Hamworthy Warmwell 120 Installation, Commissioning And Servicing Instructions Download Page 31 | Manualshive

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HAMWORTHY HEATING LTD

WARMWELL

500001091/F

Figure 11.0 - General Layout (Front View)

BURNER PRESSURE
TEST POINT

FLAME PROBE

HOT SURFACE
IGNITER

VIEWING PORT

BOILER INSULATION

BURNER MANIFOLD

GAS VALVE(S)

GAS COCK

GAS PIPE

GAS VALVE
GLAND PLATE

DROP DOWN

FASCIA

IGNITION SEQUENCE
CONTROLLER

MAIN PCB

SITE WIRING

TERMINAL PLUGS

CONTROLS HOUSING

TEMPERATURE LIMITER
(OVERHEAT THERMOSTAT)

CONTROL THERMOSTAT

FAN ASSEMBLY

SECONDARY HEAT

EXCHANGER ASSEMBLY
AND TRANSITION DUCT

EXHAUST FAN
CONTROLS PANEL

(Incl. Speed Controller
and Air Pressure Switches)

25

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Summary of Contents for Warmwell 120

Page 1: ...COMMISSIONING OPERATING OR SERVICING EQUIPMENT Warmwell Series Boilers Cast Iron Atmospheric Condensing Modular Boilers with Automatic Ignition for Heating and Domestic Hot Water Installations Install...

Page 2: ...ating safely and efficiently Maintenance Agreements 01202 662555 Regular routine servicing of equipment by Hamworthy service engineers inspects the safety and integrity of the plant reducing the risk...

Page 3: ...IS INTENDED FOR USE AS A COMMERCIAL APPLIANCE AND IS NOT CERTIFIED FOR USE IN DOMESTIC APPLICATIONS OR HABITABLE AREAS W80 AND W120 SUITABLE FOR USE ON GROUP H NATURAL GAS 2ND FAMILY I2H W60 W95 AND...

Page 4: ...eral 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...

Page 5: ...Casing and Controls Assembly 11 0 COMMISSIONING AND TESTING 24 11 1 Electrical Installation 11 2 Gas Installation 11 3 Water Circulation System 11 4 Commissioning the Boiler 11 5 Boiler Checks Prior t...

Page 6: ...t Exchanger Insulation Fitting Instructions 16 17 Figure 10 2 2 Secondary Heat Exchanger Insulation Fitting Instructions 17 Figure 10 3 Gas Pipe Fitting Instructions 18 Figure 10 6 Assembly of Seconda...

Page 7: ...et and that the relevant interlocks will shut the boiler s off should a high or low pressure fault occur The Pressurisation unit must also incorporate a low level water switch which protects the water...

Page 8: ...Hamworthy Modular Boilers P T Circulation pump System Heating load Valve Drain valve Circulation pump Primary loop UNVENTED SYSTEM Primary loop Hamworthy recommended system Expansion pipe Float valve...

Page 9: ...Flue Outlet Dia mm 152 152 152 120 395 1060 957 1141 R1 761 152 Note For modular applications the top casing from the 60 80 and 95 models can only be fitted to Purewell 40 80kW range likewise the 120...

Page 10: ...1 5 1 2 Gas Flow Rate High Fire m3 h 5 92 9 44 14 10 Injector Marking Dia mm 3 1 4 2 4 4 No Burner Bars Injectors 5 WATER DATA Water Connections Flow Rc2 Return Rc2 Maximum Water Pressure bar g 6 Wate...

Page 11: ...ccordance with any relevant requirements of the local gas region and local authority and the relevant recommendations of the following documents British Standards BS 7074 Application selection and ins...

Page 12: ...30 C to ensure condensing takes place thus achieving the correct output The boiler can also be used in the high efficiency mode with flow return temperatures of 80 60 C i e non condensing where it wi...

Page 13: ...lity of an adequate supply of gas An existing service pipe must not be used without prior consultation with the local gas region 5 2 Meters A new gas meter will be connected to the service pipe by the...

Page 14: ...as line shown below Figure 5 3 Gas Flow in Pipes Total Gas Input m hr NB 20mm 25mm 40mm 50mm 65mm 80mm 100mm 4 73 10 42 5 92 25 180 820 7 10 16 120 540 8 27 11 85 380 9 44 62 280 900 11 19 42 185 580...

Page 15: ...an 2m 6ft away 4 The flue system should be designed to achieve a negative suction at all times on all modules in a bank For optimum performance draught conditions should be between 0 05 to 0 125mbar I...

Page 16: ...nd pipework This must be avoided at all times Insulate condense pipes if freezing temperatures are likely to be encountered 6 5 Disconnection Provisions should be made for disconnection of the flue pi...

Page 17: ...ction 8 8 Minimum Water Flow Rates p12 and Figure 2 2 p4 Recommendations for the water circulation system are given in BS 6644 and CP 342 The following notes are of particular importance 1 In a combin...

Page 18: ...p4 NOTE If boilers are run off time clock control a pump overrun not HHL supply should be fitted which must run for a minimum of 5 minutes on shut down of the last boiler 8 10 Control Schemes 8 10 1...

Page 19: ...ncorporates a 10way plug socket screw terminal block to make the site wiring connections Refer to Figure 8 12 p14 and the Milton boiler sequence control installation manual for wiring connection detai...

Page 20: ...2 Site Wiring Diagram REMOTE CONTROL LOOP ON OFF NOTE TERMINAL 1 IS SUPPLIED WITH230VAC MAINS VOLTAGE BEFED ONTOTHESETERMINALS MUSTNOT TO HAMWORTHY HEATING LIMITED MILTON BOILER SEQUENCE CONTROL REFER...

Page 21: ...ACTS RATED AT 250V AC 5A CN17 L E N 15 CN8 1 2 N E L CN13 15 17 16 20 19 18 17 16 19 18 20 CN18 CN19 21 31 33 32 230V AC 50Hz SUPPLY FROM A MAINS ISOLATOR WITH MINIMUM 3mm SEPARATION IN ALL POLES N L...

Page 22: ...ding burners and gas valve s etc on a pallet 2 Casing complete with assembly instructions 3 Control panel assembly 4 Condensing section assembly fitted to item 2 Further details of each individual ass...

Page 23: ...nspection door Reference to Figure 10 2 1b Insulation should be folded around boiler such that its rear edges meet in the centre Ensure flow and return connections are clear and unobstructed Apply foi...

Page 24: ...ar from obstruction 10 5 Gas Connection The Warmwell boiler is supplied with a gas pipe which exits the casing at the rear after installation see Figure 2 1 p3 for position The incoming mains gas supp...

Page 25: ...nt on boiler model Discard the unused item Fit U nuts item 15 to the holes at each end of the side panel support Fit 2off M6 nuts and plain washers items 9 and 36 to the M6 studs located on the top of...

Page 26: ...HAMWORTHY HEATING LTD WARMWELL 500001091 F Figure 10 6 Assembly of Secondary Heat Exchanger onto Primary Heat Exchanger if Supplied Separately 20...

Page 27: ...kit ensuring that the ball studs locate correctly in the matching latches fitted to the top return of the lower side panels 4 Adjust the height of the side panel support such that its top face fits j...

Page 28: ...19 2 16 3 16 15 21 16 20 15 1 DETAIL A 11 12 8 7 24 23 25 26 4 27 6 9 10 15 31 33 16 15 9 36 15 30 16 37 FASTENERS REF DETAIL A 2 POSITIONS EACH IN LH RH PANELS FASTENERS REF DETAIL A 4 POSITIONS FAST...

Page 29: ...12 17 Top panel 1 1 18 M6 x 16mm pozi drive pan head screw 6 19 Bottom support rail 1 20 Top support rail 1 21 Rear support rail 1 22 Front support rail 1 23 Door location pin 2 2 24 M4 x 20 pozi driv...

Page 30: ...endix A p41 NOTE All propane boilers are fitted with a low gas pressure switch set at 20mbar Should the gas supply pressure fall below this level the boiler will not operate 11 0 COMMISSIONING AND TES...

Page 31: ...BURNER MANIFOLD GAS VALVE S GAS COCK GAS PIPE GAS VALVE GLAND PLATE DROP DOWN FASCIA IGNITION SEQUENCE CONTROLLER MAIN PCB SITE WIRING TERMINAL PLUGS CONTROLS HOUSING TEMPERATURE LIMITER OVERHEAT THER...

Page 32: ...HAMWORTHY HEATING LIMITED AND PROVING SWITCH FAN LOW FIRE DAMPER AND PROVING SWITCH LK5 LK4 HIGH FIRE DAMPER BOILER CONTROL PCB CN2 CN1 SERIAL NO PCB MFR DATE PCB MFR PART NO 563901 10 MAX 0 MIN OFFSE...

Page 33: ...Page 31 1 Gas supply is connected but turned to the off position Any unions or fittings are correctly tightened test points are closed burners correctly positioned injectors are in place of correct si...

Page 34: ...EW OF FAN PLENUM CHAMBER A B FAN HOUSING FLUE DISCHARGE DUCT FAN PLUG SOCKET ASSEMBLY 7 WAY AIR PRESSURE SENSING TUBE CONNECTOR TO PRESSURE SWITCHES IN CONTROL PANEL SEE BELOW LEFT HAND SIDE PANEL IMP...

Page 35: ...to carry out this procedure with all the boilers firing The long term reliability of the ignition system may well be reduced unless this procedure is carried out correctly ADJUSTMENT PROCEDURE Refer...

Page 36: ...g point Light the boiler Remove protective cap from the Hi Lo pressure regulator Turn the Hi Lo valve high fire pressure regulator outer nut clockwise until the pressure stops increasing Loosen Thrott...

Page 37: ...sible corrective scenarios Pressure switches are fitted to monitor the correct operation of the induced draught fan fitted to the Warmwell It ensures sufficient air is pulled through the boiler to fac...

Page 38: ...n Neons ISS LK13 HAMWORTHY HEATING LIMITED AND PROVING SWITCH FAN LOW FIRE DAMPER AND PROVING SWITCH LK5 LK4 HIGH FIRE DAMPER BOILER CONTROL PCB CN2 CN1 SERIAL NO PCB MFR DATE PCB MFR PART NO 563901 1...

Page 39: ...ssure switches Remove the exhaust fan control panel from the top side panels control circuit is configured to establish a light dark check thereby ensuring the switch is open no air before starting th...

Page 40: ...the Low Gas Press Switch LPG only the Condense Level Switch Is there a demand from the thermostat Is neon Ne7 illuminated on the main PCB Is remote control link 16 1 2 secure CN Replace ignition cont...

Page 41: ...plug and wiring to main PCB Cn12 Check High Fire Air Pressure Switch electrical connections and sensing tubes Temperature control circuit faulty Boiler at high fire but cycles on off rapidly Yes Poor...

Page 42: ...4 Temperature Limiter Limit Stat Renewal Part No 339011044 or 533901179 The temperature limiter renewal procedure follows secured by 4 screws This will give access to the transition duct cover Remove...

Page 43: ...LTD WARMWELL 500001091 F Figure 14 1 Diagram of Hot Surface Igniter and Sensing Probe Assembly 37 6 0mm Viewing Port 72mm REF 79mm REF Flame Probe Electrode 533805014 Hot Surface Igniter Assembly 563...

Page 44: ...yout that of the control thermostat with some minor differences These are as below Remove the push on spade connections from the temperature limiter body noting position of coloured cables Remove plas...

Page 45: ...the inside of the door and check for correct operation at both High and Low fire See Figure 2 2 p4 for correct settings If necessary refer to Section 11 4 Commissioning the Boiler p24 for correct pro...

Page 46: ...long leads 533901350 Potentiometer incl PCB harness 563901258 Ignition Sequence Controller 533901344 Hours Run Meter 563901273 Fan speed controller 563901296 Fan Assembly Complete 533901229 Pressure...

Page 47: ...n installer s guide highlight the different values and procedures to be used when firing propane and should be used in conjunction with the Main Installer s Guide Figure 2 2 Performance and General Da...

Page 48: ...e switch should operate at approximately 20mbar noted on the multi meter Turn OFF the gas supply and undo the pressure test point on the gas valve inlet and allow the gas pressure to fall The switch s...

Page 49: ...HAMWORTHY HEATING LTD WARMWELL 500001091 F NOTES INSTALLER SITE ADDRESS BOILER TYPE BOILER SIZE S UNIT NO S SERIAL NO S FLUE DATE OF COMMISSIONING USEFUL USER INFORMATION 43...

Page 50: ...HAMWORTHY HEATING LTD WARMWELL 500001091 F NOTES 44...

Page 51: ...Notes...

Page 52: ...y reserves the right to make changes and improvements which may necessitate alteration to the specification without prior notice Connect direct Direct Dial Telephone and Fax Numbers Direct Email Addre...

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