Hamworthy Purewell Variheat mk2 110c Installation, Commissioning And Servicing Instructions Download Page 1

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Purewell Variheat mk2 c 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 mk2 110c

Page 1: ...tic 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...

Page 2: ...by our own engineers accredited agents or specialist sub contractors will ensure the equipment is operating safely and efficiently Service Contracts Regular routine servicing of equipment by Hamworth...

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: ...6 0 PRE COMMISSIONING 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 Light...

Page 5: ...EWELL Variheat mk2 218612 A03 3 iii PAGE APPENDICES APPENDIX A GAS DATA 38 APPENDIX B ELECTRICAL CONNECTIONS AND CONTROLS 39 APPENDIX C FLUE DATA 41 APPENDIX D VENTILATION 44 APPENDIX E WATER DATA 45...

Page 6: ...hown in Appendix E Page 45 1 4 If the boiler is to be connected to an un vented pressurised heating system care must be taken to ensure all extra safety requirements are met and that the relevant inte...

Page 7: ...ns relating to the lifting of heavy loads Protect the boiler against slippage by means of a transport strap NOTICE Boiler damage through impact The standard delivery of the boiler includes components...

Page 8: ...ase 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 header sets are used th...

Page 9: ...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 10: ...iler 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...

Page 11: ...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 12: ...must 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...

Page 13: ...HAMWORTHY HEATING LTD 8 PUREWELL Variheat mk2 218612 A03 Figure 4 3 Flue Connection Point Flue Connection as delivered Flue Connection fitted Flue fixing bracket Flue Pipe Elbow...

Page 14: ...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 15: ...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 16: ...n 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 should only...

Page 17: ...put Remote On Off 0 10v Analogue Control Signal Input Outside Temperature sensor LPB Bus Connection Option 5 0 BOILER ASSEMBLY General Boilers are despatched to site as fully assembled units The flue...

Page 18: ...tilation and air supply to plantroom is correct refer to Appendix D page 44 Air supply around the rear of appliance is unobstructed 6 3 Pipework Valves and Pump Ensure that Pipework and valve arrangem...

Page 19: ...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 20: ...s hole in the controls fascia using a terminal screwdriver If satisfactory refit the bulb in the pocket and secure with the clip Ensure that all limiter bulbs sensors are fully inserted into the pocke...

Page 21: ...e Navistem manual HHL part no 500001310 3 As the gas valve is closed the low gas pressure switch will prevent the boiler from firing and the error code E132 will be displayed on the screen Refer to se...

Page 22: ...flame probe The boiler will shutdown attempt to relight once then lock out causing Error code E133 to appear on the display Carefully reconnect the probe lead then press the Reset button to recommence...

Page 23: ...7 If the combustion readings fall within 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 t...

Page 24: ...slot screwdriver to make adjustments To increase the CO2 level turn the adjustment clock wise Figure 7 4 4 1b Adjusting gas valve offset Low Fire Target Nat Gas 8 5 0 25 CO2 If combustion readings are...

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

Page 26: ...n should be given describing each functional step This Installer s Guide and User s In structions should then be handed over kept in a safe place for easy reference Figure 7 7 1 Burner pressure test p...

Page 27: ...de HHL part no 500001309 is supplied with each boiler This guide gives instruction on initial set up as well as a list of possible error codes The Navistem controller is located on the main control pa...

Page 28: ...setpoint Holiday function active Heating to the Reduced set point Reference to heating circuit Heating to the frost protection setpoint Service special functions Cooling to cooling setpoint Error mes...

Page 29: ...must be used to maintain the internal building temperature 8 3 2 Pump overrun When the heating mode ends the heating circuit pump remains on for a period depending on the settings used QAA74 544 In d...

Page 30: ...HAMWORTHY HEATING LTD 25 PUREWELL Variheat mk2 218612 A03 Figure 9 0 Boiler Wiring Schematic...

Page 31: ...ontroller monitors the flame s ability to rectify an AC current If the flame diminishes for whatever reason and the rectified current drops below the controller s minimum detection current the control...

Page 32: ...leads Carefully remove the power and control cable from the fan Remove the fan gas valve assembly by loosening the 4 x M8 nuts securing the transition duct to the burner Loosen the 4 x M8 nuts securi...

Page 33: ...non return valve Inspection of the fan impellor can normally be checked at this point Heat exchangers do not normally require cleaning but if deposits have accumulated compressed air or water can be u...

Page 34: ...gas soundness after replacement parts have been fitted Refer to Section 7 1 if necessary for valve integrity check procedure 4 Re light the boiler using instructions on the inside of the door Check f...

Page 35: ...1 Ignition Electrode and Flame Sensing Probe Positions Figure 11 2 1 Gas Valve Assembly Models PV70c 208 Venturi Seal 207 Venturi 205 Gas Pressure Switch 206 Gas Valve 220 View Port Glass 219 Ignitor...

Page 36: ...A03 Figure 11 2 2 Combustion System Assembly Model PV70c 207 Gas Air Mixer Venturi 206 Gas Valve 209 Fan 205 Gas Pressure Switch Figure 11 3 1 Gas Valve Assembly Models PV95c 110c 140c 208 Venturi Se...

Page 37: ...on System Assembly Model PV95c 110c 140c 207 Gas Air Mixer Venturi 206 Gas Valve 209 Fan 205 Gas Pressure Switch Figure 11 3 3 Combustion System Assembly PV70c 95c 110c 140c 201 Burner 212 Flapper Val...

Page 38: ...y PV180c 209 Fan 205 Gas Pressure Switch 206 Gas Valve 214 Gas Valve Mounting Bracket 207 Gas Air Mixer Venturi Figure 11 4 2 Combustion System Assembly Model PV180c 209 Fan 205 Gas Pressure Switch 20...

Page 39: ...ontrol Cover Assembly 510 Screw 510 Screw 510 Screw Figure 11 6 Casing Assembly 216 Gas Pipe 217 1 Ball Valve Gas Test Point 214 Gas Hose Figure 11 5 Gas Train Assembly 510 Retaining Washer 503 Top Co...

Page 40: ...istribution Screen 53242001 Secondary Heat Exchanger 512 Secondary Heat Exchanger Gasket 511 Base Top 408 Section Clamp 411 Thermostat Pocket 406 Burner Gasket 403 Combustion Chamber 405 Heat Exchange...

Page 41: ...hanger Assembly model 140c 180c shown for illustration 407 Tie Rod 404 Heat Exchanger No Fins 410 Tube 410 O Ring 410 Elbow 410 O ring 409 3 Section Flexible Connector 405 Heat Exchanger Fins 403 Comb...

Page 42: ...in this manual Please Note To ensure the correct spare parts are despatched by our spares department it is imperative that the complete Boiler Module Control Panel Serial Numbers are given The Boiler...

Page 43: ...HAMWORTHY HEATING LTD 38 PUREWELL Variheat mk2 218612 A03...

Page 44: ...ow Gasket 211 Ignitor Top Gasket 218 Ignitor Face Gasket 219 Gas Valve 206 Gas Valve O Ring 213 Gas Hose 215 Combustion Fan 209 Combustion Fan Seal 210 Low Gas Pressure Switch 205 Set of Gaskets Routi...

Page 45: ...egulations Seasonal Efficiency gross 95 3 95 6 95 8 95 7 94 6 Natural Gas GAS DATA Gas Inlet Connection Pipe Thread Size R1 Nominal Gas Inlet Pressure mbar 20 Maximum Gas Inlet Pressure mbar 25 Gas Fl...

Page 46: ...in close 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 o...

Page 47: ...HAMWORTHY HEATING LTD 42 PUREWELL Variheat mk2 218612 A03 Figure B1 2 External Control Wiring for Multiple Module Installation 15...

Page 48: ...tallations 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 exh...

Page 49: ...erminal 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 b...

Page 50: ...5c 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 Fig...

Page 51: ...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 ceiling level o...

Page 52: ...tem including the boiler and hot water storage vessel 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 f...

Page 53: ...HAMWORTHY HEATING LTD 48 PUREWELL Variheat mk2 218612 A03 Figure E1 2 Typical Piping Layouts...

Page 54: ...e 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 the...

Page 55: ...ion 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...

Page 56: ...2 218612 A03 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 System MERLEY CONTROLLER MERLEY Optiona...

Page 57: ...linder sensor kit QAZ36 563605674 Heating circuit sensor kit QAZ36 563605673 Strap On Water temperature sensor kit QAD36 533901594 Offset Room sensor QAA55 563605696 Programmable Room sensor 563605695...

Page 58: ...HAMWORTHY HEATING LTD 53 PUREWELL Variheat mk2 218612 A03 Hydraulic Schemes 1 2 These schematics are available to download at www hamworthy heating com...

Page 59: ...HAMWORTHY HEATING LTD 54 PUREWELL Variheat mk2 218612 A03 Hydraulic Schemes 3 4 These schematics are available to download at www hamworthy heating com...

Page 60: ...HAMWORTHY HEATING LTD 55 PUREWELL Variheat mk2 218612 A03 Hydraulic Schemes 5 6 These schematics are available to download at www hamworthy heating com...

Page 61: ...HAMWORTHY HEATING LTD 56 PUREWELL Variheat mk2 218612 A03 Hydraulic Schemes 7 8 These schematics are available to download at www hamworthy heating com...

Page 62: ...h respect to their parameter setting as heating cir cuits 1 2 have pre defined outputs for each extension module as shown in the table below Boiler Parameter Settings Single Boiler Note To check opera...

Page 63: ...ompensation Legend E End user I Commissioning F Heating engineer Menu Operating Line User Level Function Setting LPB System 6600 F Device address 1 6630 F Cascade Master Automatically Heating Circuit...

Page 64: ...pump Q25 5931 F Sensor input BX2 Boiler 1 Master Common flow sensor B10 Boilers additional set to none 6117 F Central compensation set up Boilers all set to 5 6200 F Save sensors Boilers all set to y...

Page 65: ...lation 5955 F Voltage value 2 H1 10 0v 5956 F Function valve 2 H1 1000 1000 100 modulation 5890 F Relay output QX1 Boiler pump Q1 BMS 0 10v Temperature Menu Operating Line User Level Function Setting...

Page 66: ...5 ect 6601 F Segment address Boilers all set to 0 6640 F Clock mode Boilers all set to Slave with remote setting Configuration 5710 F Heating Circuit 1 Boilers all set to off 6200 F Save sensors Boile...

Page 67: ...HAMWORTHY HEATING LTD 62 PUREWELL Variheat mk2 218612 A03 INSTALLER SITE ADDRESS BOILER TYPE BOILER SIZE S UNIT NO S SERIAL NO S FLUE USEFUL USER INFORMATION NOTES...

Page 68: ...HAMWORTHY HEATING LTD 63 PUREWELL Variheat mk2 218612 A03 NOTES...

Page 69: ...HAMWORTHY HEATING LTD 64 PUREWELL Variheat mk2 218612 A03 NOTES...

Page 70: ...HAMWORTHY HEATING LTD 65 PUREWELL Variheat mk2 218612 A03 NOTES...

Page 71: ...NOTES...

Page 72: ...lfast BT3 9JP Tel 028 9077 7737 Email hvacsupplies btconnect com Scotland Sales Service McDowall Modular Services 2 Penson Road Queenslie Industrial Estate Glasgow G33 4AG Tel 0141 336 8795 fax 0141 3...

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