Hamworthy Purewell Installation, Commissioning And Servicing Instruction

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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

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

NATURAL GAS I LPG-PROPANE I

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Customer Services

TECHNICAL ENQUIRIES  01202 662527 / 662528

To supplement the detailed technical brochures, technical advice on the application and use of products in the Hamworthy Heating range is available from our technical team in Poole and our accredited agents.

SITE ASSEMBLY  01202 662555

Specialist teams are available for on site assembly of the full range of Hamworthy boilers (excluding Lulworth). Boiler sections for site assembly must be positioned within the boiler house prior to the arrival of the assembly team and provide sufficient space for safe working. Handling sections into boiler houses other than at ground level may be subject to additional charges.

The normal assembly price does not include for the fitting of boiler casings or the burner, however this can be carried out at the time of build at additional cost.

Providing the facilities are available on site, a hydraulic test will be carried out within the terms of BS779. Upon completion a certificate of assembly and test will be issued.

COMMISSIONING  01202 662555

Commissioning of equipment by Hamworthy Heating's own engineers, accredited agents or specialist subcontractors will ensure that the equipment is operating safely and efficiently. Hamworthy commissioning reports provide a detailed record of the original status of the plant, which is essential for future routine maintenance and trouble free operation.

Standard warranty terms provide for the free of charge replacement of defective 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 variable, dependent upon the equipment type and usage. Annual service agreements are available on all Hamworthy products to meet individual requirements.

Planned maintenance of equipment by routine servicing reduces operational costs considerably below that associated with repair or breakdown approach.

BREAKDOWN SERVICE, REPAIR, REPLACEMENT  01202 662555

Even when the commissioning and routine servicing has been carried out to the highest standard there are always occasions when the unexpected breakdowns occur. Hamworthy provide a rapid response breakdown, repair or replacement service through head office at Poole and accredited agents located throughout the UK.

SPARE PARTS  01202 662525

A comprehensive spare parts service is operated from our factory in Poole, providing replacement parts for both current and discontinued products. In some instances spares may be available from accredited agents.

Delivery of parts and components is normally from stock within 7 days. However, a 24 hour delivery service is available for breakdowns and emergencies for the additional cost of the courier. Please contact our spares team, providing details of product type, serial number, model or any other identifying marks or codes to determine part requirements wherever possible.

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PUREWELL ATMOSPHERIC HOT WATER BOILER FOR HEATING

AND DOMESTIC HOT WATER INSTALLATIONS

INSTALLATION, COMMISSIONING AND SERVICING INSTRUCTIONS

PERMANENT IGNITION CONTROLS (ECO CONTROL)

CLASSIC MODELS WITH DRAUGHT DIVERTER

PRIMARY FLUE DAMPER

40,50,60,70,80,95,105 & 120 kW

and

INTEGRA MODELS

40,70 & 100 kW

NOTE: THESE INSTRUCTIONS SHOULD BE READ 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)I PROPANE (3

FAMILY)I3P. PLEASE ENSURE RELEVANT INFORMATION REQUIRED

2H OR LPG-

WITHIN DOCUMENT IS FOUND RELATING TO SPECIFIC GAS TO BE FIRED BEFORE FIRING BOILER.

THIS BOILER COMPLIES WITH ALL RELEVANT EUROPEAN DIRECTIVES. EC TYPE CERTIFICATE No. BG/EC-93/20 PRODUCT IDENTIFICATION No.87AO20

PUBLICATION NO. 500001090 ISSUE ‘B’ NOVEMBER 2001

HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001090/B

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HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001090/B

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CONTENTS

INDEX ................................................................................ iii

1.0 INTRODUCTION ..............................................................................…... 1

2.0 TECHNICAL DATA ..........................................................................…… 1

3.0 GENERAL REQUIREMENTS ..........................................................…… 2

3.1 Related Documents

3.2 Feed Water Quality

3.3 Adequate Water Flow

3.4 Time Clock Control

3.5 Minimum System Water Pressure

4.0 LOCATION .......................................................................................…… 4

5.0 GAS SUPPLY...................................................................................……. 4

5.1 Service Pipes

5.2 Meters

5.3 Gas Supply Pipes

5.4 Boosted Supplies

5.5 Boiler House Control Valve

5.6 Boiler Gas System Leak Check

PAGE

6.0 FLUE 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 and Cold Feed Pipe

8.4 Altitude Gauge (Water Pressure Gauge)

8.5 Thermometer

8.6 Drain Valves

8.7 Circulating Pump

8.8 Minimum Water Flow Rates

8.9 Waterside Pressure Drop

8.10 Control Schemes

8.11 Unvented Pressurised Systems

8.12 Modular Boiler Control Schemes

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PAGE

9.0 ELECTRICAL SUPPLY ...................................................................... 8

9.1 Site Wiring

10.0 BOILER ASSEMBLY AND INSTALLATION..................................... 9

10.1 General

10.2 Heat Exchanger Insulation Fitting Instructions

10.3 Gas Pipe Fitting Instructions

10.4 Connection to the Flue System

10.5 Gas Connection

10.6 Water Connections

10.7 Casing and Controls Assembly

11.0 COMMISSIONING AND TESTING ...............................................….. 13

11.1 Electrical Installation

11.2 Gas Installation

11.3 Water Circulation System

11.4 Commissioning the Boiler

11.5 Boiler Checks Prior to Lighting

11.6 Gas Pressure Adjustment and Combustion Checks

11.7 Temperature Limiter (Limit Thermostat)

11.8 User’s Instructions

12.0 FAULT FINDING............................................................................…. 15

12.1 Safety Features Summary

12.2 Fault Finding Procedures

12.3 Possible Causes 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 Instructions............................. 9/10

Figure No. 6 Gas Pipe Fitting Instructions……................................................ 10

Figure No. 7 Casing Assembly Details....................................................... 12/13

Figure No. 8 Boiler Installation Typical Layout (Vented and Un-vented)…… 20 Figure No. 9 Overall Dimensions of Boiler and Recommended Clearances . 21

Figure No. 10 Front Assembly Showing General Layout.................................... 22

Figure No. 11 Gas Flow in Pipes.......................................………………….... 23

Figure No. 12 Typical Boiler Wiring Diagram (inc. Options)............................ 24

Figure No. 13 Diagram of Igniter Assembly.................................................... 25

Figure No. 14 Diagram of Various gas valves fitted...................................... 26

Figure No. 15 General Fault Finding.............................................................. 27/28

Figure No. 16 Damper Actuator Motor ……………………………………………. 29

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1.0 INTRODUCTION

1.1 A competent person holding ‘CORGI’ registration

or equivalent must install this boiler. All installations MUST conform to the relevant Gas Safety and Building Regulations. Health & Safety requirements must also be taken into account when installing any equipment. Failure to comply with the above may lead to Prosecution.

1.2 These instructions are for Group H Natural Gas (2nd Family) and LPG-Propane (3rd Family). The information relative to propane firing is to be found in Appendix ‘A’. Boilers MUST NOT use gas other than that for which they were designed and made for.

1.3 The Purewell is an Atmospheric, Gas Fired boiler manufactured from horizontal cast iron sections, nippled at alternate ends. These sections are mounted on a fabricated mild steel basket assembly, which houses the burner bar and igniter assemblies. A unique radiant baffle is fitted beneath the burner bars, protecting the floor below by reducing heat lost from the boiler.

The ‘Classic’ version of the Purewell boiler is designed to be connected to the flue via a specifically designed draught diverter. The draught diverter MUST be fitted into the spigot on top of the heat exchanger as supplied. NO modification or variance is permitted as this may change operational characteristics. An optional On/Off Primary Flue Damper kit is available for ‘Classic’ models only. This damper MUST be fitted into the spigot on top of the heat exchanger as supplied. NO modification or variance is permitted as this may change operational characteristics. Flue outlets from more than one boiler may be connected together to form a header.

Technical Department for help or assistance if in doubt.

1.6 The Purewell boiler is not suitable for direct connection to domestic hot water supplies or gravity fed heating systems.

1.7 The Purewell boiler can be installed with either reverse return water flow layout or with single pipe header layout. See Figure No. 8 for typical schematic layout.

Hamworthy Heating can supply a pre-designed arrangement of components, which will produce a "reverse-return" assembly. Please contact Hamworthy Heating for information.

1.8 It is good practice in all heating installations to use some form of water treatment to reduce formation of lime scale and black iron oxide sludge. The high efficiencies produced by the Purewell Boiler can easily be reduced by lime scale formation. If a Pressurised unit is used, it is prudent to include an hours run meter to give an indication of pump running time and hence raw water make up. Any leaks should be attended to as soon as possible to avoid calcium salt build up within the boiler's waterways.

2.0 TECHNICAL DATA

2.1 Overall dimensions are shown in Figure No. 9.

Both single and multi boiler arrangements are shown.

The Purewell boiler can be installed as a single unit or in modular form where a 'multi' casing reduces required floor area. Each boiler has an independent door for access to the controls and other working components.

‘Integra’ versions have an in-built draught diverter and can therefore be connected direct to a header assembly via a suitable flue pipe.

1.4 The Purewell boiler is available with an optional Flame Failure kit, allowing a signal to be generated should the pilot drop out. NOTE! There is no facility to electrically interface any input/output with the boiler controls. Refer to Section 9.0 ELECTRICAL SUPPLY for details.

1.5 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 interlocks will shut down the boiler(s) 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 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

It is recommended that a maximum of 6 boilers can be positioned on 533mm (21") centres if required. Larger numbers should be split into two or more banks with 150mm (6") between each bank. NOTE! When installing modular units on 533mm (21") centres, the casing support rail or spacing plates should be fitted between each boiler before bolting together. See Section 10.1:General Installation of Boilers Ref.: spacing plates for further information.

2.2 General Information and Technical Data relating to Natural Gas is shown in Figure No. 1. Technical data relating to propane firing can be found in Appendix ‘A’.

2.3 Screw threads: All screw threads used in the Purewell boiler conform to the following: -

ISO 7/1 or ISO 228/1 for pipe threads where applicable.

ISO 262 for all general screw threads.

HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001090/B

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Figure No. 1 - Performance and General Data information.

GENERAL DATA 40 50 60 70 80 95 100 105 120

Boiler input kW (Gross) 49.3 63.4 74.5 88.4 101 120 126 132 150

Boiler input kW (Nett) 44.4 57.1 67.1 79.6 90.9 108.5 113.6 118.8 135

Boiler output kW 40 50 60 70 80 95 100 105 120

Gas flow rate m³/h 4.73 5.92 7.1 8.27 9.44 11.19 11.8 12.36 14.1

Gas manifold press

13.4 12.5 11.9 11.0 9.5 11.5 10.2 11.2 11.0

mbar

FLUE DATA

Nominal flue Dia.

206 206 206 206 206 256 - 256 256

Classic

Nominal flue Dia. Integra

Approx. flue gas tempqC

Approx. flue gas vol. @ 9% CO

& 100qC m³/h *

206 - - 206 - - 256 - -

190 200 190 220 230 200 205 215 205

73.8 92.4 110.8 129.1 147.3 174.6 184.1 192.9 220

GAS DATA

Nominal gas inlet press ------------------------------------------- 20 mbar --------------------------------

Maximum gas inlet

------------------------------------------- 25 mbar -------------------------------press. Injector Dia. mm 2.7 3.1 3.4 3.75 4.2 3.9 4.1 4.1 4.4

Pilot burner Q349A-1034 (with 56-42A injector)

No. of Burner

------------------------------- 4 ------- -------------- 5 ------------bars/Injectors Gas inlet connection. ----------------------------- R¾ ----- ------------ R1 -----------

WATER DATA

Water connections Flow Rc2 Return Rc2

Loss mbar @ 15°C 'T

2.75 4.31 8.63 11.57 14.9 22.55 25 27.45 47.06

Maximum water press. --------------------------------------------- 6 bar g -------------------------------

Water content litres 30 30 37.1 37.1 37.1 44.2 44.2 44.2 51.3

Litres/sec @ 11°C 'T

Litres/sec @ 15°C 'T

Litres/sec @ 22°C 'T

0.87 1.08 1.30 1.52 1.74 2.06 2.17 2.28 2.6

0.64 0.80 0.95 1.12 1.27 1.51 1.59 1.67 1.91

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 temperature of 100qC at 1013mbar. This is considered to be the predicted temperature of the products in the secondary flue downstream of the draught diverter.

3.0 GENERAL REQUIREMENTS

The installation of the boiler MUST be in accordance

3.1 Related Documents.

with the relevant requirements of the Gas Safety Regulations, Building Regulations, IEE Regulations

Gas Safety Installations and Use Regulations

and the byelaws of the local water undertaking. 1998, (As amended). It is Law that competent persons in accordance with the above regulations install all gas appliances. Failure to install appliances correctly could lead to prosecution. It is in your own interest, and that of safety, to ensure

The installation should also be in accordance with

any relevant requirements of the local gas region

and local authority and the relevant

recommendations of the following documents: that this law is complied with.

HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001090/B

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British Standards

BS 7074: Application, selection and installation of

expansion vessels and ancillary equipment for sealed water systems. Part 2: Code of practice for low and medium temperature hot water systems.

information, but the following extracts from the above references are emphasized since failure to comply with these requirements will almost certainly result in an unsatisfactory installation.

3.2 Feed Water Quality

BS 6891: Installation of low-pressure gas pipework

of up to 28mm in domestic premises. (For larger installations see IGE/UP/1, IGE/UP/1A and

IGE/UP/10)

BS 6644: Installation of Gas Fired Hot Water Boilers

- 60kW to 2MW.

BS 6700: Design, installation, testing and maintenance of services supplying water for domestic use.

BS 6880: Part 1, 2 & 3: Code of practice for low temperature hot water heating systems of output greater than 45kW.

BS EN 60335, Part 1. Safety of Household & similar electrical appliances. BS 3456, Part 201: Electrical Standards.

CP 342: Centralised hot water supply. Part 2: Buildings other than individual dwellings.

I. Gas E. Publications

IGE/UP/1 Soundness testing and purging of

industrial and commercial gas installations.

IGE/UP/1A Soundness testing and direct purging of small low pressure industrial and commercial natural gas installations.

IGE/UP/2 Gas installation pipework, boosters and compressors in industrial and commercial premises.

IGE/UP/10 Installation of gas appliances in industrial and commercial premises Pt.1 flued appliances.

Health and Safety Executive: Guidance note PM5 - Automatically controlled

steam and hot water boilers.

CIBSE Publications: -"CIBSE Guide" It is impractical in this document to specify all relevant

If the boiler feed water has a high degree of hardness, it is recommended that the water be treated to prevent precipitation of scale or sludge in 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 build-up of scale. It is essential therefore, that leaks are attended to promptly and draining is kept to an absolute minimum.

It is recommended that the system be flushed out at least twice with hot water before any water treatment is added. If any doubt exists regarding the internal cleanliness of an old system, consideration should be given to the fitting of a coarse filter in the return pipework to the boilers.

3.3 Adequate Water Flow

The Hamworthy Purewell boiler is designed as a quick response, low water content unit, able to run continuously with maximum reliability. Care should be taken in the initial design and layout having due regard for adequate water flow through the boilers and the influence of the system controls. NOTE! The Standards Authority recommend a minimum return temperature of 50°C in all heating systems other than condensing boilers.

Figure No. 2 shows recommended and minimum water flows required. The control system and valves, where fitted, should be regulated to avoid lower flows occurring.

The flow corresponding to 22°C temperature rise across the boiler is the minimum recommended flow at any time. For boiler pressure drop see Figure No.

Figure No. 2 - Flow-rate Pressure Drop Table.

Model 405060708095100105120

Flow @ 11°C 'T rise

0.87 1.08 1.30 1.52 1.74 2.06 2.17 2.28 2.6 litres/second Resistance mbar 5.1 7.84 15.69 20.59 26.47 37.25 41.12 50 84.31

Flow @ 15°C 'T rise

0.64 0.80 0.95 1.12 1.27 1.51 1.59 1.67 1.91 litres/second Resistance mbar 2.75 4.31 8.63 11.57 14.9 22.55 25 27.45 47.06

Flow @ 22°C 'T rise

0.43 0.54 0.65 0.76 0.87 1.03 1.08 1.14 1.3 litres/second Resistance mbar 1.27 2.06 4.12 5.49 7.06 11.76 12.94 13.23 22.55

HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001090/B

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3.4 Time Clock Control

5.0 GAS SUPPLY

In order to avoid local overheating and progressive calcium deposition at zero flow conditions where boilers are operated from time clocks, provision should be made for a 5 minute circulating pump over-run after the last boiler has ceased firing.

NOTE! As the boiler electrical connection is via a 3 pin IEC fused plug and socket, any time clock, or external means of control, must interrupt the live supply to the boiler. - see Section 9.0: ELECTRICAL SUPPLY for details. See Figure No. 12 for wiring details.

3.5 Minimum System Water Pressure

To comply with guidance note PM5 (Health and Safety Executive), the minimum pressure

requirements at the boiler are given below as examples: -

1) Single installed boiler running at 82°C flow temperature. Minimum head required is not less than 2 metres or 0.2 bar.

2) Single installed boiler running at 95°C flow temperature. Minimum head required = 5.1 metres or 0.5 bar.

3) Modular boiler installation running at 82°C flow temperature and 11°C rise across system. Minimum head required = 4.3 metres or 0.42 bar.

4) Modular boiler installation running at 82°C flow temperature and 22°C rise across system. Minimum head required = 10.5 metres or 1.03 bar.

See Section 8.11 for Pressurised Water Systems.

4.0 LOCATION

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 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 local gas region, or a local gas region contractor. An existing meter should be checked, preferably by the gas region, to ensure that it is adequate to deal with the rate of gas supply required.

5.3 Gas Supply Pipes

Supply pipes must be fitted in accordance with BS 6891 or IGE/UP/2 as appropriate. Pipework from the

meter to the boiler must be of adequate size. Do not use pipes of a smaller size than the boiler gas connection. The complete installation must be purged and tested for soundness as described in BS 6891 or IGE/UP/1 and IGE/UP/1A as appropriate.

See Figure No. 11 for recommended gas flows in pipes.

5.4 Boosted Supplies

Where it is necessary to employ a gas pressure booster, the controls must include a low-pressure cut-off switch at the booster inlet. The local gas region must be consulted before a gas pressure booster is fitted.

4.1 (See Figure No. 9 for dimensions/weights and

5.5 Boiler House Control Valve

clearances.) The location chosen for the boiler MUST permit the provision of a satisfactory flue system and an adequate air supply. The location must also provide adequate space for servicing and air circulation around each unit. This includes any

A manual valve for boiler house isolation shall be fitted in the gas supply line. It shall be clearly identified and readily accessible for operation, preferably by an exit.

electrical trunking laid along the floor.

5.6 Boiler Gas System Leak Check

Allow adequate space, this should not normally be less than 460mm at the rear, for flow and return connections. Also allow at least 460mm on one side, the other side must be no less than 150mm. Allow 610mm (minimum) in front of the boiler for servicing.

Although the boiler receives a gas leak check and gas train component integrity check prior to leaving the factory, transport and installation may cause disturbance to unions, fittings and gas valve assemblies’ etc. During commissioning a further test

for soundness should be carried out on the boiler The boiler must be installed on a level noncombustible surface that is capable of adequately supporting its weight (when filled with water) and any ancillary equipment.

Any combustible material adjacent to the boiler and the flue system must be so placed or shielded to

gas pipework and components. A procedure guide

is shown in Figure No. 3. Care must be taken not to

allow leak detection fluid on or near any electrical

parts or connections (If used).

See Figure No. 3 Gas valve/pipework leak check test

procedure. ensure that its temperature does not exceed 65°C.

TO CHECK VALVE B

Further details regarding boiler location are given in BS 6644.

1) Turn off the electrical power and gas to the

appliance.

2) Connect the manometer to gas valve test point.

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3) With A, B closed open C and monitor manometer over a 2 minute period, a rise indicates a leak on valve B.

Figure No. 3 Gas Valve Leak Check Procedure

Note: -

Main Gas Supply Pressure: G20 - 20mbar

G31 - 37mbar

TO CHECK VALVE A

1) Open C.

2) Open B to produce the main gas supply pressure between A and B.

3) Close B

4) System may be considered sound if over a period of 2 minutes any drop in pressure is less than

0.5mbar (0.2" wg.).

NOTE: Allow a manometer stabilisation period of approximately 1 minute before each 2 minute check period. Following soundness tests close valve B and remove manometer connections and tighten test points.

6.0 FLUE SYSTEM

1)‘Classic’ boilers MUST have the correct draught

diverter and primary flue duct, or optional primary flue damper, fitted in an unmodified condition before connection to the flue system. ‘Integra’ boilers MUST have the flue hood incorporating the draught diverter, fitted in an unmodified condition before connection to the flue system.

2) The bottom of the flue header should be at least 500 mm above the draught diverter skirt bottom.

3) The flue system must be self-supporting 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 should be between

-0.05 to -0.125mbar. In the case of a single boiler installation, the minimum vertical flue height is 2m above the draught diverter skirt. For multiple boiler installations consult Hamworthy Heating Technical Department. In some instances, mechanical assistance may be necessary. The boilers are suitable for connection to a fan diluted flue system, refer to I. Gas E. publication IGE/UP/10 "Installation of gas appliances in industrial and commercial premises Pt.1 flued appliances".

6) Purewell boilers are suitable for installation in a balanced compartment in accordance with the requirements of BS 6644. Consult Hamworthy Heating Technical department for help or assistance if in doubt.

6.2 Design Waste Gas Volume and Temperature

It is recommended that the volume and temperature of the waste gases used for design of the flue system be as shown in Figure No. 1 for Natural Gas. Information relating to propane firing can be found in Appendix ‘A’.

6.3 Flue Condensation

Care should be taken to ensure that the flue is installed in such a way that any condensation produced on start up will drain away naturally.

Detailed recommendations for flue systems are

6.4 Materials

given in BS 6644, I. Gas E. Publication, IGE/UP/10 "Installation of gas appliances in industrial and commercial premises Pt.1 flued appliances". The following notes are intended to give general guidance only.

Materials used for the flue system must be mechanically robust, resistant to internal and external corrosion, non-combustible and durable under the conditions to which they are likely to be subjected.

6.1 General Requirements

6.5 Disconnection

The Hamworthy Purewell Series of boilers are designed to be used with natural draught flues. Flue systems should be designed in accordance with current regulations and with reference to the I. Gas E. publication IGE/UP/10 "Installation of gas appliances in industrial and commercial premises

On ‘Classic’ models, the draught diverter is designed to enable separation from the primary flue duct, or optional damper, such that it can be lifted clear of the boiler to ease disconnection. The flue must be correctly reconnected when servicing is

Pt.1 flued appliances". The following points should be noted: -

HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001090/B

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complete ensuring locating bolts are securely fitted. See Section 13: SERVICING 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.

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.

6.7 Surface Temperatures

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 100mm below) = 40°C.

Where both low and high level openings are used,

the grilles shall have a total minimum free area of: -

Low Level (inlet): 540cm² plus 4.5cm² per kiloWatt in

excess of 60kW total rated input.

High Level (outlet): 270cm² plus 2.25cm² 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.

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.

Figure No. 4 - Mechanical Ventilation Flow Rates

Flow rate per 1000kW

Atmospheric

total rated heat input

Boilers

Inlet air (Combustion

Extract air (ventilation)

ventilation)

6.8 Flue System Location

The flue system must not be placed or fitted where

Volume 1.10 0.45

m³/s. m³/s.

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.

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.

7.0 AIR SUPPLY

8.0 WATER CIRCULATION SYSTEM

Detailed recommendations for air supply are given in

BS 6644. The following notes are intended to give

8.1 General

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.

The Purewell Cast Iron Boiler has a low water

content and the requirements of minimum water flow

are given in Section 8.8:Minimum Water Flow

Rates and Figure No. 2. Recommendations for the

7.1 Air Supply by Natural Ventilation

water circulation system are given in BS 6644 and

CP 342. The following notes are of particular

The boiler room must have, or be provided with,

importance: 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

1) In a combined central heating and hot water

system, the hot water storage vessel must be of the

indirect cylinder or calorifier type. The hot water

storage vessel should be insulated preferably with

not less than 75mm (3in) thick mineral fibre, or its

thermal equivalent.

2) Circulating pipework not forming part of the useful

heating surface should be insulated to help prevent

heat loss and possible freezing, particularly where

pipes are run through roof spaces and ventilated

cavities. Cisterns situated in areas, which may be

exposed to freezing conditions, should also be boiler house shall be as follows:

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insulated. Insulation exposed to the weather should be rendered waterproof.

3) Draining taps must be located in accessible positions, which permit the draining of the whole system, including the boiler and hot water storage vessel.

4) Each boiler has one Rc2 BS21 flow and one Rc2 BS21 return tapping. Flow and return headers should connect boilers but sufficient length of connecting pipe should be allowed to clear the casing before connecting into the headers. The headers should be connected to the system in a "reverse return" arrangement (the water flow in each header is in the same direction) to ensure equal flow in each module. Figure No. 8 shows typical layout.

8.2 Pressure Relief Valve (Safety Valve)

Each boiler, or in the case of a modular installations, each bank of boilers, must be fitted with a pressure relief valve to BS 6759 Part 1 and sized as shown in

BS 6644.

BS 6644 provides comprehensive information for the

selection and location of safety valves and attention is drawn to the higher capacity requirements of safety valves for pressurised hot water systems.

8.6 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 the boiler. The pump should be sited to facilitate servicing. It is important to note that when Purewell boilers are used to replace boilers on an existing system, the pumps should be checked for performance against the new boiler waterside pressure drop to ensure 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 cleanliness of the system, a coarse filter should be fitted in the return pipework to the boilers.

8.8 Minimum Water Flow Rates

8.3 Open Vent and Cold Feed Pipe

(See BS 6644 for further information.)

Every boiler or group of boilers should have an open vent pipe and cold feed pipe installed between the boiler and the first water isolating valve. The minimum bore (mm) of these pipes per installation is as follows: -

Boiler Output Feed Vent

< 60kW 19 25

60kW - 150kW 25 32

150kW - 300kW 32 38

300kW - 600kW 38 50

The vent pipe must rise continually, must not be valved except by a design which when closed for maintenance ensures the boiler is open to atmosphere. The pipe shall be protected against freezing where this might occur.

8.4 Altitude Gauge (Water Pressure Gauge)

Every boiler or group of boilers should be provided with a gauge complete with isolating cock. See Figure No. 8 for typical position.

8.5 Thermometer

See Figure No. 8 for typical position.

A thermometer complete with pocket should be fitted in the pipework to indicate water flow temperature.

Minimum water flow rates are shown in Figure No. 2. These flow rates must be maintained through the boiler at all times whilst the boiler is firing. If the flow rate is allowed to fall below the minimum, the boiler heat exchanger could fail due to the resultant scale formation. Particular attention should be paid to the restriction of external flow circuits during periods of low heat demand.

8.9 Waterside Pressure Drop

The waterside hydraulic resistance (Pressure drop) is shown in Figure Nos.1 & 2.

NOTE: If boilers are run off time clock control, a pump overrun (not H.H.L. supply) should be fitted which must run for a minimum of 5 minutes on shutdown of the last boiler.

8.10 Control Schemes

8.10.1 Temperature Controls

An adjustable control thermostat is supplied for each boiler and should be set to operate within the range 65-90°C for standard applications.

If a higher water temperature is required, and providing sufficient head on the water system is available, the thermostat may be adjusted to operate up to 120°C – see Note. A temperature limiter, (hand reset limit thermostat) is also fitted to the boiler and is normally set at 100°C with a maximum setting of 110°C. The minimum difference between control thermostat and temperature limiter MUST NOT be less than 10°C.

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Note! A high temperature control kit is available incorporating a new temperature limiter, and instructions. For further information contact Hamworthy Heating for details.

9.0 ELECTRICAL SUPPLY

WARNING: THIS APPLIANCE MUST BE

EARTHED.

8.10.2 Water Flow Controls

Any external mixing valves or similar controls should always ensure that the minimum water flow rate shown in Figure No. 2 is maintained.

8.10.3 Frost Protection

Consideration should be given to fitting a frost thermostat set at approximately 4°C.

8.11 Unvented Pressurised Systems

See Figure No. 8 for typical layout of a Pressurised (Un-vented) Hot Water System.

In order to correctly size a Pressurisation Unit for any Heating System certain parameters are required. These are: -

1) Static height of highest component in system.

2) System volume - if not known a general rule of thumb of 10 litres/kW installed boiler power can be used.

3) Maximum flow temperature, i.e. most systems run at 82°C.

4) Maximum system hot working pressure, generally given in barg.

Wiring external to the boiler must be installed in

accordance with the IEE Regulations and any local

regulations, which apply. Wiring must be completed

in heat resistant 3-core cable. (Size 1.0mm² 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 a contact separation of at least

3mm in all poles.

This appliance must be isolated from the mains

electricity supply in the event of electric arc

welding being carried out on any connecting

pipework.

A mains isolator must be provided adjacent to the

boiler in a readily accessible position. The supply

should only serve the boiler.

NOTE! There is no facility on the Purewell boiler for

the connection of any remote signals, alarms or

control. Any controls MUST interrupt the supply to

the boiler. Accordingly, any pumps MUST be wired

to the control to achieve operation and desired

overrun.

From the above information Hamworthy Heating can size the pressure unit and also the expansion vessel required.

Care must be taken in sizing expansion vessels to ensure maximum acceptance factors are not exceeded. Normally manufactures of vessels impose a limit of 0.5. This value must not be exceeded at any time during the operation of the boiler: this includes the over pressure condition should a safety valve lift.

Consideration should also be given to sizing of the safety valve(s) in the system. See BS 6759: Part 1 for information.

See also BS 6880: Part 1 for design considerations.

8.12 Modular Boiler Control Schemes

For Modular applications Hamworthy Heating can supply a unique boiler management control system called the 'Marshall HE' - see Figure No. 8. This system comprises of a remote master control unit, which houses the main interface processor and will control up to 8 stages. For further information contact Hamworthy Heating for details.

NOTE! When an optional On/Off Primary Flue

Damper is fitted, there is a facility for the connection

of a remote start/stop loop. This loop requires a volt

free contact for operation. Power is supplied by the

boiler to allow this circuit to function. Refer to the kit

instructions for wiring details. Further details

regarding connection to the electricity supply are

given in BS EN 60335, Part 1 or BS 3456, Part 201.

Refer to Figure No. 12 for typical site wiring

connections. See BS 6644 for further information.

9.1 Site Wiring

Access to the controls is achieved by rotating the ¼

turn latch and removing the door. A 20mm dia.

knockout is provided in each side panel if required

for electrical connections. Any other routing of site

cables should ensure that cables do not pass close

to the boiler flue hood or that any cable trunking

does not interfere with normal air circulation and

supply ducts.

An IEC 3 pin fused (2A) plug and socket

arrangement is utilised for the site terminal

connections. Care must be taken to ensure correct

connections are made to the relevant terminals

before applying power.

Refer to Figure No. 12 for typical wiring diagram.

If the optional Flame Failure kit is fitted, the electrical

input/output cannot be interfaced with the boiler

controls. Separate provisions must be made for the

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electrical connections to the gas pressure switch. Utilise the gland/cable anchorage on the pressure switch and take care in the routing of any cables within the boiler case.

10.0 BOILER ASSEMBLY AND INSTALLATION

10.1 General

Each boiler is dispatched to site as follows: -

i) Heat Exchanger & Basket including burners and gas valve(s) etc. on a pallet. ii) Casing complete with assembly instructions. iii) Control Panel Assembly. iv) Primary flue & Draught diverter. (‘Classic’ models only). NOTE! A Primary Flue on/off damper kit is available as an option. Further details of each individual assembly is given below: -

1) Factory tested heat exchanger casting assembly complete, including insulation wrap, gas valve assembly including pre-wired plug assembly. The gas connection pipe should be fitted to the boiler flue hood once the heat exchanger is located. NOTE! Care must be taken to ensure no damage occurs to either insulation wrap or gas connecting pipe.

NOTE! THIS PIPE MUST NOT BE USED TO MANOEUVRE OR POSITION THE BOILER.

Consideration must be given to the weight of the boiler (See Figure No. 9), before lifting. It is recommended that the boiler is moved complete with pallet and positioned correctly. The pallet can then be dismantled and the boiler slid into position.

2) Casing including all screws, fasteners, etc. to permit site assembly. Instructions are included in each box to show method of assembly. Two sizes are manufactured these are: - Small casing for boilers up to 80kW (NOTE! P70 ‘Integra’ model utilises larger casing), large casing for all boilers from 95kW to 120kW.

Instructions are supplied with the draught diverter on how to assemble the unit, if required. These instructions MUST be followed correctly and fully complied with to ensure correct operation. NOTE! Ensure the baffle (Not fitted to 120kW boiler) is positioned correctly and laying flat on the heat exchanger before fitting the flue hood onto the boiler (if removed). NOTE! If fitting an optional Primary Flue Damper refer to the instructions. These instructions MUST be followed correctly and fully complied with to ensure correct operation. It is recommended that the heat exchanger insulation be fitted prior to fitting the damper.

10.2 Heat Exchanger Insulation Fitting Instructions

With reference to Figure No. 5a - Unfold blanket and offer up to the boiler as shown. Ensure gas pipe cutout is positioned to the left and that the ‘petals’ are uppermost. Sit the insulation blanket onto the basket ensuring a snug fit.

Figure No. 5a

NOTE! When installing a multi-casing set the

spacing plates must be used to correctly 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

Reference to Figure No. 5b - 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 foil tape down join.

assembly.

3) Controls assembly including plug connections and thermostats. Refer to Figure No. 7 for fitting instructions. Ensure all thermostat capillaries are inserted and correctly located into the top of the boiler. The controls assembly also incorporates a socket which matches the gas valve wiring plug.

4) (‘Classic’ models only.) Primary flue duct and draught diverter complete with flue bezel.

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Figure No. 5b

10.3 Gas Pipe Fitting Instructions

With reference to Figure No. 6a - Remove half union

and gas valve from gas train. Ensure gas

valve/manifold bracket does not suffer undue

stress/movement. Affix 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

Reference to Figure No. 5c - Fold down petals as shown. Use foil tape to affix edges. Fold as required. Ensure gas pipe bracket is clear and unobstructed.

Figure No. 5c

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 fitted to

Purewell 40, 50, 95 and 105 kW boilers.

Figure No. 6c

Ensure combustion air passages are unobstructed when fully fitted.

Tighten screws ensuring ‘U’ clamp threads do not

damage insulation. It may be necessary to remove

the bottom thread of the ‘U’ clamp with the bracket in

lower position as it may foul the draught hood.

Ensure no undue stress is placed on the gas

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pipe/manifold and ensure pipe is vertical/horizontal before clamping in position.

10.4 Connection to the Flue System

Notes on the recommendation for design of the flue system are given in Section 6:FLUE SYSTEM.

Fully 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.

10.4.1 ‘Classic’ models: -

The draught diverter and primary flue duct supplied with the boiler must be fitted to the boiler in accordance with the fitting instructions, NO modifications are permitted on site. Care should be taken to ensure the seals between primary flue, draught diverter and boiler spigot are sound, as a leak may affect the boilers’ operation. NOTE! If an optional Primary Flue Damper kit is fitted, take care in routing the damper electrical cables into the control panel. . Prior to fitting the

assembly to the boiler, read the Primary Flue Damper instructions.

The top panel can be fitted after fitting the draught diverter assembly and where necessary, having made the damper electrical connections to the control panel.

10.4.2 ‘Integra’ models: -

The ‘Integra’ model incorporates its own draught diverter and care must be taken to ensure the seal between the outlet spigot and flue pipe is sound to avoid the escape of flue gas.

10.4.3

The top panel will require protecting to ensure no damage occurs to the plastic coating during subsequent site assembly of other components. It is important, for service requirements, that the flue system is fully self-supporting. Check the flue and chimney are clear from obstruction.

10.5 Gas Connection

The Purewell boiler is supplied with a gas pipe which, when assembled, exits the casing at the rear. See Figure No. 9 for position. The incoming mains gas supply must be capable of supplying gas to the boiler at the required pressure, under all firing conditions. For sizing information see Figure No. 11. An approved isolating valve & union should be installed for each boiler in a convenient and safe position and be clearly marked.

10.6 Water Connections

See Figure No. 9 for position of water connections (flow and return). A ½" BSP plug is fitted local to the return connection for the fitting of a drain cock, NOTE! (Not HHL supply.) Care must be taken when installing water system pipework that undue stress is avoided on the boiler flow and return connections. It is recommended that unions are fitted local to the boiler to permit future servicing requirements.

10.7 Casing and Controls Assembly

For assembly of casing components and controls unit see Figure No. 7.

Multi casings

Note: Where boilers are in Modular form, i.e.

MPC360 (3 x 120kW), a multi-casing pack is provided for each additional boiler. For example: a triple boiler module will require: - 1 off single casing pack plus 2 off multi-casing packs. If the bottom support rail (item 19) has not been pre-assembled, the following procedure must be taken: -

1) Loosen the nuts that clamp the basket assemblies of the 2 boilers together, (1 front and 1 rear). Remove the bolt, spacer and nut assembly.

2) Position the bottom support rail (item 19) between the boiler baskets. Assemble to boiler baskets using 2off M6 screws, nuts and shake proof washers (items 18, 9 & 10).

3) Select the rear support rail (item 21) and fit 6off ‘U’ nuts (item 15), 4off in the 2 lower pairs of holes and 2off in the angle bracket at the top. Fix the rear support rail to the bottom support rail, using 2off M6 screws and washers (items 18 and 10).

4) Select the front support rail (item 22) and fit the 2off door location brackets (item 5) using 4off M6 screws and spring washers (items 13 and 14). Fit 2off ‘U’ nuts (item 15) to the top 45° return. Fix the front support rail to the bottom support rail, using 2off M6 screws and washers (items 18 and 10).

5) Select the top support rail (item 20) and fit 2off ‘U’ nuts (item 15) to the pair of holes at the rear end. Fix the top support rail to the front and rear support rails using 6off No.8 self tapping screws (item 16).

Single and multi-casings.

6) Select the side panels (items 1 and 2) and fit

the 2off door location brackets (item 5) using 4off M6 screws and spring washers (items 13 and 14). Fit ‘U’ nuts (item 15) to the 2 holes at the rear of each panel as shown. Fix the side panels to the boiler basket using M6 nuts and shake proof washers (items 9 and 10).

7) Fit the back panel (item 3) using 4off No.8 self tapping screws (item 16). DO NOT FULLY

TIGHTEN THE SCREWS.

8) Select the control panel (item 6). Permanent pilot

boilers only, fit the door catch bracket to the control panel using the 2off M6 screws, nuts and washers supplied with the panel as shown. Loosely fit 4off M6 nuts and washers (items 9 & 10) to the pressed-in studs at the top front end of the side panels (or multicasing frame set) as shown

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Figure No. 7 - Assembling the Casing/Multi-Casing Set.

LOWLINE BOILER

CASING TOP

AUTOMATIC

BOILER

DETAIL 'A'

STANDARD BOILER

CASING TOP

REF. DETAIL 'A'

PERMANENT PILOT

BOILER

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Item Description Quantity

(Single Casing Kit)

1 Left hand side panel 1 2 Right hand side panel 1 3 Back panel 1 1 4 Door panel 1 1 5 Door location bracket 2 2 6 Control panel 1 1 7 Ball stud fastener 4 4 8 Spacer for ball stud fastener 4 4

9 M6 hexagon nut 8 6 10 M6 internally serrated shake proof washer 8 4 11 M5 x 12mm hexagon head screw 4 4 12 M5 internally serrated shake proof washer 4 4 13 M5 x 6mm pozi-drive pan head screw 4 4 14 M5 spring washer 4 4 15 ‘U’ nut for no.8 self tapping screw 4 10 16 No.8 x ½” self tapping screw 6 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-drive pan head screw 2 2 25 M4 internally serrated shake proof washer 2 2 26 M4 hexagon nut 2 2 27 Fascia bezel 1 1 28 Boiler top panel insert 1 (Classic only) 1 (Classic only)

Quantity

(Multi Casing Kit)

Fit the control panel by passing the right hand side behind the pressed-in studs and pulling the panel forwards to engage the studs into the slots in the right hand side of the panel. Push the left of the control panel backwards to engage the studs on that side into the slots in the panel. Tighten the 4off M6 nuts.

9) Select the top panel (item17) and fit 4off ball studs, spacers, M5 screws and shake proof washers (items 7, 8, 11 and 12). Should the flue already be fitted to the boiler, the top panel can be split by removing screws and washers (items 11 &

12). Place the top panel in position and press the ball studs into the matching latches in the top edge of the side panels (or multi casing frame set). Classic boilers only, if a damper is fitted, remove the screws (item 16) and discard the top panel insert (item 28) if required. Should the damper motor assembly 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 the side panels can now be tightened.

11) Select the door panel (item 4) and fit the 2off location pins, M4 screws, nuts and shake proof washers (items 23, 24, 25 & 26), to the 2 holes in the rear return. Select the fascia bezel (item 27) supplied with the control panel. Remove the paper liner from the self-adhesive foam tape affixed to the rear of the bezel, and fit to the door aperture as shown ensuring correct orientation and a strong

bond to the surface of the door panel. To fit the door, locate the slotted holes in the bottom onto the location brackets (item 5). Pivot the door backwards until the location pins engage fully into the mating holes in the front edge of the side panels (or multi casing frame set). Turn the quarter turn latch in the centre of the door panel to lock it in place.

11.0 COMMISSIONING AND TESTING

11.1 Electrical Installation

A suitably competent person MUST check wiring. Power supply required is 230 volts AC single phase 50Hz. An isolator correctly fused at 6A should be sited close to the boiler.

Access to the controls is achieved by rotating the ¼ turn latch and removing the door. The electrical connection to the boiler MUST be via the 3 pin IEC plug supplied.

Any interlocks, i.e. Pressurisation unit, BEM System should be wired to control the supply to the boiler.

A schematic of the circuit is shown in Figure No. 12, optional extras (if fitted) are also shown.

11.2 Gas Installation

For design see Section 5:GAS SUPPLY. The whole of the gas installation including the meter must be inspected and tested for soundness and purged in accordance with the recommendations of BS 6891 or IGE/UP/1, IGE/UP/1A and IGE/UP/2 as appropriate.

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11.3 Water Circulation System

11.5 Boiler Checks Prior To Lighting

For design see Section 8:WATER SYSTEM.

NOTE! Refer to Figure No. 1 for Natural Gas

maximum inlet pressure for normal operation. The system should be thoroughly flushed out with cold water without the pump in position. Ensure all

Information relating to propane firing can be found

in Appendix ‘A’. the valves are open.

Note: - all propane firing boilers are fitted with a low With the pump fitted the system should be filled and

air locks cleared. Vent the radiators and check for leaks.

If the system is unvented the pressurisation unit should not be utilised for the initial filling. This should be carried out using a WRC approved double check valve and temporary-filling loop.

gas pressure switch (set at 20mbar). Should the

pressure fall below this level, the boiler will not

operate.

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 size)

and tight and that the pilot is connected to the gas In order to comply with local Water Authority

Regulations, this loop must be disconnected when filling is complete. Water treatments should not be fed through the Pressurisation unit unless permitted by the manufacturer.

Check the expansion vessel cushion pressure as detailed by the manufacturer's Installer's Guide.

11.4 Commissioning The Boiler

A competent person holding ‘CORGI’ registration MUST be responsible for the commissioning of this boiler. Before attempting to commission any boiler, ensure that personnel involved are aware of what action is about to be taken and begin by making the following checks: -

1) Flueway passages to chimney are clear. 2a) ‘Classic’ models: - If necessary, remove the

draught diverter assembly and optional Primary Flue Damper, if fitted, flue hood and baffle, (not fitted to the 120kW boiler), to ensure the boiler flueways are clear. Reposition the gas baffle ensuring that it is lying flat on the top section. Re-fit the flue hood. Ensure draught diverter passages and Primary Flue Damper, if fitted, are clear and clean. 2b) ‘Integra’ models: - The ‘Integra’ draught diverter incorporates an integral inspection cover. To gain access, remove insulation and the M6 bolts on the sloping front of the hood assembly. This will reveal the inner part of the boiler, if further access is required, remove primary flue pipe (ensure it is

valve.

2) Ensure electricity is connected to the 3 pin IEC

plug on boiler and that the thermostat bulbs are

fully inserted into the boiler pocket. Ensure the

thermocouple is correctly connected between gas

valve and pilot burner.

3 Re-set temperature limiter by firmly pressing pin

on unit.

4) Check Piezo unit is fitted securely on to its

bracket and the lead is undamaged and correctly

located.

5) Check setting of both temperature limiter and

control thermostat. The temperature limiter is

generally set at 100°C from the factory unless

otherwise instructed. Set thermostat to required

temperature (normally 82°C). Remove knob to set

limits if required.

NOTE! Minimum temperature setting should not be

less than 72°C to avoid condensation in the flue if a

22°C system temperature rise is used.

NOTE! It is generally recommended that the

minimum return temperature to a non-condensing

boiler is 50°C.

11.5.1 Procedure for Initial Lighting

WARNING: If the pilot light is extinguished either

intentionally or unintentionally, no attempt should

be made to re-light the pilot until at least 3 minutes

have elapsed. This delay is for safety reasons

and MUST not be ignored.

correctly supported), and remove complete top of the draught diverter assembly. After cleaning the boiler re-assemble draught diverter in the reverse of dis-assembly. Ensure all joints are correctly

Ensure electricity supply to the boiler is off, i.e. (3

pin IEC plug is removed.) Turn control thermostat

to minimum. sealed.

3) Adequate ventilation as per Section 7:AIR SUPPLY exists in the boiler house.

4) The system is fully charged with water, ready to

receive heat. All necessary valves are open and the pump is circulating water.

5) The pipework and valve arrangement is installed

Light pilot burner by repeatedly pressing the button

on the piezo unit whilst pushing/twisting the 'start'

button on the control valve fully in. (See Figure No.

14 for alternative valve descriptions). Note: - for

propane models only SIT or Honeywell gas valves

are used. 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

Hold the button in for a further 20 seconds once the

pilot is seen to light. Release button slowly. The

pilot burner should remain alight. If however it goes matter, tested for soundness and purged.

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out, push in the 'stop' button and wait 3 minutes before repeating above procedure.

firing as the flue can achieve temperatures, which will produce injury if touched.

If the pilot does not light after repeatedly operating the piezo unit for several seconds, re-vent the gas line to the outside of the building. Check whether spark and gas are present at the pilot. (See Section 12:FAULT FINDING). Having established the pilot, release the 'start' button and remove the pilot adjustment cover screw on the gas control valve. (See Figure No. 14 for relevant gas valve fitted).

11.6 Gas Pressure Adjustment and Combustion Checks

Adjust the screw so that the flame envelops the tip by approx. 12mm. After pilot adjustment, check time clock circuits (if fitted) are closed. Replace the 3 pin IEC plug. Adjust control thermostat to required temperature: the gas valve should open and main burner ignite.

After the boiler has operated for approximately 10 minutes, remove the 3 pin IEC plug. Open the pressure test point screw on the burner manifold and fit a manometer (suitable for 30mbar - Natural Gas or 50mbar - Propane). Check gas pressure reading against that shown in Figure No. 1 or Appendix ‘A’. Adjust control valve regulator as required by removing cap and turning with a screwdriver. Refer to Figure No. 14 for alternative gas valve details.

Remove manometer and close all pressure test points, (Replace caps if fitted). Record all readings for future reference on relevant commissioning sheet.

Check no flue gas spillage occurs from the diverter: Ref. BS 5440:Part1 will give guidance if required. Allow system to warm up sufficiently to check operation of control thermostat.

11.7 Temperature Limiter (Limit Thermostat)

Reset and test the operation of the temperature limiter by firmly pressing the button (in the control panel), removing the clip and bulb from the pocket and carefully applying a heat source to the bulb. The reset button should operate. If satisfactory, refit the bulb in the pocket and secure with the clip. Check temperature limiter setting. This can be achieved by isolating the power supply, removing the door and removing the control panel cover. Remove the plastic cover (unscrewing) if fitted. Undo holding nut and withdraw into the controls housing. Adjust if required and replace in reverse order to above.

Combustion figures for Natural Gas should be as follows: -

= 8.5 - 9% (Dry flue gas).

CO = 0-50ppm: However figure should not exceed 200ppm under normal operating conditions. Details of flue gas composition relating to propane firing can be found in Appendix ‘A’.

The flame supervision device can now be checked by pressing/twisting the stop button on the gas control valve (Operation dependent on gas valve type fitted.). After approximately 45 seconds the solenoid valve should be heard to click closed. Wait a further 3 minutes and carry out pilot lighting procedure.

11.8 User’s Instructions

When the above is complete, the end user or their representative should be made aware of the lighting and operating instructions fitted to the inside of the boiler door. A practical demonstration should be given describing each functional step. This Installer's Guide and user’s instructions should then be handed over and be kept in a safe place for easy reference.

12.0 FAULT FINDING

12.1 Safety Features Summary

Should the control thermostat fail, the temperature limiter will trip thus creating an immediate shutdown regardless of firing mode. If this occurs the temperature limiter situated in the controls housing will require re-setting by pushing the small pin in firmly. Note! Access to this pin is gained by removing door and unscrewing safety cover (if fitted). An investigation should be carried out to ascertain the reason for the overheating. An obvious reason would be too low a water flow rate through the boiler. NOTE! The pilot will not remain established if this pin is not re-set manually.

Volt free contacts are not available for connection to BEM system. An optional Flame Failure kit is available utilising a gas pressure switch fitted in the pilot gas line and in the event of pilot failure this will activate a remote lockout signal – to be configured by a competent person.

All propane-firing 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.

A combustion check must be taken when first

12.2 Fault Finding Procedures

commissioning the boiler. A sampling point is provided, 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.

General fault finding is shown in Figure Nos.15 & 15a. If the boiler still cannot be operated satisfactorily after following the chart, consult your local office of Hamworthy Heating for assistance.

NOTE! Care should be exercised if the boiler is

HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001090/B

Page 22

12.3 Possible Causes of Boiler Lockout

13.3 ‘Classic’ models: -

1) Pilot failure due to faulty thermocouple.

2) Weak pilot due to blockage in pilot orifice.

3) No or low gas supply pressure.

4) Temperature limiter operating due to high boiler temperature or faulty thermostat.

5) Faulty main gas valve.

6) Loose ECO lead from gas valve to thermostat.

1) Check the flue above the draught diverter is selfsupporting. 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 diverter and remove the primary

13.0 SERVICING

duct, or damper assembly if fitted, and flue bezel, leaving the draught diverter assembly connected to

13.1 Regular annual servicing is recommended to ensure trouble free operation. Although cleaning of flueways may not be necessary on a yearly basis, it is important that all controls and safety features are checked for correct operation. NOTE! Measuring flue gas CO

and gas temperatures will give an

indication of the state of the boiler flueways and waterways. Results should be compared with previously measured values to establish possible loss of efficiency.

the flue system. Temporarily support the draught diverter. If an optional Primary Flue Damper kit has been fitted, disconnect the remote start/stop loop and remove the gland plate from the rear of the control panel. Disconnect the damper electrical connections from the control panel and carefully lift the damper assembly from the flue hood. Remove the top-casing panel and flue bezel. The panel is secured by spring latches. Lift off and store in a safe place to avoid damage or scratching.

13.2 Before servicing the boiler, the following procedure must be carried out: - WARNING:

Isolate all electrical supplies and turn off the gas service cock to the boiler module being serviced.

2) Undo the screws supporting the gas pipe clamp. NOTE! The boiler gas pipe may require supporting

in order not to place undue stress on the main gas header pipe.

3) Carefully prise away the silver insulation jacket from the flue hood. Undo and remove the nuts

1) Remove the front casing door using a screwdriver to rotate the ¼ turn latch.

2) Turn off gas service cock, (fitted upstream of gas control valve).

holding the flue hood to the boiler. Take care not to move the locking nuts which locate the hood's position. Remove the gas baffle, (Not fitted to the 120kW boiler).

3) Remove the 3 pin plug connecting the gas valve to the control panel.

13.4 ‘Integra’ models: -

4) Disconnect ECO connectors from beneath the

control panel, undo and disconnect pilot bundy tube from gas valve: disconnect piezo lead and thermocouple.

5) Slacken union below gas service cock and release. Slacken and remove nuts/washers holding gas valve and manifold assembly. Remove manifold assembly taking care not to damage or twist bundy tubing or gas valve, etc.

6) Undo and remove pilot assembly by removing screws from front tie bar (2 off). Carefully remove pilot assembly from under burner bar tie bar taking

1) Check the flue above the flue pipe is selfsupporting. Remove the top panel to gain access to the draught diverter. Remove the insulation and inspection cover (M6) bolts on sloping front.

2) If further access is required remove M6 bolts along top of draught diverter. The top section should now drop down to free the flue pipe. Undo M6 bolts from baffle top and swing baffle away.

3) NOTE! This baffle MUST be relocated in the correct position when re-assembling the draught diverter.

care not to twist or bend igniter electrode or bundy tubing. See Figure No. 10 for position of items. Check condition of igniter, thermocouple and injectors for damage, clean as required.

7) Carefully remove burner assembly by pulling and lifting burner front plate.

4) All models:- The boiler flueways are now exposed and can be brushed through diagonally in both directions to remove deposits from the cast iron finned surfaces. Re-assemble the boiler in the reverse order to that shown above. Ensure a new rope seal is fitted to the flue hood to maintain a gas

Check burner bars condition and clean using a soft brush if required (if possible use compressed air to blow out the dust inside the bar). Damaged or cracked burner bars should be replaced. To replace an individual bar will require drilling out the

tight seal. (See spares list). Ensure primary flue, or damper if fitted, and draught diverter are sealed to each other and into flue hood spigot. The boiler’s operation may be affected if these seals are not completely fitted.

rivets holding it on to the front plate. A new single burner bar will be supplied with clinch nuts and screws to fix onto the front plate.

Before replacing the burner bar assembly, lift out both halves of the radiant reflector and brush off any dust and fallen deposits accumulated on it.

The boiler flueways can now be cleaned as follows:

Also clean area under the reflector before replacing it in its correct location. Re-assemble the

HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001090/B

Page 23

burner bar assembly ensuring correct location on the rear support bracket. Re-fit the gas manifold taking care not to damage any fragile components.

Check all gas connections are tightened securely before opening the gas service cock. Switch on the electricity supply and re-light the boiler following the correct procedure on the inside of the door. Take gas pressure readings and exhaust gas readings and compare with Figure No. 1 or for propane refer to Appendix ‘A’, adjust as required. Ensure no gas leaks are evident from the gas connections. See Figure No. 3 for procedure.

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 thermostat body can now be removed by gently feeding capillary through the controls bulkhead. Fit the new thermostat and ensure the capillary is correctly located within the pocket. Do not force the bulb into the pocket by placing undue stress on the capillary. Replace the cover and re-fit top panel correctly.

Check thermostat settings and adjust if required.

Run the boiler and turn the thermostat up and down to check for correct operation. Set thermostat to

Re-fit door and tidy floor around boiler as

previously noted setting.

necessary.

14.3 Temperature Limiter (Limit Stat) Renewal Part No. 533901168/533901180

14.0 REPLACEMENT OF FAILED COMPONENTS

The temperature limiter renewal procedure follows

There are a number of components listed below which can be replaced simply and quickly by

that of the control thermostat with some minor differences. These are as below: -

following the given procedure. In each case the operation of each replaced component must be checked by carrying out the appropriate part of the commissioning procedure. See Section

11.0:COMMISSIONING & TESTING.

Remove the 'push on' spade connections from the temperature limiter body noting position of coloured cables. Remove plastic cover (if fitted) and unscrew holding nut/screws to detach temperature limiter from housing. Gently feed the capillary back

NOTE: Isolate all electrical supplies to the boiler and turn off the gas supply before removing controls cover and commencing any servicing or component exchange procedure.

through the controls bulkhead. Set temperature limiter to 100°C and assemble into controls housing ensuring correct cable notation. Refer to the thermostat diagram if terminal identification differs from those given in Figure No. 12.

14.1 Pilot Burner Assembly

14.4 Main Gas Valve

Reference to Figure No. 10 shows position of pilot burner. To remove pilot assembly the bundy tube, thermocouple and piezo spark cable must first be disconnected from the gas valve. Figure No. 13 shows diagram of pilot assembly and relevant components and part numbers. Renew components as required and generally remove any loose sooty deposits and clean as required. Ensure positions of components are as

NOTE! Some gas valve components can be replaced without completely removing the whole assembly from the boiler. However, Hamworthy Heating strongly recommend that a new gas valve assembly is fitted to ensure safe, reliable operation of the boiler. Please refer to Hamworthy Heating Technical Department before attempting to remove components from the gas valve.

recommended in Figure No. 13.

NOTE! Only gas valves with an identical type No.

14.2 Control Thermostat Renewal: Part No. 339009345 or 533901178

may be used for replacement. Please contact Hamworthy Heating Spares dept. for further information.

Alternative thermostat manufacturers may be used in the Purewell boiler controls assembly. However, the fitting and wire spade connections are physically identical. The terminal identification may

Various types and manufacturers of gas valves are used. Refer to Figure No. 14 for alternative type of valve fitted.

well be different from that shown on the wiring diagram inside the fascia. Please refer to thermostat to ensure correct connections are made and correct operation is obtained.

1) Ensure power and gas supplies are isolated.

2) To remove the gas valve first undo and remove

the pilot bundy tube, thermocouple, ECO connections and the piezo spark generator bracket.

To replace the thermostat the following procedure must be followed. NOTE! Record existing temperature setting of thermostat for reference before removal. Remove the top panel infill and lift of the boiler top panel to reveal thermostat pocket.

3) Remove the gas valve wiring plug from the controls housing. Undo the union connection and 8mm nuts holding the gas valve/manifold assembly to front plate, this will allow the whole assembly to be removed from the boiler.

Remove the cover to reveal boiler controls .

HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001090/B

Page 24

4) Remove the gas valve by unscrewing cap head screws or screwed fitting holding valve to pipework. NOTE! The position of the relevant electrical cables should be noted.

When replacing the gas valve, it is advisable to renew the `O` ring seals (if fitted). See Section

15.0 RECOMMENDED SPARES for Part Nos. Do not over tighten cap head screws in gas valve body. Ensure electrical plugs are firmly and correctly located and holding screws are tightened.

5) Replace assembly ensuring correct orientation of the gas valve. Ensure that the gas flow is in the same direction as the arrow on the valve. Refit all external components and replace plug into controls housing socket. Switch on gas and power supply and check for integrity of all joints using a proprietary leak detector. Ensure gas valve’s operation is correct and safe before continuing. Refer to Figure No. 3 if necessary, for valve integrity check procedure.

6) Re-light the boiler using instructions on the inside of the door. Check and adjust the manifold gas pressure, refer to Figure No. 1 or Appendix ‘A’ for correct setting relating to the boiler size installed.

If necessary, refer to Section 11.4: Commissioning the Boiler, for correct procedures.

the damper blade. Check the position of the damper blade via the indicator, and that it is central in the duct. Manually operate the actuator fully clockwise to check the open position of the damper blade. Should adjustment be necessary in either open or closed positions, reposition the end stops, and secure the fixing screws.

6.2) Set the actuator reversing switch to the ‘L’ position and with the damper in the open position, adjust the position switch dial as shown in Figure No. 16. Check the operation of the position switch by rotating the actuator about the open position listening for the switch operation. Adjust as necessary.

6.3) Fit the flue bezel over the primary duct, refit and secure the damper to the flue hood. Remake the electrical connections in the control panel, refit the remote start/stop loop. Secure the gland plate to the rear of the control panel and carefully route and secure the cables.

6.4) Prior to refitting the draught diverter, check for correct operation of the damper by briefly firing the boiler. Upon satisfactory operation, refit the motor cover and draught diverter assembly. Support the flue bezel and fit the top panel and infill.

6.5) Re-light the boiler using instructions on the inside of the door and check for correct operation.

14.5 Damper Actuator Motor

1) Remove the 2 screws securing the split top

casing panel and remove the two halves of the top panel from the ballstuds..

2) Remove the cable gland from the rear of the control panel and disconnect the damper cables and remote start/stop loop. Unclip the cables from the boiler side panels.

3) 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 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 withdraw the motor.

6) Refit the replacement parts in reverse order noting the following:

6.1) Depress the manual operating button on the side of the motor body and rotate the clamp arrangement fully counter-clockwise. See Figure No. 16. Rotate the damper blade into the horizontal position, refit the motor and tighten the ‘U’ clamp. Note: The damper shaft passing through the motor clamp, has a hole through, indicating the position of

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15.0 RECOMMENDED SPARES

Please Note! To ensure our spares department dispatches the correct spare parts, it is imperative that the

complete Boiler/Control Panel Serial Numbers are given. The Boiler Serial Number is located on the gas manifold inside the door. The Control Panel Serial Number is located inside the Control panel on the maximum power-rating label. These numbers MUST be quoted when ordering spare parts.

SPARES ITEM PART NO. Electrical Items

2 Amperes Control Fuse.................................................................... 533922002

3 pin IEC plug…………………………………………………………….. 533926044

Thermocouple.................................................................................. 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

Control Thermostat.......................................................................... 533901178(Imit)

"............................................................................................ 339009345(L&G)

Temperature Limiter (ECO Type marked 100mV)............................. 533901180(Imit)

"............................................................................................ 533901168(L&G)

NOTE! For any service/replacement parts (Especially Gas Valves) the boiler Serial No. (on Data Plate inside boiler) MUST be quoted.

For service or spares please contact: - Hamworthy Heating Ltd.

Fleets Corner

Poole

Dorset BH17 OHH

Phone No. 01202 662500

Fax No. 01202 665111

HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001090/B

Page 26

Figure No. 8 – Typical Boiler Installations

‘

Marshall HE’ Boiler Sequence

Expansion pipe

Mains water

Feed & expansion tank

Feed pipe

Control System

Float valve

Drain

Safety valve

1 2 3

Hamworthy Modular Boilers

Pressure & Temperature gauges

'Marshall HE’ Water Flow Temperature Sensor

'Marshall HE’ Outside Air Temperature Sensor

'Marshall HE’ Room Temperature Sensor

Val ve

Circulation pump

alternative

(

position

(

Automatic Air Vent

Heating load

Circulation pump

VENTED SYSTEM: Reverse return pipework, Hamworthy recommended system.

‘Marshall HE’ Boiler Sequence Control System

Drain

Safety valve

123

Hamworthy Modular Boilers

Circulation pump

Pressure & Temperature gauges

Val ve

'Marshall HE’ Water Flow Temperature Sensor

'Marshall HE’ Outside Air Temperature Sensor

'Marshall HE’ Room Temperature Sensor

Drain valve

Val ve

Circulation pump

alternative

(

position

Heating load

(

Automatic Air Vent

Drain valve

Double check valve

Val ve

Expansion

Temporary

fill line

Automatic Air Vent

Lockshield

valve

UNVENTED SYSTEM: Reverse return pipework, Hamworthy recommended system.

‘Marshall HE’ Boiler Sequence

Expansion pipe

Val ve

Mains water

Feed pipe

Float valve

Feed & expansion tank

Control System

Drain

Safety valve

123

Hamworthy Modular Boilers

Circulation pump

Pressure & Temperature gauges

Circulation pump

alternative

(

position

'Marshall HE’ Water Flow Temperature Sensor

'Marshall HE’ Outside Air Temperature Sensor

'Marshall HE’ Room Temperature Sensor

(

Val ve

Heating load

Val ve

Mains water

Lockshield

valve

LockshieldLockshield

valvevalve

Hamworthy Pressurisation Unit

Automatic Air Vent

Drain valve

VENTED SYSTEM: Single pipe header

‘Marshall HE’ Boiler Sequence Control System

Drain

Safety valve

123

Hamworthy Modular Boilers

Circulation pump

Pressure & Te mp e ra t u re gauges

Circulation pump

alternative

(

position

'Marshall HE’ Water Flow Temperature Sensor

'Marshall HE’ Outside Air Temperature Sensor

'Marshall HE’ Room Temperature Sensor

(

Val ve

Heating load

Val ve

Automatic Air Vent

Double check valve

Val ve

Drain valve

Temporary

fill line

Automatic valve Air Vent

Expansion

Lockshield

UNVENTED SYSTEM: Single pipe header

HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001090/B

valve

Mains water

Lockshield

LockshieldLockshield

valvevalve

Hamworthy Pressurisation Unit

Page 27

Figure No. 9 - Boiler Dimensions/Clearances.

Note! C = Classic model 40/50 40 60/70/80 70 95/105 100 120

I = Integra model

Approx. Dry Weight kg. 235 240 285 290 345 350 400

A - Boiler Height (Casing) mm. 870 1007 870 1195 1060 1195 1060

B - Flue height from floor mm. 1383 1035 1475 1126 1577 1201 1671

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) R¾ R¾ R¾ R¾ 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).

235

532

GAS

460

RECOMMENDED

150 MIN

INTEGRA

954610 MIN 460 MIN

380

126

PPROX

GAS

FLOW

455

62.5

533 CRS

62.5

RET'N

269

FRONT VIEW

Rc2"

SIDE VIEW

FLOW

RETURN

612 74

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Page 28

Figure No. 10 - General Layout (Front View).

FLUE SOCKET

INTEGRA CLASSIC

DRAUGHT

SSEMBLY

FLUE SAMPLING POINT

PRIMARY FLUE o ON/OFF DAMPER

SSEMBLY

CONTROLS

PIEZO IGNITER

GAS VALVE

BURNER

GAS PIPE

GAS COCK

TEMPERATURE (OVERHEAT

CONTROL

FUSED 3 PIN IEC SUPPLY PLUG

ECO CONNECTOR

BOILER

VIEWING PORT

BURNER TEST POINT

PILOT ASSEMBLY

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Page 29

Figure No. 11 - Gas Flow in Pipes.

Purewell Boiler

Maximum length of gas pipe (Metres)

Output

Dia 20mm 25mm 40mm 50mm 65mm 80mm 100mm

40kW 1042-----

50kW - 25 180 820 - - -

60kW - 16 120 540 - - -

70kW - 11 85 380 - - -

80kW - - 62 280 900 - -

95kW - - 42 185 580 - -

105kW - - 33 145 470 - -

120kW - - 25 110 345 - -

160 (2 x 80kW) - - 12 56 180 - -

190 (2 x 95kW) - - - 38 120 750 -

210 (2 x 105kW) - - - 30 96 600 -

240 (2 x 120kW) - - - 22 72 440 -

285 (3 x 95kW) - - - 15 47 290 -

315 (3 x 105kW) - - - 11 37 235 -

360 (3 x 120kW) - - - - 27 170 810

380 (4 x 95kW) - - - - 24 150 730

420 (4 x 105kW) - - - - 19 115 570

480 (4 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 1.5m 2.0m 2.5m 3.5m

Per Tee 0.5m 0.5m 1.0m 1.5m 2.0m 2.5m 3.5m

Per 90qBend

0.3m 0.3m 0.3m 0.5m 0.5m 1.0m 1.5m

For example: - 2 Purewell 120kW Boilers being fed by 65mm NB pipe with 6 elbows between gas meter and boiler header can have a maximum length of 72m - (6 x 2m) = 60 metres run to achieve a 1mbar loss. Note!

Information above is based on IM/16.

HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001090/B

Page 30

Figure No. 12 - Standard Controls Wiring Diagram Schematic.

230V ~ 50Hz SUPPLY FROM A FUS ED ISOLATOR WITH MINIMUM 3mm

CONTACT

SEPARATION IN ALL POLES

KEY:-

MAINS

MAINS INLETFREE SOCKET

FUSED

GREEN/YELLOW GREEN/YELLOW

BLUE

BROWN

GREEN/YELLOW

RED

YELLOW

GAS VALVE

SOCKET

YELLOW

GAS VALVE

PLUG

BULKHEAD

CONNECTOR

BROWN

GAS VALVE ECO LEADS

Figure No. 12a - Standard Controls Wiring Diagram Schematic -(with On/Off Flue Damper).

REMOTE

RED/BROWN

ON/OFF LOOP

SOCKET

FLUE DAMPER

ACTUATOR

'1'

'2'

'3'

'S3'

'S2'

'S1'

REMOTE

ON/OFF LOOP

PLUG

GREEN/YELLOW

BLUE

RED/ BROWN

REMOTE ON/OFF CONTROL LOOP (REMOVE WIRE LINK IF UTILISED)

MAINS

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 TERMINAL

MAINS INLETFREE SOCKET

NOTE! Ensure all power supplies are completely isolated prior to working on the electrical circuits of this appliance.

FUSED

GREEN/YELLOW GREEN/YELLOW

BROWN

GREEN/YELLOW

RED

BLUE

YELLOW

GAS VALVE

OUTLET

YELLOW

GAS VALVE

PLUG

BULKHEAD

CONNECTOR

BROWN

GAS VALVE ECO LEADS

GREEN/YELLOW

BLUE

HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001090/B

Page 31

Figure No. 13 - Diagram of Igniter Assembly

HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001090/B

Page 32

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

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Page 33

Figure No. 15 – Fault-Finding Procedures

Initiate start procedure

Is Pilot Alight ?

Yes

Does Pilot Remain ‘On’

When ‘Start’ Button is

Released ?

Is Gas Cock Open ?

Yes

Check Gas at Pilot ?

Yes

Check Spark Across

Electrode When

Operating Piezo ?

Yes

Repeat Pilot Lighting

Procedure

Are ECO Leads Connected and Correctly Fitted to the Temperature

Limiter ?

Open Gas Cock

Purge Pilot Line, Check

for Blocked Orifice in

Pilot Burner. Check Gas

Valve Start Button is

Fully Depressed.

Check Piezo Spark Igniter

is Operating Correctly.

Check Electrode Gap.

It Should Be 3 - 4 mm.

Check Spark Lead is

Connected Correctly.

Check and Clean as

Required.

Continued

on next page

Yes

Is Temperature Limiter

Pin (on Controls Panel)

Reset ?

Yes

Is Pilot Flame Sufficient

To Hold in Thermocouple ?

Yes

Check Thermocouple

Operation by Inserting a

mVolt (DC) Multi-Meter in

Parallel with ECO Lead.

Reading Should be at

least 8mVolts.

Reset Temperature Limiter (Limit Stat).

Adjust Pilot Pressure until Flame Envelopes Thermocouple Tip by Approximately 12mm.

Replace Thermocouple

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Page 34

Figure No. 15a – Fault-Finding Procedures (Continued)

Continued from previous page

Main Gas Valve Lifts, Lighting Main Burner.

Yes

Optional On/Off Damper - Classic models only

Is 230V Available at

Control Thermostat ?

Ye s

Is Thermostat Calling

for Heat ?

Ye s

LPG models only

Is the Remote Control

Link Secure ?

Ye s

Is There Power at the

Gas Valve ?

Check Power Supply.

Check 2A Fuse in

IEC Socket.

Check System Controls.

Produce Demand.

Check Operation of Low

Gas Pressure Switch

Close Remote Control

Link Circuit.

Check the Damper

Electrical Connections

and Mechanism. Check

the Gas Valve Plug

and Wiring.

Normal Run

Stop.

Boiler Cycles On/Off

Rapidly ?

Boiler Overheats,

System remains Cool ?

Boiler Noisy?

Yes

Ye s

Replace Gas Valve.

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.

Boiler is Operating

Satisfactorily !

HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001090/B

Page 35

Figure No. 16 – Damper Actuator Motor

POSITION

SWITCH DIAL

SHOWING

SETTING

POSITION

ACTUATOR END STOP

MANUAL OPERATION PUSH-BUTTON

ACTUATOR

REVERSING SWITCH

HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001090/B

Page 36

APPENDIX ‘A’ TO INSTALLER’S GUIDE

INFORMATION RELATING TO PROPANE FIRING

NOTE! LPG FUELS - IT IS STRONGLY RECOMMENDED THAT, ON LPG INSTALLATIONS, GAS DETECTION EQUIPMENT BE FITTED. THIS EQUIPMENT SHOULD BE POSITIONED NEAR THE BOILER AND AT LOW LEVEL. IT IS ALSO IMPORTANT THAT THE SPACE HOUSING THE BOILER IS ADEQUATELY VENTILATED AT HIGH AND LOW LEVEL. REFER TO MAIN INSTALLER’S GUIDE.

1.0 INTRODUCTION

Performance and General Data Information table

below. The operation of the Purewell range of boilers on LPG-Propane (3 Natural Gas (2

family)I3P is similar to that on

family)I2H and the design and

installation details described in the main body of the

c) The nominal gas inlet pressure for propane

should be 37mbar.

d) Relevant labels are replaced to indicate the

appropriate gas for which the boiler is set up to fire. installer’s guide should be followed. There are however, differences in the construction and setting of the propane fired boiler which are as follows: -

The following tables and paragraphs, using the

same numbering system as the main installer’s

guide, highlight the different values and procedures a) The pilot injector marked 56/42A for Natural Gas is replaced with an injector for Propane, marked

to be used when firing propane, and should be

used in conjunction with the Main Installer’s Guide.

0.23P (perm/pilot only). b) The main gas injectors (located in the gas manifold) are replaced with those detailed the

Performance and General Data Information

Model

GENERAL 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 temp qC

180 190 190 200 210 200 200 210 190

Approx. flue gas vol. @ 68 83 81 97 110 132 147 147 175 9% CO2 & NTP. m3/h CO2 % 8.0 9.0 11.0 11.0 11.0 11.0 10.0 11.5 10.0

GAS DATA

Nominal gas inlet pressure mbar 37 Maximum gas inlet pressure mbar 45 Injector marking/ Dia. mm 2.1 2.3 2.6 2.8 2.9 2.4 2.7 2.7 2.9 Pilot burner(Perm/Pilot) Q349A-1034 (with 0.23P injector)

11.5 BOILER CHECKS PRIOR TO LIGHTING

pressure to fall. The switch should operate at

approximately 20mbar - noted on the multi-meter. Ensure that the gas supply is connected but turned to the ‘OFF’ position. Remove the cover on the low gas pressure switch and connect a multi-meter

11.5.1 Gas Pressure Adjustment

across terminals ‘C & NO’ - to measure circuit continuity.

After approximately 30 minutes of normal firing,

connecting a manometer to test point on the Connect a manometer suitable for 50mbar to the pressure tapping on the switch body and gradually turn ‘ON’ the gas supply. The switch should operate at approximately 20mbar - noted on the multi-

manifold should check the manifold gas pressure.

Minor adjustments to the appliance governor may

be necessary to correct for site gas pressure

conditions. meter.

NOTE: The above is a first order check. Final Turn ‘OFF’ the gas supply and undo the pressure

setting must be made using a gas meter. test point on the gas valve inlet and allow the gas

HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001090/B

Page 37

11.5.2 Combustion Checks

A flue gas sampling point is provided in the front boiler casing (see Figure No. 10). To check combustion take a flue gas sample from each module test point and for reference CO measurements should be between 8.0% and 11.5% or 9.0 to 4.0% O

(dependant upon model). Normal

CO levels should not exceed 200ppm.

NOTE: All the above measurements refer to dry flue gas samples.

Gas Pressure Switch Location

HAMWORTHY HEATING LIMITED PUREWELL PERMANENT IGNITON

BOILER CONTROL PANEL

230V ~ 50Hz

35W MAX.

Gas Pressure Switch Adjustment

With the cover removed, turn the M3 nut clockwise to increase the set point and vice-versa. Seal the adjuster after setting.

15.0 RECOMMENDED SPARES

Key: I - Gas Pressure Switch

II - Main Gas Valves

MECHANICAL ITEMS PART No.

Pilot Injector - Propane....................... 331101850

(marked 0.23P)

Low Gas Pressure Switch................... 339009477

For electrical connections to the Low Gas Pressure Switch, see Figure 12.

HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001090/B

Page 38

INSTALLER SITE ADDRESS

DATE OF COMMISSIONING:

USEFUL USER INFORMATION

BOILER

TYPE

BOILER

SIZE(S)

UNIT

NO(S).

SERIAL NO(S). FLUE

NOTES:

HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001090/B

Page 39

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Page 40

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HAMWORTHY HEATING LIMITED

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A comprehensive spare parts service is operated from our factory in Poole, providing 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.

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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 network of Authorised Service Agents who can provide the same high level of service and product expertise.

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Our factory in Birmingham offers a comprehensive range of flue products from stock, or alternatively provides a full design and installation service incorporating sizing, site survey and drawings for approval prior to manufacture.

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Hamworthy reserves the right to mak e changes and improvements which ma y neces sitate alteration to the specificat ion without prior notice.