers.

Assembling the furnace door and lower crosspiece panels

� First assemble the panels on the front using the as-sembly length table opposite and continue up to therear section ➀.� Fix the front side panels to the positioning brackets

with H 8 x 16 screws and serrated washers ➁.� Push the insulating material into the top of the sidepanels ➂ and fasten the panels to the lower rails by meansof the self-drilling screws with the electric screwdriver (2screws per panel) �.

� Fasten the side panels to each other with the clips .

44

Length and arrangement of panels forthe boiler model

Insulation

m27

8555N146

� Place the front crosspiece underneath the controlpanel bracket and fasten from below with H8 x 30screws and serrated washers.

� Fix to the side panels with two ø 3.94 x 12.7 tappingscrews and serrated washers.

46

45

1

2

2

� Fit the four “Rapid nuts” on the front of the cable channels ➀.

� Fit the Rapid nuts in the slots ➁ :- 4 Rapid nuts for 7-17 sections,

- 8 Rapid nuts for 18-25 sections.� Fix the control panel bracket (package FA136 orFA137) underneath the two cable channels by meansof two H 8x 16 screws and two serrated washers.

8555N141

Assembling the control panel bracket (all control panels)

Standard Control Panel

m28

� Fasten the control panel to the panel base with two ø 3.94 x 25 tapping screws and serrated washers ➀.

� Carefully unroll the various bulbs and bring them outof the control panel through the opening designed forthat purpose. Cut out the top insulating material andinsert the bulbs in the boiler pocket and hold them inplace using the spring ➁.

� Fasten rear cover H (package FA136 or FA137) tothe control panel bracket using two EC CB 4 x 40 screwsand serrated washers ➂.

� Make the electrical connections to the two terminalblocks provided for this purpose inside of the controlpanel. See the “Electrical Connections” section of theinstructions supplied with the control panel.

� Close the control panel.

47 Installing the standard control panel

3 x

1

2

2

8555N139

� Position the control panel on the rear studs ➀.

� Open the control panel (3 screws at the back) ➁.� Bring the burner cable behind the casing support anddown to the burner between the side panel and insu-lating material.

8555N183

48 Standard control panel

49

1

133

2

8555N161

Standard control panel

FRONT

REAR

m29

50 51

5352

8555N150

� Fit the left and right-hand side front panels (package FA136 or FA137) onto the lower front cross-piece and fit them onto the studs of the side panels.

� Place the insulating material in the lower centralfront panel (black cloth facing outward).

� Fit the lower central front panel (package FA136or FA137) onto the lower front crosspiece and fix it tothe furnace door panel.

8555N152

8555N151

� Place the retaining crosspiece (package FA136or FA137) on the left and right-hand front panels,taking care to place the two central tabs behind thefurnace door panel. � Fit the upper front panel (package FA136 or FA6)onto the side panels via the four studs.

8555N153

� Put in place the insulation of the flue gas box andthe lower rear insulating material (package FA136or FA137).

m30

55

57

54

1 3

4

2

� Put the two clip-on nuts in place on the side panels ➀.� Fit the upper rear panel (package FA136 or FA137)onto the studs and push it up ➁. Fasten with two H

8x16 screws and serrated washers ➂.� Fit the two lower rear panels (package FA136 orFA137) onto the rear crosspieces �.

8555N159

� Put in place the two rear crosspieces (packageFA136 or FA137) behind the bend of the rear sidepanels and fasten each crosspiece to the side panelsusing two ø 3.94 x 12.7 screws.

8555N155

56

1

2

3

3

Assembling the central platefor 7 - 17 sections

� Place the central plate on the cable channels withthe round holes towards the front of the boiler. � Fasten with H 8x30 screws and serrated washers.

Assembling the central plate for 18 - 25 sections

� Place the rear plate, which is 1200 mm long ➀.� Fasten with four H 8x30 screws and serrated washers.� Place the front plate with the round holes towards thefront of the boiler .� Fasten with four H 8 x 30 screws and serrated washers.� Fasten the joining plate ➂ with the round holestowards the front of the boiler with four tapping screwsand serrated washers.

8555N2638555N262

m31

59

6658

8555N264

� Put in place the sweeping cover insulating material (packages FA 30 - FA41) :- E 7 - 17 : 2 pieces- E 18 - 25 : 4 pieces.

� Place the side covers (package FA7 to FA11, seetable) from the front to rear. They have the same lengthsas the side panels.

Cover packages :

400 mm long panel in Package FA 10600 mm long panel in Package FA 11800 mm long panel in Package FA 7900 mm long panel in Package FA 8

1050 mm long panel in Package FA 9

Type Front Rearof Central and

boiler side covers(Length in mm)

E 7 800 400E 8 940 400E 9 1050 400E 10 940 600E 11 1050 600E 12 940 400 400E 13 1050 400 400E 14 800 600 600E 15 940 600 600E 16 1050 600 600E 17 940 600 400 400E 18 1050 600 400 400E 19 940 600 600 400E 20 940 600 600 600E 21 1050 600 600 600E 22 940 600 600 400 400E 23 1050 600 600 400 400E 24 940 600 600 600 400E 25 1050 600 600 600 400

8555N265

m32

60

8555N261

Identification plate and CE marking

� Glue the identification plate and CE marking on thecasing of the boiler in an easily visible location.

(1) 00 = 2000,01 = 2001,…

Hartley & Sugden Halifax U.K.

XX - XX

Type of boiler

Year (1)

Week

Date of manufacture

Unit serial no.

Hartley & SugdenHartley & Sugden follows a policy of continual improvement, and reserves the right to change specification without notice.

Hartley & Sugden, Atlas Works, Gibbet Street, Halifax HX1 4DB Tel: 01422 355651 Fax: 01422 359636

Servicing company :Fitter :

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