Hamworthy Purewell VariHeat 110c Installation, Commissioning And Servicing Instructions Download Page 1

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Purewell Vari

Heat

Boilers

Cast Iron, Pre-mix, Condensing, Modular Boilers with

Automatic Ignition for Heating and Domestic Hot Water

Installations

Installation, Commissioning

and Servicing Instructions

MODELS - 70c, 95c, 110c, 140c & 180c

NATURAL GAS

IMPORTANT NOTE

THESE INSTRUCTIONS MUST BE READ

AND UNDERSTOOD BEFORE INSTALLING,

COMMISSIONING, OPERATING OR

SERVICING EQUIPMENT

Summary of Contents for Purewell VariHeat 110c

Page 1: ...c Ignition for Heating and Domestic Hot Water Installations Installation Commissioning and Servicing Instructions MODELS 70c 95c 110c 140c 180c NATURAL GAS I2H IMPORTANT NOTE THESE INSTRUCTIONS MUST B...

Page 2: ......

Page 3: ...2ND 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 RELEVA...

Page 4: ...SIONING 13 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...

Page 5: ...f Sample Point Plug 18 Figure 7 4 2 Combustion Analyser Probe setting 18 Figure 7 4 5 Burner Pressure Test Point 19 Figure 7 4 3 Fan Assembly PV70 95 110c High fire Low Fire Adjustment 20 Figure 7 4 4...

Page 6: ...igure C1 Flue Data 50 Figure C1 1 Flue Resistance 52 Figure C1 2 Open Flue Natural Draught B23 Flue System 52 Figure D1 Mechanical Ventilation Flow Rates 53 Figure E1 Water Data 54 Figure E1 1 Cold Fe...

Page 7: ...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 shut down the boiler pla...

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: ...r sales service team Please provide details of your order such as order number and contract number as well as a detailed description of the missing item Reverse Return Header Sets Where reverse return...

Page 10: ...llowance for sufficient access at front sides and rear of boiler for flue and pipework connections Ensure a minimum height of 150mm above the boiler for removal of the covers Do not run cabling throug...

Page 11: ...installation Safety Valve As each kit is provided with a 3 port isolating valve for use on the flow pipe individual safety valves are not required on each module and a common valve can be fitted in th...

Page 12: ...n 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 su...

Page 13: ...ust be designed to limit the max suction cold to 30Pa negative measured at the connection to the boiler If the suction is greater than 30Pa refer to HHL Technical This condition must then be checked h...

Page 14: ...HAMWORTHY HEATING LTD 8 PUREWELL VariHeat c 500001169 T Figure 4 3 Flue Connection Point Flue Connection as delivered Flue Connection fitted Flue fixing bracket Flue Pipe Elbow...

Page 15: ...e system pipework is flushed twice before water treatment In hard water areas 180mg CaCO3 litre precautions such as water treatment are strongly recommended to prevent the build up of sludge and scale...

Page 16: ...d not copper Hamworthy recommend 32mm dia Plastic 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...

Page 17: ...solation Electrical isolators must have contact separation of minimum 3mm in all poles Electrical isolators must be installed in readily accessible locations Electrical supplies to boiler modules shou...

Page 18: ...Remote On Off 0 10v Analogue Control Signal Input External sensors Cascade Management of Multiple Boiler Installations with Merley sequence controller 5 0 BOILER ASSEMBLY General Boilers are despatch...

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

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: ...crews visible on the outside of the moulding anti clockwise a 1 4 turn Then unscrew the screws securing the thermostat from its mounting plate found on the rear of the bridging piece of the metal cont...

Page 22: ...the boiler At this point no gas is present in the boiler so no ignition occurs 8 On failure to sense presence of a flame the boiler will display a flashing Error code of 133 before making a second ig...

Page 23: ...oth 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...

Page 24: ...the required range the boiler is set and operating 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 is outside...

Page 25: ...mbustion readings are outside target range use Torx Bit to make adjustments To increase the CO2 level turn the adjustment clock wise Figure 7 4 4 1 Adjusting gas valve offset Low Fire Target Nat Gas 8...

Page 26: ...r s In structions should then be handed over kept in a safe place for easy reference Figure 7 4 5 Burner pressure test point Burner pressure test point 7 7 Burner Resistance Check The burner pressure...

Page 27: ...e 7 4 3 Example Fan Assembly PV70c High Fire Gas Adjustment Factory Sealed Pressure Feed Back Tube Outlet Gas Pressure Test Point Low Fire Gas Adjustment Factory Sealed Pressure Switch Pressure Switch...

Page 28: ...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 29: ...Overview of Controls 533901438 Clip in Module Vfc 0 10v 533901441 Igniter Transformer 532496004 Air Pressure Switch 533901179 Safety Temperature Limiter 533901437 Display Screen 533926116 IEC Mains Ou...

Page 30: ...rmation 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 the information level dhw temperature not us...

Page 31: ...lection down up Selection of operating parameter Adjustment of settings Adjustment of parameter settings Information Select information display screens Enable Maintenance mode Press buttons simultaneo...

Page 32: ...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 mo...

Page 33: ...HAMWORTHY HEATING LTD 27 PUREWELL VariHeat c 500001169 T Figure 8 2 1 3 Operation and display philosophy...

Page 34: ...aning 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 Oper...

Page 35: ...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 shows alternative...

Page 36: ...e fault press the reset button 0 6 seconds to reset the LMU Figure 8 2 4 Display of lockout code 8 2 5 Adjusting the heating circuit setpoint temperature Press the flow temperature button to adjust th...

Page 37: ...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 38: ...tion 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 b...

Page 39: ...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 40: ...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 41: ...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 5...

Page 42: ...oiler temperature set point change the setting by using the or key and set value to 4 Press mode button to store change and return to home screen Press and hold both up and down arrow keys for at leas...

Page 43: ...HAMWORTHY HEATING LTD 37 PUREWELL VariHeat c 500001169 T Figure 8 3 11 Operating phases...

Page 44: ...HAMWORTHY HEATING LTD 38 PUREWELL VariHeat c 500001169 T Figure 9 0 Boiler Wiring Schematic...

Page 45: ...equire 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 fault...

Page 46: ...ng a soft brush compressed air is as follows I For model PV70c 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...

Page 47: ...assembly is fitted to ensure safe reliable operation 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...

Page 48: ...WELL VariHeat c 500001169 T Figure 11 1 Hot Surface Igniter and Flame Sensing Probe Positions Figure 11 2 Gas Valve Assembly Models PV70c 531201067 Venturi Seal 532418005 Venturi 533901497 Gas Pressur...

Page 49: ...stion System Assembly Model PV70c 53301016 Burner 563007023 Flapper Valve 531201071 Burner Elbow Gasket 533901376 Fan Elbow Seal 533901376 Fan 563801016 HSI 533805021 Flame Probe 532418005 Gas Air Mix...

Page 50: ...1238 Venturi Seal 532418007 Venturi 533901497 Gas Pressure Switch 533903044 Gas Valve 533704003 Fan 533925004 Gas Pressure Switch 533903036 Gas Valve 741083676 M5x 12 Screw 532403170 Gas Valve Mountin...

Page 51: ...e 11 4 2 Combustion System Assembly Model PV 95c 110c 140c 53301016 Burner 563007023 Flapper Valve 531201071 Burner Elbow Gasket 531201069 Fan Elbow Seal 533901376 Fan 563801016 HSI 533805021 Flame Pr...

Page 52: ...lip 530650355 Front Cover Brace 530650358 LHS Panel 530650359 RHS 748551001 1 4 Turn Screw 530650351 Side Rail 530650204 Back Panel Figure 11 6 Casing Assembly 748551010 1 4 Turn Screw 532403172 Gas P...

Page 53: ...Distribution Screen 531201119 Tube Flange Seal 531201119 Tube Flange Seal 530105095 Condensate 531201118 Flue Spigot Gasket 530650335 Variheat Skid 524120041 Base Top 524120049 Section Clamp 53105001...

Page 54: ...shown for illustration 532012014 Tie Rod 5324120044 Heat Exchanger 532403166 Tube 742121186 O Ring 532403167 Elbow 742121238 O ring 562403166 3 Section Flexible Connector 5324120043 Heat Exchanger 52...

Page 55: ...16 AGU2 310A109 Display PCB 533901437 Flow Return Sensor 533901431 Temperature Limiter 533901179 Hot Surface Igniter HSI Replacement Kit 563605626 Flame Sensing Probe 533805015 T2A 5x20 Fuse 533922002...

Page 56: ...3 99 8 134 4 172 8 Boiler Output minimum 80 60 C kW 21 2 28 8 33 3 44 8 57 6 Natural Gas GAS DATA Gas Inlet Connection Pipe Thread Size R1 Nominal Gas Inlet Pressure mbar 20 Maximum Gas Inlet Pressur...

Page 57: ...ose proximity to each other MUST NOT be supplied from different phases of a 3 phase supply The method of connection to the mains electricity supply must facilitate complete electrical isolation of the...

Page 58: ...HAMWORTHY HEATING LTD 52 PUREWELL VariHeat c 500001169 T Figure B1 2 External Control Wiring for Multiple Module Installation...

Page 59: ...fuse has been introduced on the power supply between the ignition transformer and the main LMU The fuse is rated at T1A slow blow and can be located on the control panel as in fig B2 0 below The condi...

Page 60: ...ations 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 direction of the exhaust...

Page 61: ...terminal or grille to stop ingress of birds etc C1 7 Surface Temperatures Combustible materials in the vicinity of the boiler and flue shall not exceed 65 C during boiler operation The flue shall not...

Page 62: ...c 110c 140c 180c Straight tube 150mm maximum length m 131 114 114 79 57 45 bend 150mm Equivalent tube length m 1 6 1 7 1 7 1 8 1 8 90 bend 150mm Equivalent tube length m 2 1 2 2 2 2 2 3 2 3 Model Figu...

Page 63: ...ntilation shall be such that the maximum temperatures within the boiler house shall be 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 ceili...

Page 64: ...4 Each boiler module has R2 male flow indicated with a red spot and return indicated with a blue spot connections Boilers should be connected by flow and return headers Headers should be connected to...

Page 65: ...HAMWORTHY HEATING LTD 59 PUREWELL VariHeat c 500001169 T Figure E1 2 Typical Piping Layouts...

Page 66: ...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 67: ...vessel required Care must 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 exce...

Page 68: ...igure 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 System SENSOR B1 533901593 SENSOR B3 533901593 QAC34...

Page 69: ...HAMWORTHY HEATING LTD 63 PUREWELL VariHeat c 500001169 T INSTALLER SITE ADDRESS BOILER TYPE BOILER SIZE S UNIT NO S SERIAL NO S FLUE USEFUL USER INFORMATION NOTES...

Page 70: ...HAMWORTHY HEATING LTD 64 PUREWELL VariHeat c 500001169 T NOTES...

Page 71: ......

Page 72: ...Road Glasgow Scotland G33 4AG tel 0141 336 8795 fax 0141 771 9635 North East England Service Allison Heating Products 12 Sunnyside Lane Cleadon Village Sunderland SR6 7XB tel 0191 536 8833 fax 0191 53...

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