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HAMWORTHY HEATING LTD  

 

 

WARMWELL 

 

500001091/F 

7.1

 

Air Supply by Natural Ventilation

 

 
The boiler room must have, or be provided with, 
permanent air vents directly to the outside air, at 
high level and at low level.  For an exposed boiler 
house, air vents should be fitted preferably on all 
four sides, but at least on two sides.  Air vents 
should have negligible resistance and must not be 
sited in any position where they are likely to be 
easily blocked or flooded or in any position adjacent 
to an extraction 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 or 100mm above floor level               = 25°C. 
2) At mid-level (1.5m above floor level)      = 32°C. 
3) At or 100mm below ceiling level)           = 40°C. 
 
Where both low and high level openings are used, 
the grilles shall have a total minimum free area of: - 
 
Low Level (inlet) 540cm

2

 plus 4.5cm

2

 per kilowatt in 

excess of 60kW total rated input. 
 
High Level (outlet) 270cm

2

 plus 2.25cm

2

 per kilowatt 

in excess of 60kW total rated input. 

 
7.2

 

Air Supply by Mechanical Ventilation 

 
Air supplied to the boiler room by Mechanical means 
should be as follows: - 
 
1) Mechanical inlet and mechanical extract can be 
utilised providing design extraction rate does not 
exceed one third of the design inlet rate. 
2) Mechanical extract ventilation with natural inlet 
ventilation 

MUST NOT

 be used. 

 

NOTE:

 For Mechanical ventilation systems an 

automatic control should be provided to cut off the 
gas supply to the boiler, in the event of failure of air 
flow in either inlet or extract fans.

 

Discharge piping from a tun-dish should be of a 
synthetic material due to the mild acidity of the 
condensate (pH 3-5).  Consideration should be given 
to possible freezing of condense water traps and 
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 pipe for servicing.  It is advisable that bends are 
fitted with removable covers for inspection and 
cleaning as appropriate.  

NOTE!

  The flue system 

must be self-supporting. 
 
See section 

13:

 

SERVICING 

(p33) for further 

information

.

 

 

6.6

 

Flue Discharge

 

 
The flue system must ensure safe and efficient 
operation of the boiler to which it is attached, protect 
the combustion process from wind effects and 
disperse the products of combustion to the external air. 
 
The flue must terminate in a freely exposed position 
and be so situated as to prevent the products of 
combustion entering any opening in a building. 
 

6.7

 

Surface Temperatures

          

 
Combustible materials in the vicinity of the boiler and 
flue shall not exceed 65°C during boiler operation. 
The flue shall not be closer than 50mm to any 
combustible material, except where it passes through 
such material with a non-combustible sleeve when 
the air gap may not be less than 25mm. 
 

6.8 Flue System Location

 

 
The flue system must not be placed or fitted where 
there is undue risk of accidental damage to the flue 
pipe or undue danger to persons in the vicinity.  
 

NOTE! 

 The flue 

MUST

 be self-supporting. Check 

that the flue and chimney are clear from any 
obstruction. 

 

Where the flue diameter is less than 200mm (8") a 
terminal must be fitted. Where the flue is of a larger 
size consideration should be given to the fitting of a 
flue discharge terminal or grill to stop ingress of birds, 
etc. 

 
7.0

 

AIR SUPPLY

 

 
Detailed recommendations for air supply are given in 

BS 6644

.  The following notes are intended to give 

general guidance.  In all cases there must be 
provision for an adequate supply of air for both 
combustion and general ventilation, in addition to that 
required for any other appliance. 

Figure 7.2 Mechanical Ventilation Flow Rates 

Flow rate  per 1000kW 

total rated heat input (Gross) 

Inlet air 

(Combustion 

ventilation) 

Extract air 

(ventilation) 

m³/s. 

m³/s. 

Volume 

1.10 

0.45 

Atmospheric 

Boilers 

10 

Содержание Warmwell 120

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 51: ...Notes...

Страница 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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