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Hamworthy 65he, Installation, Comissioning And Servicing Instructions, Page: 1 / 66

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Hamworthy 65he Installation, Comissioning And Servicing Instructions Download Page 1

IMPORTANT NOTE 

 

THESE INSTRUCTIONS MUST BE READ 

 

AND UNDERSTOOD BEFORE INSTALLING, 

 

COMMISSIONING, OPERATING OR 

 

SERVICING EQUIPMENT 

Purewell Vari

Heat

 

he 

Boilers 

 

Cast Iron, Pre-mix, High Efficiency, Modular Boilers with 

Automatic Ignition for Heating and Domestic Hot Water 

Installations 

 

Installation, Commissioning 

and Servicing Instructions 

 

 MODELS  -  65he, 85he, 105he, 125he 

 

NATURAL GAS 

 I

2H

 

Summary of Contents for 65he

Page 1: ...NING OPERATING OR SERVICING EQUIPMENT Purewell VariHeat he Boilers Cast Iron Pre mix High Efficiency Modular Boilers with Automatic Ignition for Heating and Domestic Hot Water Installations Installati...

Page 2: ......

Page 3: ...D FAMILY I2H PLEASE ENSURE RELEVANT INFORMATION REQUIRED WITHIN DOCUMENT IS FOUND BEFORE FIRING BOILER COUNTRY OF DESTINATION UNITED KINGDOM REPUBLIC OF IRELAND THIS BOILER COMPLIES WITH ALL RELEVANT...

Page 4: ...6 1 Gas Supply 6 2 Ventilation 6 3 Pipework Valves and Pump 6 4 Flue 6 5 Electrical 7 0 CHECKS PRIOR TO LIGHTING 14 7 1 Boiler Gas System Leak Check 7 2 Checks Prior to Lighting the Boiler 7 3 Initia...

Page 5: ...ressure Lock out 16 Figure 7 3 4 Display For Boiler Ignition 16 Figure 7 4 1 Removal of Sample Point Plug 18 Figure 7 4 2 Combustion Analyser Probe setting 18 Figure 7 4 3 Fan Assembly PV65he PV85he H...

Page 6: ...C1 1 Flue Resistance 51 Figure C1 2 Open Flue Natural Draught B23 Flue System 51 Figure D1 Mechanical Ventilation Flow Rates 52 Figure E1 Water Data 53 Figure E1 1 Cold Feed and Vent Pipe Sizes 53 Fig...

Page 7: ...ut down the boiler s should a high or low pressure fault occur The pressurisation unit must also incorporate a low level water switch which protects the water pumps and will directly or indirectly shu...

Page 8: ...er is designed to pass through a standard doorway where access is restricted Figure 2 1 Boiler Delivery NOTE The boiler is supplied with cardboard corner protection and shrink wrapped for protection d...

Page 9: ...everse return header sets are used these are packaged separately from the boilers Ancillary items such as isolation valves and flexible boiler connectors are packaged in a cardboard box on the same pa...

Page 10: ...he top or display covers See Figure 3 1 below 3 2 The Hamworthy Heating Ltd water manifold kit is designed to provide a compact solution for connecting the boilers to the gas supply and flow and retur...

Page 11: ...s are not required on each module and a common valve can be fitted in the combined flow pipe However each boiler has a Rp1 connection plugged in the rear of the boiler heat exchanger assembly for use...

Page 12: ...on of boilers manifold kits pipework pumps controls flues ventilation access and servicing and other items of plant 4 2 Gas Supply Gas supply pipes must be in accordance with BS 6891 or IGE UP 2 Gas s...

Page 13: ...a twin wall insulated type to maintain buoyancy within the flue Care should be taken to ensure that the flue system is installed in such a way that any condensation produced on start up will drain awa...

Page 14: ...stem pipework is flushed twice before water treatment In hard water areas precautions such as water treatment should be implemented to prevent the build up of sludge and scale Leaks in the system pipe...

Page 15: ...c waste pipe Condense may be discharged to a standard drain subject to National or Local regulations Boiler Condensate Connection 32mm o d Figure 4 5 1 Boiler Condensate Connection Figure 4 5 2 Boiler...

Page 16: ...have contact separation of minimum 3mm in all poles Electrical isolators must be installed in readily accessible locations Electrical supplies to boiler modules should only serve the boiler Where vol...

Page 17: ...1 Flue Pipe So as to avoid damage the flue connecting pipe is supplied separately Fit the elbow to the base of the boiler and secure using the gasket and 4 M8 nuts and washers Moisten the lip seal an...

Page 18: ...and common safety valve to be three way type such that when boiler is isolated from safety valve it is open to atmosphere The boiler is provided with a connection on the boiler for the safety valve Wh...

Page 19: ...Hamworthy Heating recommendations Circulating system is full of water vented and pressurised appropriately Circulation pump is fitted working and interlocked where required Pipework connections to boi...

Page 20: ...the electrical power and gas to the appliance 2 By unscrewing screw at Position X of Figure 7 1 1 remove the red gas pressure switch L H S picture or loosen the test point valve plug R H S picture 3...

Page 21: ...anti clockwise a 1 4 turn by unscrewing it s fixing screws and unscrew the screws securing the thermostat from its mounting plate The control thermostat is factory set to a flow temperature of 85 C a...

Page 22: ...of the boiler At this point no gas is present in the boiler so no ignition occurs 7 On failure to sense presence of a flame the boiler will display a flashing Error code of 133 before making a second...

Page 23: ...up down keys together for 5 seconds To bring you into the Extended Info Mode 7 3 3 3 Using up down arrow keys scroll through B C or D modes select Mode C 7 3 3 4 Using the keys scroll through the opt...

Page 24: ...correctly 8 Remove the combustion analyser probe replace the sample point plug in the front of the base of the boiler 9 If the combustion readings fall outside the required range DO NOT adjust the gas...

Page 25: ...eed Back Tube Outlet Gas Pressure Test Point Low Fire Gas Adjustment Factory Sealed Pressure Switch Pressure Switch Low Fire Gas Adjustment Factory Sealed High Fire Gas Adjustment Factory Sealed Outle...

Page 26: ...pplied by Hamworthy Heating Ltd to ensure safe and reliable opera tion The system provides as standard 2 volt free contacts for external fault indication Normal Run General Fault The Siemens LMU64 con...

Page 27: ...0 V 4 20 mA OCI ACS Figure 8 1 2 General Overview of Controls 533901179Safety Temperature Limiter 533926116 IEC Mains Outlet Socket 533901437 Display Screen 533901438 Clip in Module Vfc 0 10v 53390144...

Page 28: ...tton refer to figure 8 1 A change on the information level can be made at any time by pressing the Info button Additional pushes of the Info button will deliver the following data sequence provided by...

Page 29: ...PWM C 4 RelModLevel Relative output C 5 Pumpe_PWM Pump setpoint PWM Not used C 6 ek0 Control differential C 7 C8 C9 Reserved Setpoints Service level d 0 Reserved d 1 Tsoll Setpoint of 2 position or m...

Page 30: ...HAMWORTHY HEATING LTD 24 PUREWELL VariHeat he 500001170 K Figure 8 2 1 3 Operation and display philosophy...

Page 31: ...eaning of symbols Display of dhw temperature or dhw heating active not used Display of boiler or room temp set point or space heating active Display of outside temperature Operational level Normal Ope...

Page 32: ...ault display If no button is pressed for about 8 minutes the screen will automatically return to the default display Figure 8 2 3 2 Display of Status Code When a status code is displayed the display 1...

Page 33: ...of the fault press the reset button 0 6 seconds to reset the LMU Figure 8 2 4 Display of lockout code 304 7494z35 0202 8 2 5 Adjusting the heating circuit setpoint temperature Press the flow temperatu...

Page 34: ...1 Time of day 0 23 59 h min 1 min Setpoints 5 Reduced room temperature setpoint TrSollRed or reduced boiler temperature setpoint TvSollRed When using an additional room unit line 5 will be hidden TRF...

Page 35: ...ction serves for making measurements on the boiler and allows the boiler output to be increased decreased by pressing buttons Minimum and maximum output can be selected by pressing the line selection...

Page 36: ...t Investigate cause of overheating see section 9 3 113 Flue gas supervision equipment has cut out 117 Water pressure too high 118 Water pressure too low 119 Water pressure switch has cut out 128 Loss...

Page 37: ...ATION DHW mode 12 Parallel operation of space heating and DHW heating PH_TI PH_MODULATION Heating and DHW mode 20 Postpurging with the last control of operation PH_THL2_1 PH_TN_1 21 Postpurging with c...

Page 38: ...selector valve kick If either the heating circuit pump or dhw selector valve have not been activated for more than 24hours then dur ing an off period the pump or valve is activated for 5 seconds 8 3...

Page 39: ...ly stored in the LMU When a new startup is made or after power On the previous settings will be stored in the LMU Also the software version number of the operator module and that of the connected type...

Page 40: ...HAMWORTHY HEATING LTD 34 PUREWELL VariHeat he 500001170 K Figure 8 3 11 Operating phases...

Page 41: ...HAMWORTHY HEATING LTD 35 PUREWELL VariHeat he 500001170 K Figure 9 0 Boiler Wiring Schematic...

Page 42: ...require a manual re set on off button situated on the controls fascia to re start the control sequence 9 2 Fault Finding Procedures General error messages are detailed in section 8 to assist with fau...

Page 43: ...V70c 95c 110c Refer to Figures 11 2 11 3 for parts assembled between the gas valve fan A Disconnect the silicon tube attached to the gas valve B Disconnect the gas valve from the air box lid by removi...

Page 44: ...ion of the boiler The gas valve is supplied as a factory set component must not be tampered with 1 Disconnect the gas valve electrical plug Remove the four socket head screws securing the gas valve in...

Page 45: ...ns Figure 11 2 Gas Valve Assembly model 65he 85he shown for illustration 531201103 Fan Airbox Seal 532407002 Airbox 531201104 Venturi Seal 532418003 Venturi Clamp 533001030 Baffle 532418002 Venturi 53...

Page 46: ...Mixer Venturi 533903036 Gas Valve 532403170 Gas Valve Mounting Bracket 533704003 Fan 741083676 M5x 12 Screw 748520218 M8x20 Screw 533925004 Gas Pressure Switch 53301016 Burner 531201123 Burner Elbow...

Page 47: ...748551010 1 4 Turn Screw 748551010 1 4 Turn Screw 530650353 Top Cover 748551006 1 4 Turn Fastener Clip 530650355 Front Cover Brace 530650348 LHS Panel 530650347 RHS 748551001 1 4 Turn Screw 530650351...

Page 48: ...stat Pocket 531201121 Burner Gasket 524120042 Combustion Chamber 531201120 Section Seal 53201204 Tie Rod 524120043 Heat Exchanger 524120045 Heat Exchanger 531050011 R1 4 Sensor Pocket 532403217 Inlet...

Page 49: ...model 105he 125he shown for illustration 524120049 Section Clamp 531201121 Burner Gasket 524120042 Combustion Chamber 531201120 Section Seal 532012017 Tie Rod 524120045 Heat Exchanger 524120045 Heat E...

Page 50: ...he 533901520 AGU2 310A109 Display PCB 533901437 Flow Return Sensor 533901431 Temperature Limiter 533901179 Hot Surface Igniter 563801016 Flame Sensing Probe 533805015 T2A 5x20 Fuse 533922002 MECHANICA...

Page 51: ...s 80 1 107 5 128 0 Boiler Input maximum kW Nett 72 1 96 8 115 3 Boiler Output maximum 80 60 C kW 65 85 105 Boiler Output minimum kW 21 5 30 1 33 6 125 he 154 3 138 9 125 39 8 GAS DATA Gas Inlet Connec...

Page 52: ...itate complete electrical isolation of the single boiler with a separation of at least 3mm in all poles 1 3 A mains isolator must be provided adjacent to each boiler in a readily accessible position T...

Page 53: ...m providing local or remote access to boiler operational information via intergrated web server software resident in the device see figure B1 3 The IQ3 is fully compatible with all Trend BMS systems a...

Page 54: ...HAMWORTHY HEATING LTD 48 PUREWELL VariHeat he 500001170 K Figure B1 3 Configuration of Hamworthy Trend IQ3 Remote Monitoring Unit RMU...

Page 55: ...external flue installations b Care should be taken to ensure that the flue is installed such that any condensation is continuously drained All flues should have a maximum slope of 2 upwards in the dir...

Page 56: ...d be so situated as to prevent the products of combustion entering any opening in a building Where the flue diameter is less than 204mm 8 diameter a terminal must be fitted Where the flue is of a larg...

Page 57: ...mponent 65 he 85 he 105 he Straight tube 150mm maximum length m 149 88 69 45 bend 150mm Equivalent tube length m 2 2 2 90 bend 150mm Equivalent tube length m 2 2 2 2 2 3 125 he 47 2 2 3 Straight tube...

Page 58: ...as follows 1 At floor level or 100mm above floor level 25 C 2 At mid level 1 5m above floor level 32 C 3 At ceiling level or 100mm below ceiling level 40 C Where both low and high level openings are...

Page 59: ...lowing page show typical layouts 5 Ideally individual valves should be fitted to each module to enable isolation from the system however the arrangement must comply with the requirements of BS 6644 E1...

Page 60: ...Vent Automatic Valve valve Drain Valve Module Hamworthy Modular Boilers Safety T valve Module 1 2 Drain 3 Module P gauges Pressure Temperature T Automatic Air Vent Heating lo ad Lockshield va lve fil...

Page 61: ...nsure that the minimum flow rate can be obtained It is also important that the existing system be flushed through twice to remove any loose matter which may have accumulated If in any doubt regarding...

Page 62: ...ust be taken in sizing expansion vessels to ensure maximum acceptance factors are not exceeded Normally manufacturers of vessels impose a limit of 0 5 This value must not be exceeded at any time durin...

Page 63: ...THY HEATING LTD 57 PUREWELL VariHeat he 500001170 K Figure E 1 3 4 Schematic for Multiple Boiler Cascade Primary Circuit System Figure E 1 3 3 Schematic for Single Boiler External 0 10V Multi Circuit...

Page 64: ...HAMWORTHY HEATING LTD 58 PUREWELL VariHeat he 500001170 K INSTALLER SITE ADDRESS BOILER TYPE BOILER SIZE S UNIT NO S SERIAL NO S FLUE USEFUL USER INFORMATION NOTES...

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