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Hamworthy Purewell Series, Installation, Commissioning And Servicing Instruction

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Hamworthy Purewell Series Installation, Commissioning And Servicing Instruction Download Page 1

Installation, Commissioning

and Servicing Instructions

Atmospheric Cast Iron Boiler

40kW to 120kW Output

PERMANENT IGNITION CONTROLS

Classic and Integra Models

Purewell

Gas Fired
Modular Boiler System

NATURAL GAS

I

2H

LPG-PROPANE

I

3P

IMPORTANT NOTE

THESE INSTRUCTIONS MUST BE READ AND UNDERSTOOD BEFORE
INSTALLING, COMMISSIONING, OPERATING OR SERVICING EQUIPMENT.

BS EN ISO 9001:1994

Certificate No. FM 10082

Summary of Contents for Purewell Series

Page 1: ...put PERMANENT IGNITION CONTROLS Classic and Integra Models Purewell Gas Fired Modular Boiler System NATURAL GAS I2H LPG PROPANE I3P IMPORTANT NOTE THESE INSTRUCTIONS MUST BE READ AND UNDERSTOOD BEFORE INSTALLING COMMISSIONING OPERATING OR SERVICING EQUIPMENT BS EN ISO 9001 1994 Certificate No FM 10082 ...

Page 2: ...ctive parts but does not include labour When the equipment is commissioned and routinely maintained by Hamworthy Heating under a Service Maintenance Agreement then the warranty terms will cover both parts and labour MAINTENANCE AGREEMENTS 01202 662555 Regular routine servicing by Hamworthy Heating s engineers ensures trouble free operation and optimum efficiency The frequency of visits required is...

Page 3: ...AND UNDERSTOOD BEFORE ATTEMPTING TO INSTALL COMMISSION OR OPERATE THIS UNIT THE PUREWELL BOILER IS INTENDED FOR USE AS A COMMERCIAL APPLIANCE AND IS NOT CERTIFIED FOR USE IN DOMESTIC APPLICATIONS OR HABITABLE AREAS THIS BOILER IS FOR USE ON GROUP H NATURAL GAS 2ND FAMILY I2H OR LPG PROPANE 3RD FAMILY I3P PLEASE ENSURE RELEVANT INFORMATION REQUIRED WITHIN DOCUMENT IS FOUND RELATING TO SPECIFIC GAS ...

Page 4: ...HAMWORTHY HEATING LTD PUREWELL PERMANENT IGNITION 500001090 B ii ...

Page 5: ... SYSTEM 5 6 1 General Requirements 6 2 Design Waste Gas Volume and Temperature 6 3 Flue Condensation 6 4 Materials 6 5 Disconnection 6 6 Flue Discharge 6 7 Surface Temperatures 6 8 Flue System Location 7 0 AIR SUPPLY 6 7 1 Air Supply by Natural Ventilation 7 2 Air Supply by Mechanical Ventilation 8 0 WATER CIRCULATION SYSTEM 6 8 1 General 8 2 Pressure Relief Valve Safety Valve 8 3 Open Vent Pipe a...

Page 6: ...of Boiler Lockout 13 0 SERVICING 16 14 0 REPLACEMENT OF FAILED COMPONENTS 17 15 0 RECOMMENDED SPARES 19 APPENDIX A INFORMATION RELATING TO PROPANE FIRING 30 FIGURES PAGE Figure No 1 Performance and General Data 2 Figure No 2 Flow Rates Pressure Drop Table 3 Figure No 3 Gas Valve Leak Check Procedure 5 Figure No 4 Mechanical Ventilation Flow Rates 6 Figure No 5 Heat Exchanger Insulation Fitting Ins...

Page 7: ...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 shut down the boiler plant should a low water condition occur Consideration should also be given to the maximum working pressure of the boiler as given in Section 2 TECHNICAL DATA Consult Hamworthy Heating Technical Department for help or...

Page 8: ... Water content litres 30 30 37 1 37 1 37 1 44 2 44 2 44 2 51 3 Litres sec 11 C T 0 87 1 08 1 30 1 52 1 74 2 06 2 17 2 28 2 6 Litres sec 15 C T 0 64 0 80 0 95 1 12 1 27 1 51 1 59 1 67 1 91 Litres sec 22 C T 0 43 0 54 0 65 0 76 0 87 1 03 1 08 1 14 1 3 ELECTRICAL DATA Normal Supply Voltage 230 V AC 50 Hz 1 ph fused 2A Power Consumption 35W NOTE Flue gas volumes are based on a gross flue gas temperatu...

Page 9: ...the boiler water passageways Details of additives can be obtained from any reliable manufacturer of water treatment products or the local water authority It should be noted however that even if the boiler water is of average hardness not requiring treatment subsequent draining of the system for repair or constant make up water due to an undetected leak would cause additional deposits and gradual b...

Page 10: ...e material adjacent to the boiler and the flue system must be so placed or shielded to ensure that its temperature does not exceed 65 C Further details regarding boiler location are given in BS 6644 5 0 GAS SUPPLY 5 1 Service Pipes The local gas region must be consulted at the installation planning stage in order to establish the availability of an adequate supply of gas An existing service pipe m...

Page 11: ...in the correct position to avoid compression of the draught diverter and enable its removal for boiler cleaning 4 Boilers should be located as near the chimney as possible the nearest being not more than 2m 6 ft away 5 The flue system should be designed to achieve a negative suction at all times at the draught diverter outlet on all modules in a bank For optimum performance draught conditions shou...

Page 12: ...n system which is carrying flammable vapour Grilles or louvres must be so designed that high velocity air streams do not occur within the space housing the boiler The air supplied for boiler house ventilation shall be such that the maximum temperatures within the boiler house shall be as follows 1 At floor level or 100mm above 25 C 2 At mid level 1 5m above floor level 32 C 3 At ceiling level or 1...

Page 13: ...Drain Valves Each boiler should have a 15mm NB drain valve not H H L supply fitted to drain the boiler only The heating system in total should have drain valves as recommended by BS 6644 See Figure No 8 for recommended positions 8 7 Circulating Pump One or more circulating pumps will be required to circulate water around the boilers and heating system Figure No 1 shows the hydraulic resistance of ...

Page 14: ...IEE Regulations and any local regulations which apply Wiring must be completed in heat resistant 3 core cable Size 1 0mm csa Boilers are normally supplied suitable for 230 volts 50Hz Control panel fuse rating is 2A External fuses should be 6A for all single boiler sizes The method of connection to the mains electricity supply must facilitate complete electrical isolation of the single boiler with ...

Page 15: ...space the boilers approx 3mm apart prior to fitting the casing See label attached to the basket fixing It is recommended that all mechanical work is carried out prior to fitting the casing assembly this will reduce possible damage to the panels The casing assembly includes a component list which is also shown in Figure No 7 You should check to ensure that all parts are supplied prior to assembly 3...

Page 16: ...half union and gas valve assembly to gas pipe as shown using proprietary sealing compound Ensure gas valve lever is correctly orientated Offer gas pipe to boiler as shown Bracket should be mounted as shown Bracket s position will be dependent on boiler size Figure No 6a Figure No 6b shows the pipe clamp fitted to Purewell 60 70 80 and 120 kW boilers Figure No 6b Figure No 6c shows the pipe clamp f...

Page 17: ... closing valves must not be connected to both flow and return pipes unless the boiler is fitted with an individual correctly sized safety valve It is recommended that a 3 way L port valve is fitted in the flow connection to allow an open vent situation should the boiler need to be fully isolated from the system 10 7 Casing and Controls Assembly For assembly of casing components and controls unit s...

Page 18: ...mbling the Casing Multi Casing Set 13 14 5 18 10 9 10 22 19 2 16 3 16 15 21 16 20 15 11 12 8 7 8 7 12 11 17 LOWLINE BOILER CASING TOP STANDARD BOILER CASING TOP 1 REF DETAIL A REF DETAIL A DETAIL A 11 12 8 7 24 23 25 26 4 6 27 28 AUTOMATIC BOILER 6 PERMANENT PILOT BOILER 9 10 15 16 ...

Page 19: ...embly sit above the top panel discard the blanking plug from the top panel insert Fit the edging strip to the hole and route the damper cable assembly through the hole into the control panel securing the cables to the casing side panel using the self adhesive clips supplied Note The damper must be fitted with the motor assembly at the front of the boiler 10 The 4off screws fixing the back panel to...

Page 20: ...k and valve arrangement is installed to Hamworthy Heating recommendations in such a way that water flow rates will be in accordance with Figure No 1 6 The gas supply pipework is clear of any loose matter tested for soundness and purged 11 5 Boiler Checks Prior To Lighting NOTE Refer to Figure No 1 for Natural Gas maximum inlet pressure for normal operation Information relating to propane firing ca...

Page 21: ...vided in the flue on Classic models or on the inspection door of Integra models fitted under rear casing Remove plug and insert sampling probe Replace plug when test is complete NOTE Care should be exercised if the boiler is firing as the flue can achieve temperatures which will produce injury if touched Combustion figures for Natural Gas should be as follows CO2 8 5 9 Dry flue gas CO 0 50ppm Howe...

Page 22: ...lue above the draught diverter is self supporting Remove the clamp band and collapse the draught diverter onto the primary flue Remove the screw securing the primary flue to the boiler flue hood and carefully remove the complete assembly and flue bezel Alternatively remove the clamp band and 2 screws securing the draught diverter to the primary duct Collapse the short primary duct into the draught...

Page 23: ... top panel to reveal thermostat pocket Remove the cover to reveal boiler controls Remove the push on spade connectors from the thermostat body noting position of coloured cables Pull off the control knob and remove bezel Note The two M3 screws holding the thermostat to its bracket may retain this Note if screws are of different type length for re assembly purposes before removing them The thermost...

Page 24: ...ollapse the short primary duct into the draught diverter and remove the primary duct or damper assembly if fitted and flue bezel leaving the draught diverter assembly connected to the flue system Temporarily support the draught diverter 4 Remove the motor cover secured by four screws 5 Remove the two screws securing the actuator location bracket to the mounting plate Slacken the U clamp and withdr...

Page 25: ...ermocouple 747439864 Mechanical Items Pilot Pressure Switch 339009477 Single Burner Bar 533301003 Heat Exchanger Nipple 330502033 Flue hood thermoseal Yarn 10 mm Dia 331299233 Injector Copper Washer 339008347 Pilot burner injector Natural Gas only 331101843 Gas Valve O Ring Joint 40 80kW only 742111245 Gas Valve O Ring Joint 95 120kW Pilot Stat only 742122069 Piezo Generator and Lead 333805342 Con...

Page 26: ...hy recommended system Heating load Air Vent Automatic Valve Circulation pump Hamworthy Modular Boilers 1 2 3 Drain valve Safety Temperature P gauges Pressure valve Drain Temperature Sensor Marshall HE Outside Air Temperature Sensor Marshall HE Water Flow Temperature Sensor Marshall HE Room position alternative Circulation pump Valve Lockshield valve Drain valve Pressurisation Hamworthy Unit fill l...

Page 27: ...C Flow Connection Height mm 580 580 667 667 761 761 855 D Gas Connection Height mm 769 769 769 769 957 957 957 E Gas Connection BS21 R R R R R1 R1 R1 F Flue Outlet Dia mm Nominal 206 206 206 206 256 256 256 NOTE The 533 centres relates to boilers close coupled in modular form For stand alone applications a minimum of 150mm should be allowed between casings Space baskets 200mm apart SIDE VIEW FRONT...

Page 28: ...AUGHT DIVERTER ASSEMBLY FLUE SAMPLING POINT PRIMARY FLUE DUCT or ON OFF DAMPER ASSEMBLY CONTROLS HOUSING BOILER INSULATION FUSED 3 PIN IEC SUPPLY PLUG TEMPERATURE OVERHEAT OS CONTROL THERMOSTAT GAS COCK GAS PIPE GAS VALVE BURNER O BURNER TEST POINT VIEWING PORT PILOT ASSEMBLY PIEZO IGNITER ECO CONNECTOR INTEGRA CLASSIC ...

Page 29: ... x 120kW 14 86 430 525 5 x 105kW 11 71 340 600 5 x 120kW 51 245 630 6 x 105kW 46 220 720 6 x 120kW 34 165 The above table expresses pipe lengths from gas meter to appliance which will produce approx 1mbar pressure loss This table must be used in conjunction with losses of various fittings fitted in the gas line shown below Fitting Type 20mm 25mm 40mm 50mm 65mm 80mm 100mm Per elbow 0 5m 0 5m 1 0m 1...

Page 30: ...c with On Off Flue Damper GREEN YELLOW GREEN YELLOW BLUE BROWN RED BROWN GREEN YELLOW BLUE BROWN MAINS INLET FREE SOCKET MAINS OUTLET GAS VALVE PLUG GAS VALVE BROWN RED GREEN YELLOW FUSED ECO LEADS BULKHEAD CONNECTOR GAS VALVE YELLOW YELLOW 230V 50Hz SUPPLY FROM A FUSED ISOLATOR WITH MINIMUM 3mm CONTACT SEPARATION IN ALL POLES KEY SCREWED TERMINAL IN IEC FREE PLUG AND SOCKET PUSH ON SPADE CRIMP TE...

Page 31: ...HAMWORTHY HEATING LTD PUREWELL PERMANENT IGNITION 500001090 B 25 Figure No 13 Diagram of Igniter Assembly ...

Page 32: ...HY HEATING LTD PUREWELL PERMANENT IGNITION 500001090 B 26 Figure No 14 Various Gas Valves Fitted to Purewell Boilers a Honeywell V4400 Series b Honeywell V4600 Series c Robertshaw 7000 Series d SIT NOVA Series ...

Page 33: ... Clean as Required No No No No Check Spark Across Electrode When Operating Piezo Are ECO Leads Connected and Correctly Fitted to the Temperature Limiter Yes Repeat Pilot Lighting Procedure Does Pilot Remain On When Start Button is Released Yes Yes Is Temperature Limiter Pin on Controls Panel Reset Reset Temperature Limiter Limit Stat No Is Pilot Flame Sufficient To Hold in Thermocouple Yes Adjust ...

Page 34: ...nnections and Mechanism Check the Gas Valve Plug and Wiring Thermostat Faulty Poor Circulation due to Faulty Pump or Air Pockets Insufficient Circulation Air Pockets Restricting Circulation Pump Failure Insufficient Circulation Thermostat Set too High Faulty Thermostat Boiler Waterways Scaled Up Gas Valve Faulty Gas Pressure Incorrect Check Manifold Pressure No No No No No Yes Yes Yes Is There Pow...

Page 35: ...LTD PUREWELL PERMANENT IGNITION 500001090 B 29 Figure No 16 Damper Actuator Motor 6 8 4 2 0 1 M L M R MANUAL OPERATION PUSH BUTTON ACTUATOR REVERSING SWITCH POSITION SWITCH DIAL SHOWING SETTING POSITION ACTUATOR END STOP ...

Page 36: ... DATA 40 50 60 70 80 95 100 105 120 Boiler Input kW Gross 49 3 63 4 74 5 88 4 101 0 120 0 126 0 132 0 150 0 Boiler Input kW Net 45 4 58 4 68 6 81 4 93 0 110 5 116 0 121 6 138 1 Boiler Output kW 40 50 60 70 80 95 100 105 120 Gas flow rate m3 h 1 9 2 4 2 8 3 3 3 8 4 5 4 7 5 0 5 7 kg h 3 5 4 6 5 3 6 3 7 2 8 6 9 0 9 5 10 7 Gas manifold pressure mbar 15 15 15 15 17 29 23 25 24 FLUE DATA Approx flue gas...

Page 37: ...m NOTE All the above measurements refer to dry flue gas samples Gas Pressure Switch Location 230V 50Hz 35W MAX HAMWORTHY HEATING LIMITED PUREWELL PERMANENT IGNITON BOILER CONTROL PANEL I II Key I Gas Pressure Switch II Main Gas Valves For electrical connections to the Low Gas Pressure Switch see Figure 12 Gas Pressure Switch Adjustment With the cover removed turn the M3 nut clockwise to increase t...

Page 38: ...HAMWORTHY HEATING LTD PUREWELL PERMANENT IGNITION 500001090 B 32 USEFUL USER INFORMATION INSTALLER SITE ADDRESS DATE OF COMMISSIONING BOILER TYPE BOILER SIZE S UNIT NO S SERIAL NO S FLUE NOTES ...

Page 39: ...Modular Services 14 46 Lomond Street Glasgow G22 6JZ Tel 0141 336 8795 Fax 0141 336 8954 Hamworthy Heating Accredited Distributors Southern Ireland Northern Ireland HEVAC Limited HVAC Supplies Limited Muirfield Drive Unit 2 Antrim Line Business Park Naas Road Sentry Lane Dublin 12 Newtownabbey Ireland BT3 8XX Tel 003531 14191919 Tel 02890849826 Fax 00353114584806 Fax 02890847443 For all other area...

Page 40: ...replacement parts for both current and discontinued products Please contact our spares team providing details of product type serial number model and part requirements wherever possible SERVICE DEPARTMENT 01202 662555 At Hamworthy Heating we employ our own skilled service engineers who are trained to work on all of our products Our National coverage of all UK mainland sites is supported by a netwo...

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