Hamworthy Warmwell 60, Warmwell 80, Warmwell 120, Warmwell 95, Warmwell 140 Installation, Commissioning And Servicing Instructions
Page 1
IMPORTANT NOTE
THESE INSTRUCTIONS MUST BE READ
AND UNDERSTOOD BEFORE INSTALLING,
COMMISSIONING, OPERATING OR
SERVICING EQUIPMENT
Warmwell Series Boilers
Cast Iron, Atmospheric, Condensing, Modular Boilers
with Automatic Ignition for Heating and Domestic Hot
Water Installations
Installation, Commissioning
and Servicing Instructions
Warmwell 60, 80, 95 120 & 140 Models
Page 2
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
Hamworthy offer a service of site assembly for many of our products in instances where plant room area is restricted.
Using our trained staff we offer a higher quality of build and assurance of a boiler built and tested by the manufacturer.
Commissioning 01202 662555
Commissioning of equipment by our own engineers, accredited agents or specialist sub – contractors will ensure the
equipment is operating safely and efficiently.
Maintenance Agreements 01202 662555
Regular routine servicing of equipment by Hamworthy service engineers inspects the safety and integrity of the plant,
reducing the risk of failure and improving performance and efficiency. Maintenance agreements enable our customers to
plan and budget more efficiently.
Breakdown service, repair, replacement 01202 662555
Hamworthy provide a rapid response breakdown, repair or replacement service through head office at Poole and accredited agents 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. Delivery of parts and components is normally from stock within seven days. However, a next
day delivery service is available for breakdowns and emergencies.
Customer Services
Page 3
HAMWORTHY HEATING LTD
WARMWELL
500001091/F
Warmwell Series Boilers
Cast Iron, Atmospheric, Condensing, Modular Boilers
with Automatic Ignition for Heating and Domestic Hot
Water Installations
Installation, Commissioning
and Servicing Instructions
Warmwell 60, 80, 95 120 & 140 Models
NOTE: THESE INSTRUCTIONS MUST BE READ AND UNDERSTOOD BEFORE
INSTALLING, COMMISSIONING, OPERATING OR SERVICING EQUIPMENT.
THE WARMWELL BOILER IS INTENDED FOR USE AS A COMMERCIAL APPLIANCE AND IS
NOT CERTIFIED FOR USE IN DOMESTIC APPLICATIONS OR HABITABLE AREAS.
W80 AND W120 SUITABLE FOR USE ON GROUP H NATURAL GAS (2ND FAMILY) I2H.
W60, W95 AND W140 SUITABLE FOR USE ON GROUP H NATURAL GAS (2ND
FAMILY) I2H OR LPG-PROPANE (3RD FAMILY) I3P.
PLEASE ENSURE RELEVANT INFORMATION REQUIRED 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 Nos. (GAD) BG/EC-87/95/47, (BED) BE-87/97/38.
PRODUCT IDENTIFICATION No. 87AQ47.
PUBLICATION NO. 500001091
ISSUE ‘F’
SEPT 2004
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HAMWORTHY HEATING LTD
WARMWELL
500001091/F
CONTENTS
PAGE
1.0 INTRODUCTION ............................................................................................................................... 1
2.0 TECHNICAL DATA ...................................... ................................................................................. .... 5
3.0 GENERAL REQUIREMENTS ........................................................................................................... 5
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 ........................................................................................... ............................................. 7
5.0 GAS SUPPLY ............................................... .................... .................... .................... ......................... 7
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
6.0 FLUE SYSTEM ......................................... ..................... ................. ................ ................. .................. 9
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 ................................................................................................................................... 10
7.1 Air Supply By Natural Ventilation
7.2 Air Supply By Mechanical Ventilation
8.0 WATER CIRCULATION SYSTEM ......................... ......................................................................... 11
8.1 General
8.2 Pressure Relief Valve (Safety Valve)
8.3 Open Vent 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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HAMWORTHY HEATING LTD
WARMWELL
500001091/F
PAGE
9.0 ELECTRICAL SUPPLY ................................................................................................................... 13
9.1 Site Wiring
9.2 Indication Signals and Volt Free Contacts
9.3 Milton Boiler Sequence Control and Sequencing Interface Module (Optional)
10.0 BOILER ASSEMBLY AND INSTALLATION .............................................. .................................... 16
10.1 General
10.2 Heat Exchanger Insulation Fitting Instructions
10.3 Gas Pipe Fitting Instructions
10.4 Connection of Boilers to the Flue System
10.5 Gas Connections
10.6 Water Connections
10.7 Casing and Controls Assembly
11.0 COMMISSIONING AND TESTING ................................................................................................. 24
11.1 Electrical Installation
11.2 Gas Installation
11.3 Water Circulation System
11.4 Commissioning the Boiler
11.5 Boiler Checks Prior to Lighting
11.6 Procedure for Initial Lighting
11.7 Gas Pressure Adjustment and Combustion Checks
11.8 Temperature Limiter (Limit Thermostat)
11.9 Safety Checks
11.10 User’s Instructions
12.0 FAULT FINDING ............................................................................................................................. 31
12.1 Safety Features Summary
12.2 Fault Finding Procedures
12.3 Possible Causes of Boiler Lockout
13.0 SERVICING ..................................................... ................................................................................ 33
14.0 REPLACEMENT OF FAILED COMPONENTS ............................................................................... 36
15.0 RECOMMENDED SPARES ................................................ ............................................................ 40
APPENDIX ‘A’ – INFORMATION RELATING TO PROPANE FIRING 41
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HAMWORTHY HEATING LTD
WARMWELL
500001091/F
FIGURES PAGE
Figure 1.1 Boiler Installation (Typical) ............................................................................................................ 2
Figure 2.1 Boiler Dimensions / Clearances .................................................................................................... 3
Figure 2.2 Performance & General Data Information ..................................................................................... 4
Figure 3.3 Balancing of Mixed Boiler Systems ............................................................................................... 6
Figure 5.3 Gas Flow In Pipes ......................................................................................................................... 8
Figure 5.6 Gas Valve / Pipework Leak Test Procedure ................................................................................. 9
Figure 7.2 Mechanical Ventilation Flow Rates ............................................................................................. 10
Figure 8.3 Cold Feed and Vent Pipe Sizes .................................................................................................. 11
Figure 8.10.1 Temperature Controls and Boiler On/Off Switch ......................................................................... 12
Figure 8.12 Site Wiring Diagram .................................................................................................................... 14
Figure 9.1 Wiring Schematic ........................................................................................................................ 15
Figure 10.2.1 Primary Heat Exchanger Insulation Fitting Instructions ......................................................... 16/17
Figure 10.2.2 Secondary Heat Exchanger Insulation Fitting Instructions ......................................................... 17
Figure 10.3 Gas Pipe Fitting Instructions ....................................................................................................... 18
Figure 10.6 Assembly of Secondary Heat Exchanger onto Primary Heat Exchanger ................................... 20
Figure 10.7 Casing Kit and Assembly Details ........................................................................................... 22/23
Figure 10.7.3a Condensate Trap ........................................................................................................................ 21
Figure 10.7.3b Float Switch ................................................................................................................................ 21
Figure 11.0 General Layout (Front View) ....................................................................................................... 25
Figure 11.1 Main PCB Layout ........................................................................................................................ 26
Figure 11.5 Pressure Sensing Tube / Fan Plug Assembly ............................................................................ 28
Figure 11.7a Diagram of Automatic Gas Valves ............................................ .................................................. 29
Figure 11.7b Diagram of ‘Hi’ Flow Gas Valve Assembly (Natural Gas Only) ................................................... 30
Figure 12.1 Boiler Function Neons ................................................................................................................. 32
Figure 12.2 Fault Finding Procedures ....................................................................................................... 34/35
Figure 14.1 Diagram of Hot Surface Igniter and Sensing Probe Assembly ................................................... 37
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HAMWORTHY HEATING LTD
WARMWELL
500001091/F
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’ (p41). Boilers MUST NOT use gas
other than that for which they were designed and
made.
1.3 The Warmwell 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 and
reducing heat lost by the boiler. The condensing
section is attached to the rear of the boiler
assembly. It is arranged such that the flue gases
and condensate run in a co-current flow path. This
design ensures the heat exchanger is continually
flushed of any salts which may form therefore
ensuring no re-entrainment of flue gases which
could increase acidic levels leading to aggressive
condensate. The heat exchanger utilises proven
materials both in the waterways (copper) and
flueways (aluminium). No special water additives
are required in the waterways, normal water
treatment should be adequate.
An exhauster unit pulls the flue gases through both
heat exchangers and supplies adequate pressure
for the connection to a header. The flue spigot is
angled at 45° allowing a 45° flue piece (supplied by
others) to be rotated through 180° permitting vertical
or horizontal connection as required.
1.4 If the boiler is to be connected to an un-vented
(pressurised) heating system, care must be taken to
ensure all extra safety requirements are met and
that the relevant interlocks will shut the boiler(s) off
should a high or low pressure fault occur.
The Pressurisation unit must also incorporate a low
level water switch, which protects the water 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 (p5). Consult Hamworthy
Heating Technical Department for help or
assistance if in doubt.
1.5 The Warmwell boiler is not suitable for direct
connection to domestic hot water supplies or gravity
fed heating systems.
1.6 The Warmwell boiler can be installed with either
reverse return water flow layout or with single pipe
header layout. See Figure 1.1 (p2) for typical
schematic layout.
1.7 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 very high efficiencies produced by the
Warmwell 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 waterways.
The Warmwell range is available with Hi/Lo operation
as standard. See Section 11.0 COMMISSIONING
AND TESTING (p24) for procedure.
1.8 Options
1.8.1 Optional reverse return header kits, comprising a
pre-designed arrangement of components, are
available for modular installations of all Warmwell boiler
models, and also combinations of Warmwell and
Purewell boilers. Please contact Hamworthy Heating for
information.
1.8.2 Milton boiler sequence control system for timed
remote control of single and multiple on/off and high/low
boilers, with outside temperature compensation and
optimum start.
Note: Optional Hamworthy Heating Ltd Sequencing
Interface Modules will be required, to be installed within
the control panel of each boiler, to enable sequence
control of the boilers by the Milton boiler sequence
control.
Refer to Milton and Sequence Interface Module kit
instructions for details.
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HAMWORTHY HEATING LTD
WARMWELL
500001091/F
Figure 1.1 Boiler Installation (Typical)
Expansion pipe
Mains water
Float
valve
Feed &
expansion
tank
Drain
Safety
valve
Pressure &
Te mp er a tu r e
gauges
P
T
Val ve
Automatic
Air Vent
Circulation pump
(System)
Heating load
Val ve
Drain
valve
Circulation pump
(Primary loop)
Feed
pipe
Hamworthy Modular Boilers
123
Module Module Module
T
VENTED SYSTEM: Primary loop, Hamworthy recommended system.
Mains water
Automatic
Air Vent
Drain
Safety
valve
Pressure &
Temperature
gauges
Val ve
Val ve
Lockshield
valve
Automatic
Air Vent
Expansion
vessel
Lockshield
valve
Drain
valve
Lockshield
valve
Te mp or a ry
fill line
Double
check
valve
T
Module1Module2Module
3
Hamworthy Modular Boilers
P
T
Circulation pump
(System)
Heating load
Val ve
Drain
valve
Circulation pump
(Primary loop)
UNVENTED SYSTEM: Primary loop, Hamworthy recommended system.
Expansion pipe
Float
valve
Val ve
Mains water
Feed &
expansion
tank
Feed
pipe
Circulation pump
(Primary loop)
Module1Module2Module
3
Hamworthy Modular Boilers
Drain
Safety
valve
PT
Pressure &
Temperature
Gauges
Val ve
Circulation pump
(System)
Heating load
Automatic
Air Vent
VENTED SYSTEM: Single pipe header
Mains water
Lockshield
valve
Automatic
Air Vent
Expansion
vessel
Lockshield
valve
Lockshield
valve
Te mp or a ry
fill line
Drain
valve
Double
check
valve
Circulation pump
(Primary loop)
Hamworthy Modular Boilers
Module1Module2Module
3
Drain
Safety
valve
Pressure &
Temperature
gauges
PT
Val ve
Circulation pump
(System)
Automatic
Air Vent
Heating load
Val ve
Drain
valve
UNVENTED SYSTEM: Single pipe header
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HAMWORTHY HEATING LTD
WARMWELL
500001091/F
Figure 2.1 Boiler Dimensions / Clearances
Boiler Model
60 80/95 140
Approx. Dry Weight kg 285 335 450
A - Boiler Height (Casing) mm 872 872 1060
B - Gas Connection Height mm 769 769 957
C - Return Connection Height mm 953 1047 1235
D - Gas Connection - (BS21) R¾ R¾ R1
E - Flow Connection Height mm 573 667 855
F - Flue Outlet Dia. mm 152 152 152
120
395
1060
957
1141
R1
761
152
Note! For modular applications, the top casing from the 60, 80 and 95 models can only be fitted to Purewell 40 80kW range, likewise the 120 and 140 model top casing can only be fitted to Purewell 95 - 120kW range. If a
different mix is required the Warmwell will have to be installed in stand-alone form.
The 533 centres relate to boilers close coupled in modular form. For stand-alone applications a minimum of
150mm should be allowed between casings (space baskets 200mm apart).
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HAMWORTHY HEATING LTD
WARMWELL
500001091/F
Figure 2.2 Performance and General Data Information
GENERAL DATA 60 95 140
Boiler Input High Fire - kW (Gross) 63.4 101.0 150.0
Boiler Input High Fire - kW (Nett) 57.1 90.9 135.0
Boiler Input Low Fire - kW (Gross) 39.0 38.6 46.6
Boiler Input Low Fire - kW (Nett) 35.1 34.8 42.0
Boiler Output High Fire (Condensing) - kW 59.0 93.0 135.0
Boiler Output High Fire (Non-Condensing - kW 54.0 86.0 128.0
Boiler Output Low Fire (Condensing) - kW
36.3 35.5 41.9
Boiler Output Low Fire (Non-Condensing) - kW
33.2 32.9 39.8
FLUE DATA
Nominal Flue Diameter. - mm 150
Approx. Flue Gas Temperature (Condensing) - °C 45 45 45
Approx. Flue Gas Temperature (Non-Condensing) - °C 65 65 65
Approx. Flue Gas Volume @ 9.0% CO2 - m3/h*
82.8 132.0 197.2
GAS DATA
Gas Inlet Connection R¾ R1
Nominal Gas Inlet Pressure - mbar 20
Maximum Gas Inlet Pressure - mbar 25
Gas Manifold Pressure High Fire - mbar 12.5 9.5 11.0
Gas Manifold Pressure Low Fire - mbar 5.0 1.5 1.2
Gas Flow Rate High Fire - m3/h 5.92 9.44 14.10
Injector Marking / Dia. - mm 3.1 4.2 4.4
No. Burner Bars / Injectors 5
WATER DATA
Water Connections
Flow - Rc2 Return - Rc2
Maximum Water Pressure - bar g 6
Water Content - litres
36 43 57
Minimum Water Flow Rate @ 15°C ∆T Rise - litre/s 0.94 1.46 2.15
Waterside Pressure Loss @ 15°C ∆T Rise - mbar 35.0 86.0 206.0
Design Water Flow Rate @ 20°C ∆T Rise - litre/s 0.70 1.10 1.61
Waterside Pressure Loss @ 20°C ∆T Rise - mbar 17.6 50.0 117.7
Minimum Water Flow Rate @ 22°C ∆T Rise - litre/s 0.64 1.00 1.46
Waterside Pressure Loss @ 22°C ∆T Rise - mbar
15.0 41.0 97.0
ELECTRICAL DATA
Normal Supply Voltage
230V ~ 50Hz
Power Consumption (maximum) - W 190
Shunt Pump Output (optional)
230V ~ 50Hz fused @ 2A
4
Pressure Switch Setting (Normal) High Fire - mbar 1.8 2.4 2.4
Pressure Switch Setting (Normal) Low Fire - mbar 1.5 1.5 0.4
120
132
119
55
50
120
117
50
45
45
65
173.5
11.6
2.0
3.0
0.4
12.6
4.1
50
1.91
158.0
1.43
91
1.30
75
4 5
80
86.5
78
33.3
30
78
72.5
31.2
27.0
45
65
111.0
10.7
1.9
0.9
0.4
7.9
3.75
4
43
1.21
63.0
0.91
32.0
0.83
24.0
* NOTE! Flue gas volumes are based on a gross flue gas temperature of 15°C at 1013.25mbar
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HAMWORTHY HEATING LTD
WARMWELL
500001091/F
2.0 TECHNICAL DATA
2.1 Overall dimensions are shown in Figure 2.1 (p3).
Both single and multiple boiler arrangements are
shown.
The Warmwell 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.
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!
To install 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 (p16)
Ref.: - spacing plates for further information. See
Figure 2.1 (p3) re: - coupling of Warmwell and
Purewell boilers. The boiler can also be installed in
a 'stand alone configuration' if required.
2.2 General Information and Technical Data relating
to Natural Gas is shown in Figure 2.2 (p4).
Technical data relating to propane firing can be
found in Appendix ‘A’ (p41).
2.3 Screw threads: All screw threads used in the
Warmwell boiler conform to the following: -
ISO 7/1 or ISO 228/1 for pipe threads where
applicable. ISO 262 for all general screw threads.
3.0 GENERAL REQUIREMENTS
3.1 Related Documents
Gas Safety Installations and Use Regulations
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
that this law is complied with.
The installation of the boiler MUST be in accordance
with the relevant requirements of the Gas Safety
Regulations, Building Regulations, IEE Regulations
and the bylaws of the local water undertaking.
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: -
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.
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/2)
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 information, but the following extracts from
the above references are emphasised since failure
to comply with these requirements will almost
certainly result in an unsatisfactory installation.
3.2 Feed Water Quality
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.
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HAMWORTHY HEATING LTD
WARMWELL
500001091/F
Figure 3.3 Balancing of Mixed Boiler Systems
Warmwell Boiler
Purewell Boiler(s)
Balancing Valves
LOAD
System Pump
Reverse return header system
Position of
shunt pump
(if required)
It should be noted however, that even if the boiler
water were 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, those 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 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 Warmwell boiler is designed as a
quick response, low water content unit, 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.
The Warmwell boiler is tested with flow/return
temperatures of 50/30°C to ensure condensing
takes place thus achieving the correct output. The
boiler can also be used in the high efficiency mode
with flow/return temperatures of 80/60°C, i.e. noncondensing where it will provide the lower heat
output as given in Figure 2.2 (p4).
If the temperature/flow rates of the application
cannot meet those given in Figure 2.2 (p4), it may
be necessary to incorporate mixing valves and
shunt pumps to ensure that the boiler will operate
satisfactorily. See Figure 3.3.
The pressure loss though the Warmwell boiler is
generally higher than the equivalent Purewell unit. It
therefore may be necessary to incorporate
balancing valves where these units are mixed on the
same header. See Figure 3.3.
Figure 2.2 (p4) 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 at any time. For boiler
pressure drop see Figure 2.2 (p4).
3.4 Time Clock Control
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! Time clocks should not interrupt live, neutral
or earth connections, see Section 9.0:
ELECTRICAL SUPPLY (p13) for details. See
Figure 9.1 (p15) for wiring details.
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HAMWORTHY HEATING LTD
WARMWELL
500001091/F
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. See Section 8.10.1 (p12).
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 20°C rise across system. Minimum
head required = 9.4 metres or 0.92 bar. See
Section 8.11 (p12) for Pressurised Water Systems.
4.0 LOCATION
4.1 See Figure 2.1 (p3) for dimensions/weights and
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
electrical trunking laid along the floor.
Allow adequate space, this must not 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.
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
ensure that its temperature does not exceed 65°C.
For further details regarding boiler location refer to
BS 6644.
5.0 GAS SUPPLY
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 5.3 (p8) 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.
5.5 Boiler House Control Valve
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.
5.6 Boiler Gas System Leak Check
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
gas pipework and components. A procedure guide
is given below. Care must be taken not to allow leak
detection fluid on or near any electrical parts or
connections (If used). See Figure 5.6 (p9) - Gas
valve/pipework leak check test procedure.
Note: - Main gas supply pressure - G20 - 20mbar
- G31 - 37mbar
To Check Valve B
1) Turn off the electrical power and gas to the
appliance.
2) Connect the manometer to gas valve test point.
3) With A, B closed open C and monitor manometer
over a 2 minute period, a rise indicates a leak on
valve B.
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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.
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.
Figure 5.3 Gas Flow in Pipes
Total Gas Input
m³/hr
NB
20mm 25mm 40mm 50mm 65mm 80mm 100mm
4.73 10 42 - - - - -
5.92 - 25 180 820 - - -
7.10 - 16 120 540 - - -
8.27 - 11 85 380 - - -
9.44 - - 62 280 900 - -
11.19 - - 42 185 580 - -
12.36 - - 33 145 470 - -
14.1 - - 25 110 345 - -
18.88 - - 12 56 180 - -
22.38 - - - 38 120 750 -
24.72 - - - 30 96 600 -
28.20 - - - 22 72 440 -
33.57 - - - 15 47 290 -
37.08 - - - 11 37 235 -
42.30 - - - - 27 170 810
44.76 - - - - 24 150 730
49.44 - - - - 19 115 570
56.40 - - - - 14 86 430
61.80 - - - - 11 71 340
70.50 - - - - - 51 245
74.16 - - - - - 46 220
84.60 - - - - - 34 165
Maximum length of gas pipe (Metres)
Fitting Type(NB) 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 90°Bend 0.3m 0.3m 0.3m 0.5m 0.5m 1.0m 1.5m
8
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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 0.5
mbar (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
Detailed recommendations for flue systems are
given in BS 6644, I.Gas.E. 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.
6.1 General Requirements
The Hamworthy Warmwell 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. IGE/UP/10 "Installation of gas appliances in
industrial and commercial premises Pt 1 flued
appliances." The following points should be noted: -
1) Flue gas temperatures from traditional boilers will
be typically 150-200°C which gives buoyancy thus
tending to balance resistances through the boiler
and primary/secondary flueways. Condensing
boilers (in condensing mode) have flue gases at/or
approaching water return temperatures. These
gases will be in a saturated condition, therefore
Figure 5.6 Gas valve/pipework leak test procedure.
continuous condensation in the flueways must be
expected.
2) The flue system must be self-supporting in the
correct position to enable its removal for boiler
cleaning (condensing heat exchanger only).
3) Boilers should be located as near to the chimney
as possible, the nearest being not more than 2m
(6ft) away.
4) The flue system should be designed to achieve a
negative suction at all times on all modules in a
bank. For optimum performance, draught conditions
should be between -0.05 to -0.125mbar. 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. IGE/
UP/10, "Installation of gas appliances in industrial
and commercial premises Pt 1 flued appliances."
5) Warmwell boilers are suitable for installation in a
balanced compartment in accordance with the
requirements of BS6644. Consult Hamworthy
Heating Technical Department for help or
assistance if in doubt.
6.2 Design Waste Gas Volume and Temperature
The flue gas temperature will be dependant on the
system return temperature - Figure 2.2 (p4) gives
maximum and minimum temperatures based on
non-condensing and condensing modes. It should
be assumed that there would be no buoyancy aid
from the hot gas leaving the boiler. It is therefore
recommended that the flue resistance should not
exceed 0.25mbar.
It is recommended that the volume and temperature
of the waste gases used for design of the flue
system be as shown in Figure 2.2 (p4).
6.3 Flue Condensation
Care should be taken to ensure the flue is installed
in such a way that condensation produced on start
up or during normal run is piped to an appropriate
drain via the condense trap supplied, discharging
into a tun-dish (not supplied).
The discharge piping from a tun-dish shall slope at
least 30mm/m.
6.4 Materials
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.
Condense will be produced in normal operation of
the Warmwell boiler. The materials used in the flue
construction must be suitable for saturated flue gas
and assembled such that condense naturally drains
to traps and does not `leak' from joints.
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7.1 Air Supply by Natural Ventilation
The boiler room must have, or be provided with,
permanent air vents directly to the outside air, at
high level and at low level. For an exposed boiler
house, air vents should be fitted preferably on all
four sides, but at least on two sides. Air vents
should have negligible resistance and must not be
sited in any position where they are likely to be
easily blocked or flooded or in any position adjacent
to an extraction system which is carrying flammable
vapour. Grilles or louvres must be so designed that
high velocity air streams do not occur within the
space housing the boiler.
The air supplied for boiler house ventilation shall be
such that the maximum temperatures within the
boiler house shall be as follows: -
1) At or 100mm above floor level = 25°C.
2) At mid-level (1.5m above floor level) = 32°C.
3) At or 100mm below ceiling level) = 40°C.
Where both low and high level openings are used,
the grilles shall have a total minimum free area of: -
Low Level (inlet) 540cm
2
plus 4.5cm2 per kilowatt in
excess of 60kW total rated input.
High Level (outlet) 270cm
2
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.
NOTE: For Mechanical ventilation systems an
automatic control should be provided to cut off the
gas supply to the boiler, in the event of failure of air
flow in either inlet or extract fans.
Discharge piping from a tun-dish should be of a
synthetic material due to the mild acidity of the
condensate (pH 3-5). Consideration should be given
to possible freezing of condense water traps and
pipework. This must be avoided at all times. Insulate
condense pipes if freezing temperatures are likely to
be encountered.
6.5 Disconnection
Provisions should be made for disconnection of the
flue pipe for servicing. It is advisable that bends are
fitted with removable covers for inspection and
cleaning as appropriate. NOTE! The flue system
must be self-supporting.
See section 13: SERVICING (p33) for further
information.
6.6 Flue Discharge
The flue system must ensure safe and efficient
operation of the boiler to which it is attached, protect
the combustion process from wind effects and
disperse the products of combustion to the external air.
The flue must terminate in a freely exposed position
and be so situated as to prevent the products of
combustion entering any opening in a building.
6.7 Surface Temperatures
Combustible materials in the vicinity of the boiler and
flue shall not exceed 65°C during boiler operation.
The flue shall not be closer than 50mm to any
combustible material, except where it passes through
such material with a non-combustible sleeve when
the air gap may not be less than 25mm.
6.8 Flue System Location
The flue system must not be placed or fitted where
there is undue risk of accidental damage to the flue
pipe or undue danger to persons in the vicinity.
NOTE! The flue MUST be self-supporting. Check
that the flue and chimney are clear from any
obstruction.
Where the flue diameter is less than 200mm (8") a
terminal must be fitted. Where the flue is of a larger
size consideration should be given to the fitting of a
flue discharge terminal or grill to stop ingress of birds,
etc.
7.0 AIR SUPPLY
Detailed recommendations for air supply are given in
BS 6644. The following notes are intended to give
general guidance. In all cases there must be
provision for an adequate supply of air for both
combustion and general ventilation, in addition to that
required for any other appliance.
Figure 7.2 Mechanical Ventilation Flow Rates
Flow rate per 1000kW
total rated heat input (Gross)
Inlet air
(Combustion
ventilation)
Extract air
(ventilation)
m³/s. m³/s.
Volume 1.10 0.45
Atmospheric
Boilers
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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
shown in Figure 8.3.
The vent pipe must rise continually, it 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 1.1 (p2) for typical position.
8.5 Thermometer
See Figure 1.1 (p2) for typical position. A
thermometer complete with pocket should be fitted
in the pipework to indicate water flow temperature.
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 1.1 (p2)
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 2.2 (p4) shows the hydraulic
resistance of the boiler. The pump should be sited to
facilitate servicing. It is important to note that when
Warmwell 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.
8.0 WATER CIRCULATION SYSTEM
8.1 General
The Warmwell Boiler has a low water content and
the requirements of minimum water flow are given in
Section 8.8:Minimum Water Flow Rates (p12) and
Figure 2.2 (p4). Recommendations for the water
circulation system are given in BS 6644 and CP
342. The following notes are of particular
importance: -
1) In a 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 insulated. Insulation exposed to the weather
should be rendered waterproof.
3) Drain valves 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 1.1 (p2) shows typical layout.
5) Due to the higher pressure losses of the
Warmwell heat exchanger compared to the
Purewell, it may be necessary to install a shunt
pump or balancing valve to enable correct flow
through these combined boiler systems. See Figure
3.3 (p6).
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.
Figure 8.3. Cold Feed and Vent Pipe Sizes
Boiler Output Feed Vent
< 60 kW 19 25
60 kW - 150 kW 25 32
150 kW - 300 kW 32 38
300 kW - 600 kW 38 50
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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 1.1 (p2) for typical layout of a
pressurised (Un-vented) Hot Water System. For
system design refer to BS 7074 Part 2.
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.
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 manufacturers 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.
8.8 Minimum Water Flow Rates
Minimum water flow rates are shown in Figure 2.2
(p4). These flow rates should be maintained through
the boiler at all times whilst the boiler is firing. If the
water 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 Water Pressure Drop
The waterside hydraulic resistance (Pressure drop)
is shown in Figure 2.2 (p4).
NOTE: If boilers are run off time clock control, a
pump overrun (not HHL supply) should be fitted
which must run for a minimum of 5 minutes on shutdown of the last boiler.
8.10 Control Schemes
8.10.1 Temperature Controls
An electronic control thermostat using a 10kΩ NTC
thermistor temperature sensor is incorporated within
the boiler controls. A potentiometer is used to adjust
the control thermostat set point between the range
25 to 95°C. The potentiometer also acts as the
boiler on/off switch via a push and release action.
An additional potentiometer (fitted to the boiler main
control PCB) provides a temperature offset below
the main control set point for high/low control
switching, which can be adjusted up to 10°C below
the main set point (5°C recommended).
If the boiler is required to run in condensing mode the
return temperature should be between 30-45°C. The
control thermostat should therefore be set at 45-55°C.
This will be dependent on boiler water flow-rate and
hence ∆T achieved.
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 95°C.
A standard electro-mechanical temperature limiter,
(hand reset limit thermostat) is also fitted to the boiler
and must be set at 100°C.
NOTE! To meet the requirements of the EN
standard the temperature limiter’s maximum setting
should be 100°C. The minimum difference between
control thermostat and temperature limiter MUST
NOT be less than 10°C.
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 2.2 (p4) is maintained.
Figure 8.10.1 Temperature Controls and Boiler
On/Off Switch
°C
Temperature
Limit Thermostat
/ Reset Switch
On/Off Knob
Push to activate
25
30
75
90
95
80
85
40
35
45
50
65
60
70
55
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HAMWORTHY HEATING LTD
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details regarding connection to the electricity supply
are given in BS EN 60335, Part 1 or BS 3456, Part
201.
The mains power supply MUST NOT be switched
by a time clock, especially if a single header pump kit
is utilised. The Warmwell boiler has a remote stop/start
loop which can be used to operate the boiler(s) under
a timed regime. The boiler control provides a 230V ~
signal that can be fed through a volt free contact for
operation. Refer to Figures 8.12 (p14) and 9.1 (p15)
for typical site wiring connections. See BS 6644 for
further information. DO NOT feed mains voltage
onto these terminals.
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.
A removable bracket is supplied with every Warmwell
boiler having three 20mm dia. holes for electrical cable
anchorage. A plug and socket arrangement is utilised
for the site terminal connections, the plug terminals
being attached to the removable bracket.
NOTE! Rigid conduit MUST NOT be connected to the
bracket as this will prevent removal. Care must be
taken to ensure correct connections are made to the
relevant terminals before applying power.
Refer to Figures 8.12 (p14) and 9.1 (p15) for typical
wiring diagram.
9.2 Indication Signals and Volt Free Contacts
Volt free contacts are provided to enable external
indicator lights or alarms to derive signals for normal
run, overheat and lockout.
Note:- These external circuits MUST be isolated
before obtaining access to the controls for any service
or maintenance procedures to be carried out.
9.3 Milton Boiler Sequence Control and
Sequencing Interface Module (Optional)
Refer to the Milton boiler sequence control manuals for
details of its installation.
The sequencing interface module is supplied as a kit
for site assembly to the boiler control panel(s). Refer to
the installation instructions supplied with the kit for
assembly details.
The sequencing interface module incorporates a
10way plug/socket screw terminal block to make the
site wiring connections. Refer to Figure 8.12 (p14) and
the Milton boiler sequence control installation manual
for wiring connection details.
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 boiler installations, Hamworthy Heating
can supply an optional Milton boiler sequence control
system.
This system comprises a wall mounted ‘Boiler
Sequence Control’ unit, and a ‘Sequencing Interface
Module’ unit mounted to the fascia of each boiler’s
control panel, which provides on/off or high/low
switching of the boiler. The Boiler Sequence Control
communicates with the ‘Sequencing Interface
Modules’ via a 2 wire data BUS. PT1000 type water
flow temperature, optional room temperature and
optional outside air temperature sensors are available,
which are wired to the Boiler Sequence Control. Refer
to Figure 8.12 and the Milton boiler sequence control
and sequencing interface module instructions for
further details.
Where a modular installation comprises of a
combination of Purewell and Warmwell boilers, the
Warmwell condensing boilers should always be the
lead boilers.
Alternatively, the boilers can be controlled on/off or high/
low via the remote on/off and high/low control loops, by
a non-HHL control system - see Figure 8.12 (p14).
9.0 ELECTRICAL SUPPLY
WARNING: THIS APPLIANCE MUST BE
EARTHED.
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.
Internal fuse rating is 6.3A (T rated). External fuses
should be 10A for all single boiler sizes.
The method of connection to the mains electricity
supply must facilitate complete electrical isolation of
the single boiler/battery 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! Volt free contact electrical supplies must also
be isolated when fitted (see note on fascia). Further
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HAMWORTHY HEATING LTD
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Figure 8.12 Site Wiring Diagram
REMOTE CONTROL LOO P - ON/OFF
NOTE: TERMINAL ‘1’ IS SUPPLIED
WITH 230V AC.
MA INS VOLTA GE BE FED
ONTO THESE TERMINALS !
MUST NOT
TO HAM WORTHY HEATIN G LIMITED
MILTON BOILER SEQUENCE CONTROL
(REFER TO MILTON INSTALLATION
MANUAL FOR FURTHER DETAILS)
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Figure 9.1 Wiring Schematic
NOTE! Maximum rating of volt free contact(s) is 3 Amperes Resistive
WARNING! External voltage MUST NOT be applied to remote stop/start terminals CN16 or high/low control loop
terminals CN16 or any terminals on the fascia. NOTE! * Volt free contacts may have separate supply. Ensure all power
supplies are completely isolated prior to working on the electrical circuits of this appliance.
WHITE/BLACK
GREY/BLACK
PINK/BLACK
BROWN
GREY
1
2
C
ON/OFF SWITCH
POTENTIOMETER &
NO
NC
C
SAFETY TEMP
RED/BROWN
LIMITER
54231312
RED/GREEN
RED/BLUE
1 32
CN5
1 243
CN14
5
FLAME PROBE
FLAME SIGNAL
TEST POINT
HSI PROBE
IGNITION SEQUENCE CONTROL
PEKTRON ASS-0459G05A
8 8
1
BLUE
3
2
BROWN
12
11
10
9
1
2
1
CN11
3
2
CN9
12
10
11
9
467
523
1
BLACK
BLACK
1
2
1
467
5
CN3
231
1
2
CN211CN22
TEMPERATURE SENSOR
BLUE
RED
1
2
1
2
CN23
RED
HOURS RUN METER
HOURS RUN METER
00000.00h
00000.00h
MAIN GAS VALVE
GV1a
GV1b
HIGH/LOW COIL
BLACK
HIGH FIRE
BOILER FASCIA PCB
CN2
1
1
789562341
CN1
612345 978
212
CN3
L
212
L1
L2
967854312
RED
RED
RED
RED
RED
RED
RED
RED
RED
BLACK
6132 4 5
CN15
97 8
0V
RED
RED
12V
0V
LOW FIRE
12V
BROWN
GREEN/YELLOW
BLUE
BROWN
BLACK
BROWN
BLUE
GREEN/YELLOW
BROWN
BLACK
BLUE
GREEN/YELLOW
N
N
FLOW SHARE VALVE
GV2
(IF FITTED)
L2
L1 N
NC
C
NO
10
10
891234567
21 3
CN12
54 6 87 9
431211 12 1 3
LOW GAS SUPPLY
PRESSURE SWITCH
11 12 13 21 3
CN10
4
MAIN SITE WIRING CONNECTIONS - PLUG BRACKET
34
GREEN/YELLOW
BOILER SHUNT PUMP CONNECTION -
230V AC SIGNAL FUSED AT 2A
NORMAL RUN VOLT FREE CONTACT
LOCKOUT VOLT FREE CONTACT
OVERHEAT VOLT FREE CONTACT
CONTACTS RATED
AT 250V AC 5A
CN17
LEN 15
CN8
12 NE L
CN13
15
1716 201918
1716 1918 20
CN18 CN19
21
31 3332
230V AC 50Hz SUPPLY FROM A MAINS
ISOLATOR WITH MINIMUM 3mm
SEPARATION IN ALL POLES
N L
NL
BOILER MAIN PCB
WHEN FITTING S OME OPTIONAL
COMPONENTS, WIRE LINKS WILL REQUIRE
REMOVAL - ALWAYS READ THE FITTING
INSTRUCTIONS AND REFER TO THE
BOILER INSTALLATION MANUAL BEFORE
OPERATING THE BOILER SUBSEQUENT TO
FITTING THESE COMPONENTS. FAILURE
TO COMPLY COULD LEAD TO DANGEROUS
OPERATION AND/OR DAMAGE TO THE
BOILER.
NOTE:
- 230V ~ 50Hz LIVE CON NECTION
- 230V ~ 50Hz N EUTRAL CONNECTION
- LOW FIRE COMMON CONTACT
- LOW FIRE NORMALLY OPEN CONTACT
- HIGH FIRE COMMON CONTACT
- HIGH FIRE NORMALLY OPEN CONTACT
- NOT UTILISED
- NOT UTILISED
- SEQUENCER DATA BUS GROUND
- SEQUENCER DATA BUS SIGNAL
CN1
645 312
645312
~
M
CN2 CN16 CN7
REMOTE C ONTROL
5
5
21 34
2134
C
67
67
12 34
12 34
NC
HIGH/LOW
ON/OFF
BROWN
RED
NO
CONNECTIONS
1 32465798
CN20
1234
FEMALE CONNECTOR
MALE CONNECTOR
SCREW TERMINAL
STANDARD BOILER COMPONENT
OPTIONAL BOILER COMPONENT
C
NO
NC
RL14
A1 A2
BOILER EXHAUST FAN CONTROL PANEL
RL14a
1411
L
N
EAB
SPEED
CONTROL
PCB
L1 N1
HIGH FIRE AIR
PROVING SWITCH
E
L1
N
T1
T2
S3
B4
B4
E
S3
T2
T1
N
L1
CAPACITOR
FAN
EXHAUST
BLACK
BLUE
VIOLET
GREY
GN/YE
BROWN
BLUEGREEN/YELLOW
RED
BLUE
BROWN BROWN
BLUE
GN/YE
WHITE
WHITE
BROWN
BLUE
BROWN
BLUE
RED
LOW FIRE AIR
PROVING
SWITCH
2µF
'1'
'2'
'3'
BROWN
BLUE BROWN
C1
N1
L1
3WAY TERMINAL BLOCK SCREW
TERMINAL (EXHAUST FAN PANEL)
1
2
CN11
1
22
1
(MOUNTED IN FAN HOUSING)
FLOAT SWITCH
CONDENSE TRAP
RED
RED
A1
RL15
A2
RL15a
14 11
1 2
BLUE
BROWN
BLUE
RL14
RL15
FAN HIGH/LOW
SPEED CHANGE-
OVER RELAY
CONDENSATE TRAP
BLOCKAGE RELAY
2143
SEQUENCING INTERFACE MODULE
4
4
GREEN/YELLOW
756 89
SEQUENCER DATA BUS
CONNECTIONS
'6' CORE
'5' CORE
10
9
876
5
10
9
876
5
'2' CORE
'4' CORE
'3' CORE
'1' CORE
231
2
3
1
(OPTIONAL)
KEY:
KEY:
15
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HAMWORTHY HEATING LTD
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incorporates a socket which matches the gas valve
wiring plug. Care must be taken to ensure both plug
and gland plate are correctly located and fixed in
position by the screws provided.
4) A 45° flue elbow (not HHL supply) may be located
in the flue spigot at the rear of the boiler. This elbow
can be rotated to give vertical or horizontal flue
discharge. Ensure the flue pipework is adequately
sealed against condense leakage. In condensing mode
the flue gases are saturated and will contain slightly
acidic water which must be channelled into drains and
not allowed to drip from seams.
The condensing section may be despatched
separately, if required, and can be site assembled onto
the cast iron heat exchanger on site. Figure 10.6 (p20)
shows method of assembly.
Care must be taken in order not to damage the copper
tubes or fan assembly during erection.
All the necessary cabling and pressure sensing tubes
are supplied ready to attach to the controls housing
when fitted. Please follow assembly instructions
regarding these attachments, as incorrect connection
will result in commissioning problems at a later stage.
See Figure 11.5 (p28) for further details.
10.2 Heat Exchanger Insulation Fitting Instructions
10.2.1 Primary Heat Exchanger Insulation
With reference to Figure 10.2.1a - 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.
Note: For correct operation of the sequencing
interface module a number of wire links MUST be
removed from the boiler main PCB - refer to
Section 11.5 clause 8) (p27) for details.
10.0 BOILER ASSEMBLY AND INSTALLATION
10.1 General
Each boiler is despatched to site as follows: -
1) Heat exchanger & basket including burners
and gas valve(s) etc. on a pallet.
2) Casing complete with assembly instructions.
3) Control panel assembly.
4) Condensing section assembly (fitted to item 2).
Further details of each individual assembly are 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 & insulation wrap are supplied
separately and should be fitted to the boiler as shown.
THE GAS PIPE MUST NOT BE USED TO
MANOEUVRE OR POSITION THE BOILER.
NOTE! Consideration must be given to the weight of
the boiler (See Figure 2.1 p3), 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: small casing for the 60 and 95 boilers
and large casing for the 140 boiler.
The condensing section casing is supplied separately.
See assembly instructions in Section 10.7 (p19).
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 10.7 (p22/23). You should check
to ensure that all parts are supplied prior to assembly.
3) Control panel assembly including fascia bezel and
exhaust fan control panel with pressure switches.
These assemblies will be suited to the desired controls
variant and include any optional extras required. Refer
to Figure 10.7 (p22/23) for fitting instructions. Ensure all
thermostat capillaries are inserted and correctly located
into the top of the boiler. The controls assembly also
Figure 10.2.1a
16
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HAMWORTHY HEATING LTD
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Refer to Figure 10.2.2b - Fit jacket over the
transition duct and secondary heat exchanger.
Ensure the two air vents protrude through the jacket.
Feed jacket between the two M6 studs, which will
eventually hold the casing support bar.
Refer to Figure 10.2.2c - Close flaps around bottom
of secondary heat exchanger. Ensure unit is
completely covered. The insulation jacket should
not cover the stainless steel collector hood.
Seal all joints with tape provided. Loosely close the
front flaps covering the inspection door. Place two
pieces of tape on front split to allow access to the
inspection door.
Reference to Figure 10.2.1b - Insulation should be
folded around boiler such that its rear edges meet in
the centre. Ensure flow and return connections are
clear and unobstructed.
Apply foil tape down join. Leave ‘petals’ in upright
position at the sides for installation of secondary
heat exchanger insulation. Mould the rear ‘petal’
into the shape of the boiler and fold the front ‘petal’
such that the access door is not covered. Use foil
tape to secure joins and folds whilst ensuring gas
pipe bracket and thermostat pocket are clear and
unobstructed.
10.2.2 Secondary Heat Exchanger Insulation
Refer to Figure 10.2.2a - Offer insulation jacket to
transition duct as shown. Ensure insulation is not
snagged or ripped by any sharp objects.
Figure 10.3a
Figure 10.2.1b
Figure 10.2.2a
Figure 10.2.2b
Figure 10.2.2c
17
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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 pipe/
manifold and ensure pipe is vertical/horizontal before
clamping in position.
10.4 Connection of Boilers to the Flue System.
Notes on the recommendation for design of the flue
system are given in Section 6:FLUE SYSTEM (p9).
It is recommended that each individual condensing
boiler have its own flue if possible. Due consideration
should be given to obtain constant draught conditions
if possible at the boiler discharge.
Flueways must be designed with continuous falls to
low points where a suitable condensation trap should
be fitted. All joints in the flue should be fitted such
that condense drains into the preceding flue pipe
without leakage.
Some of the flue may be under slight positive
pressure therefore escaping vapour may condense
on the outer skin of the flue. Again, all joints should
therefore be suitably sealed against leakage.
Flues must be constructed with suitable materials to
resist corrosion against the acidic nature of the flue
gases. Materials used in the joints must also resist
attack.
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 Warmwell boiler is supplied with a gas pipe
which exits the casing at the rear after installation,
see Figure 2.1 (p3) for position. The incoming mains
gas supply must be capable of supplying gas to the
boiler at the required pressure, under all firing
conditions. For sizing information see Figure 5.3
(p8). 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 2.1 (p3) for position of water connections
(flow and return). An R½ BS21 plug is fitted local to
the return connection for the fitting of a drain valve
(not HHL supply). Care must be taken when
installing water system pipework that undue stress is
avoided on the boiler flow and return connections.
The return connection is fitted to the copper header
on the heat exchanger. WHEN ATTACHING
PIPEWORK TO THIS HEADER IT IS IMPERATIVE
THAT NO UNDUE STRESS IS PLACED ON THE
Rc2 BS21 CONNECTIONS.
10.3 Gas Pipe Fitting Instructions
Refer to Figure 10.3a - 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 position will be
dependent on boiler size.
Figure 10.3b shows the pipe clamp fitted to
Warmwell 95, 120 and 140kW boilers.
Figure 10.3c shows the pipe clamp fitted to
Warmwell 60kW boilers.
Figure 10.3a
Figure 10.3b
Figure 10.3c
18
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HAMWORTHY HEATING LTD
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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).
10.7.2 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 multi-casing frame set) as shown. 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.
10.7.3 Warmwell top casing.
1) Tighten the 4off screws fixing the back panel to
the side panels.
2) Select the appropriate side panel support (item
34 or 35) dependent on boiler model. Discard the
unused item. Fit ‘U’ nuts (item 15) to the holes at
each end of the side panel support. Fit 2off M6 nuts
and plain washers (items 9 and 36) to the M6 studs
located on the top of the Warmwell boiler secondary
The header must be suitably supported when
screwing in and tightening pipework to this header.
It is recommended that unions be fitted locally to the
boiler to permit future servicing requirements. 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.
The secondary & primary heat exchangers can be
dispatched separately if required, and will require
assembly on site. Refer to Figure 10.6 (p20).
This is achieved as follows: -
1) Carefully unpack secondary heat exchanger
assembly. A flexible pipe assembly connects both
heat exchangers together and is normally
dispatched fitted onto the primary heat exchanger.
2) Ensure rope seal is aligned within rope groove
on the top casting. Screw on four M8 nuts &
washers onto the tie rods. Gently lower the
transition duct onto the top casting - ensure rope
seal does not move. Fit M8 nuts & washers to
restrain the assembly, DO NOT TIGHTEN AT THIS
STAGE.
3) Connect the flexible pipe to the secondary heat
exchanger and tighten - TAKE CARE NOT TO
DAMAGE OR PLACE UNDUE STRESS ON THE
COPPER TUBES OR HEADERS. Tighten nuts
onto the transition duct. Do not over tighten
otherwise lugs will be distorted. Lock M8 nuts
together. Remove transition duct cover and visually
inspect rope seal integrity.
4) Ensure all connections are watertight starting at
the base. Re-fit transition duct cover and continue
installation.
10.7 Casing and Controls Assembly
For assembly of casing and controls refer to Figure 10.7
(p22/23).
10.7.1 Multi casings
Note: Where boilers are in Modular form, i.e.
MW420 (3 x 140kW), 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.
19
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Figure 10.6 - Assembly of Secondary Heat Exchanger onto Primary Heat Exchanger if Supplied Separately
20
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HAMWORTHY HEATING LTD
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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.
9) Condense Trap Connection
Select the condense trap kit from the fan control &
condense trap kit, and fit the ¼ BSP plug into the
base of the trap using suitable sealant. Secure the
trap to the fan housing using the gasket and 2 off
each M5 nuts and washers provided. The trap is
suitable for connection to 22mm plastic waste pipe
(not HHL supply) with the waste pipe being routed
down to a local tundish. A small amount of sealant
must be used on the waste pipe connection to the
condense trap – see Figure 10.7.3a.
10) Float Switch Connection
Remove the condense level float switch from the fan
control and condense trap kit and fit to the tapping in
the fan housing taking care to seal the threads with
PTFE tape and also to secure the switch in the
correct orientation as shown in Figure 10.7.3b
below. Connect the condense level float switch plug
to the adjacent socket on the rear face of the side
panel.
heat exchanger. Fit the side panel support to the M6
studs and loosely secure with the remaining M6 nuts
and plain washers. Leave the fastenings loose at
this stage to allow adjustment of the height of the
side panel support.
3) Select the left hand and right hand upper side
panels (items 30 & 31) and fit 4off ball studs,
spacers, M5 screws and shake proof washers
(items 7, 8, 11 & 12 – supplied with the Purewell
lower casing kit) to the 2 holes in the bottom return
of each panel. Fit 4off ‘U’ nuts (item 15) to the 2
holes in the inner return on the angled edge of each
side panel. Fit the upper side panels to lower side
panels (or multi casing frame set) of the Purewell
lower casing kit ensuring that the ball studs locate
correctly in the matching latches fitted to the top
return of the lower side panels.
4) Adjust the height of the side panel support such
that its top face fits just below the top return of the
upper side panels, and securely fasten the M6 nuts.
Secure the side panels to the side panel support
with 2off No.8 self tapping screws (item 16).
5) Select the exhaust fan control panel (item 37 –
supplied with the fan control and condense trap kit –
HHL part no. 563605201) and place between the
angled front edges of the upper side panels. Secure
to the 4off ‘U’ nuts using 4off No.8 self tapping
screws (item 16). Note: It is advisable at this stage
to make the electrical connections between the
boiler control panel, exhaust fan control panel and
exhaust fan, and the sensing tube connections.
6) Select the upper top panel and fit 4off ball studs,
spacers, M5 screws and shake proof washers
(items 7, 8, 11 & 12) to the 4 holes in the bottom
returns. Fit the upper top panel to the upper side
panels ensuring that the ball studs locate correctly in
the matching latches fitted to the top returns of the
upper side panels.
7) Select the upper front panel and fit 4off ball
studs, spacers, M5 screws and shake proof washers
(items 7, 8, 11 & 12) to the 4 holes in the bottom
returns. Fit the upper front panel to the upper side
panels ensuring that the ball studs locate correctly in
the matching latches fitted to angled front returns of
the upper side panels.
8) 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
Figure 10.7.3a - Condensate Trap
Fan Housing
Gasket
Drain
connection
Condensate
trap
Figure 10.7.3b - Float Switch
21
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Figure 10.7 Exploded View of Casing Set
13
14
5
18
10
9
10
22
19
2
16
3
16
15
21
16
20
15
1
DETAIL 'A'
11
12
8
7
24
23
25
26
4
27
6
9
10
15
31
33
16
15
9
36
15
30
16
37
FASTENERS REF. DETAIL
'A' (2 POSITIONS EACH IN
LH & RH PANELS)
FASTENERS REF.
DETAIL 'A' (4
POSITIONS)
FAS TENER S REF.
DETAIL 'A' (4
POSITIONS)
32
35
34
60 MODEL ONLY
95 & 140 MODELS ONLY
TYPICAL
APPLICATION
OF 'U' NUTS
22
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HAMWORTHY HEATING LTD
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Parts List of Figure 10.7 - Inventory of Warmwell Casing Set.
Item Description
Quantity
(Single Casing Kit)
Quantity
(Multi 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
Item Description Quantity
7 Ball stud fastener 8
8 Spacer for ball stud fastener 8
9 M6 hexagon nut 4
11 M5 x 12mm hexagon head screw 8
12 M5 internally serrated shake proof washer 8
15 ‘U’ nut for no.8 self tapping screw 6
16 No.8 x ½” self tapping screw 6
30 Left hand top side panel 1
31 Right hand top side panel 1
32 Upper front panel 1
33 Upper top panel 1
34 Side panel support (95 and 140 models) 1
35 Side panel support (60 model) 1
36 M6 plain washer 4
37 Exhaust fan control panel 1
Warmwell lower casing assembly
Warmwell top casing assembly
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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. 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.
2) If necessary, remove the inspection cover and
ensure the boiler flueways are clear. Ensure
secondary heat exchanger passages are clear and
clean. Re-fit the cover.
3) Adequate ventilation as per Section 7: Air
Supply (p10) 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. Ensure secondary heat
exchanger is purged of air.
5) The pipework and valve arrangement is installed
to Hamworthy Heating recommendations in such a
way that water flow rates will be in accordance with
Figure 2.2 (p4).
6) The gas supply pipework is clear of any loose
matter, tested for soundness and purged.
11.5 Boiler Checks Prior To Lighting
NOTE! Refer to Figure 2.2 (p4) for maximum gas
inlet pressure for normal operation. Information
relating to propane firing can be found in Appendix
‘A’ (p41).
NOTE! - All propane boilers are fitted with a low gas
pressure switch (set at 20mbar). Should the gas
supply pressure fall below this level, the boiler will
not operate.
11.0 COMMISSIONING AND TESTING
For general layout of boiler refer to Figure 11.0.
11.1 Electrical Installation
A suitably competent person MUST check wiring.
Normal supply required is 230 volts AC, single
phase, 50 Hz. An isolator correctly fused at 10A
should be sited close to the boiler.
Access to the controls is achieved by rotating the ¼
turn latch and removing the door. Connections to
the boiler should pass through the 3 x 20mm wiring
gland plate. If a single header pump kit is used then
this power source must be constant and not
switched by any time clock. The boiler is supplied
with a remote stop/start circuit for time clock
operation. Any other interlocks, i.e.
Pressurisation unit, BEM System should be
wired in series with the remote stop/start loop.
The site wiring terminal rail is marked with Live,
Neutral and Earth connections. See Figure 9.1
(p15) for details.
IMPORTANT READ THE WARNING NOTE
REGARDING EXTERNAL VOLTAGES.
The terminal rail is of the plug/socket type and can
be unplugged for wiring if required.
The main PCB is provided with four T rated fuses to
protect the following circuits – see Figure 11.1 (p26).
Main PCB F1 – T6.3A
Boiler controls F2 – T2A
Shunt Pump F3 – T2A
Sequencing Interface Module F4 – T2A
A schematic of the electrical control circuit(s) is shown in
Figure 9.1.
The fan motor is pre-wired to a plug/socket assembly
and must be connected to the controls assembly as
shown in Figure 9.1 (p15).
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.
11.3 Water Circulation System
For design see Section 8:WATER SYSTEM.
The system should be thoroughly flushed out with
cold water without the pump in position. Ensure all
the valves are open.
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Figure 11.0 - General Layout (Front View)
BURNER PRESSURE
TEST POINT
FLAME PROBE
HOT SURFACE
IGNITER
VIEWING PORT
BOILER INSULATION
BURNER MANIFOLD
GAS VALVE(S)
GAS COCK
GAS PIPE
GAS VALVE
GLAND PLATE
DROP DOWN
FASCIA
IGNITION SEQUENCE
CONTROLLER
MAIN PCB
SITE WIRING
TERMINAL PLUGS
CONTROLS HOUSING
TEMPERATURE LIMITER
(OVERHEAT THERMOSTAT)
CONTROL THERMOSTAT
FAN ASSEMBLY
SECONDARY HEAT
EXCHANGER ASSEMBLY
AND TRANSITION DUCT
EXHAUST FAN
CONTROLS PANEL
(Incl. Speed Controller
and Air Pressure Switches)
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Figure 11.1 Main PCB Layout
ISS.
LK13
HAMWORTHY HEATING LIMITED
AND PROVING SWITCH
FAN / LOW FIRE DAMPER
AND PROVING SWITCH
LK5
LK4
HIGH FIRE DAMPER
BOILER CONTROL PCB
CN2
CN1
SERIAL NO.
PCB MFR DATE
PCB MFR
PART NO. 563901
10 MAX
0 MIN
OFFSET
LOW FIRE
LK3
Lk1
Lk2
R21
Lk3
Lk4
Lk5
Lk13
Lk6
Lk9
Lk7
Lk12
F1
F2
F3
F4
Sw1
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8.3 For low gas pressure switch (Propane boilers)
cut LK9.
9) Ensure pressure switch sensing tubes are
correctly fitted, without twists or kinks. Refer to
Figure 2.2 (p4) for provisional (factory set) pressure
switch settings. Refer to Figure 11.5 (p28) for
pressure switch locations.
11.6 Procedure for Initial Lighting
Ensure gas service cock is in the "off" position.
Press the control thermostat knob to switch ‘on’ the
boiler. Press lockout button on fascia to re-set timer
(wait at least 15 seconds before pressing again if
lockout neon does not go out. After a delay the HSI
neon should illuminate on the fascia and the igniter
should be visible through the viewing port on the
burner front plate. As the gas service cock is
closed, the controls should go to lockout after
approximately 3 seconds (amber neon on fascia lit).
If the above occurs correctly, open service cock and
press reset button on fascia.
After a delay, the ignition should be visible and the
main gas valve should energise, lighting the main
burner. Turn the control thermostat to the required
flow temperature. NOTE! The multi-meter should
be reading at least 1µA.
11.7 Gas Pressure Adjustment and Combustion
Checks
After the boiler has operated for approximately 10
minutes, press the control thermostat knob to switch
‘off’ the boiler. Open the pressure test point screw
on the burner manifold and fit a manometer (suitable
for 30mbar - Natural Gas or 50mbar - Propane).
Check low fire (start rate) against pressure shown in
Figure 2.2 (p4) or Appendix ‘A’ (p41). If necessary
adjust low fire pressure (refer to Figure 11.7a p29
for relevant gas valve fitted).
Having checked the low fire pressure, carefully
adjust the differential (low fire offset) R21 (see
Figure 11.1 p26) between high and low fire (0 to 10°
C) on the main PCB. A recommended setting is 5°C.
Re-fit high/low plug connection CN16 to the main
PCB and check the high fire gas pressure against
that shown in Figure 2.2 (p4) or Appendix ‘A’ (p41).
If necessary adjust high fire governor to suit.
Occasionally this high fire adjustment can influence
the low fire (start rate), therefore remove plug
connection CN16 and check low fire pressure again.
Adjust if required. Repeat until low and high fire
pressures are as shown in Figure 2.2 (p4) or
Appendix ‘A’ (p41).
Cont: Page 31
1) Gas supply is connected but turned to the "off"
position. Any unions or fittings are correctly
tightened, test points are closed, burners correctly
positioned, injectors are in place (of correct size)
and tight and that the ignition and probe leads are
connected correctly. Ensure Hot Surface igniter and
sensing probe assembly are not cracked or broken.
2) Ensure electricity is connected, the gas valve
PCB connection is correctly located and that the
sensor and thermostat bulbs are fully inserted into
the boiler pocket. Reset temperature limiter by
firmly pressing pin (in controls housing.)
3) If a sequencing interface module is fitted to the
boiler control panel, locate and the hand auto switch
‘SW1’ on the boiler main PCB (refer to Figure 11.1
p26), and set it to the ‘hand’ position to override
operation of the sequencing interface module for the
purposes of commissioning.
4) Check setting of both temperature limiter and
control thermostat. The temperature limiter must be
set at 100°C from the factory unless otherwise
instructed. Set thermostat to required temperature.
5) Drop down fascia on the controls housing to
reveal access to the main PCB. Figure 9.1 (p15)
shows the correct location of incoming wires.
Remove the plug connection CN21 from the main
PCB and replace the link by inserting a multi-meter
set to read DC µA. Carefully remove high/low plug
connection CN16 from the main PCB, this will
ensure burner stays at start rate (low fire) when
fired.
6) The Warmwell fully automatic boiler utilises a
low fire start gas rate ignited by hot surface igniter
(HSI), see Figure 14.1. To ascertain which type of
gas valve is fitted and the method of low fire and
high fire adjustment, refer to Figure 11.7. You
should familiarise yourself with this procedure for
use later when required.
7) If a single header pipe kit is fitted, ensure that
the shunt pump is connected to the plug connection
CN13 on the main PCB. The run on timer is preset
to 5 minutes. Check that the fuse on the main PCB
is fitted and sound.
8) IMPORTANT:- PRIOR TO LIGHTING UP THE
BOILER, THE SAFETY LINKS ON THE MAIN PCB
MUST BE REMOVED AS DETAILED, TO ENSURE
SAFE OPERATION OF THE BOILER – REFER TO
FIGURE 11.1. THE LINKS MUST BE CAREFULLY
CUT USING A SMALL PAIR OF ELECTRICAL SIDE
CUTTERS AND THE RESULTANT LOOSE LINKS
MUST BE REMOVED FROM THE PCB SO AS NOT
TO CAUSE AN ELECTRICAL SHORT.
8.1 Check that LK2, LK3, LK4, LK5, LK6, LK10, &
LK13 have been factory removed.
8.2 For optional sequencing interface module
control cut LK7 & LK12.
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Figure 11.5 Pressure Sensing Tube / Fan Plug Assembly
TO POINT A
TO POINT B
VIEW OF FAN EXHAUST CONTROL PANEL
SIDE VIEW OF FAN PLENUM CHAMBER
A
B
FAN HOUSING & FLUE
DISCHARGE DUCT
FAN PLUG /SOCKET
ASSEMBLY - 7 WAY
AIR PRESSURE SENSING
TUBE CONNECTOR
TO PRESSURE
SWITCHES IN
CONTROL PANEL
(SEE BELOW)
LEFT HAND
SIDE PANEL
IMPORTANT!
ENSURE SENSING TUBE
CONNECTIONS ARE AS
DETAILED.
REF. CONNECTIONS
A & B
FAN
CAPACITOR
FAN SPEED CONTROLLER PCB
BLUE INDICATOR
SLEEVE
LOW FIRE
+-
HIGH FIRE
-+
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Figure 11.7a Diagram of Automatic Gas Valves
cross-head screw, whilst keeping the outer nut from
rotating. Turn the boiler off then on again and fine
trim the pressure.
Insert or make high fire link on terminals C3 and C4
(CN16); the boiler should now drive to high fire.
Replace protective cap on Hi/Lo gas valve.
Note! The low fire setting must always be set
last of all. The valves operation may be incorrect
if this omitted.
Note! It is also advisable to carry out this procedure
with all the boilers firing. The long-term reliability of
the ignition system may well be reduced unless this
procedure is carried out correctly.
ADJUSTMENT PROCEDURE.
Refer to Figure 2.2 to find the low fire/start and high
fire gas pressures for the boiler being fired.
Fit a manometer (suitable for 30mbar) onto manifold
test point.
Light the boiler, then remove the protective cover
from the Hi/Lo pressure regulator.
To adjust the high fire gas pressure, turn the outer
nut on the hi/lo pressure regulator.
To adjust low fire/start gas pressure, remove the link
between terminals C3 and C4 (CN16); nominally set
the low fire/start gas pressure by rotating the inner
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Figure 11.7b Diagram of ‘Hi’ Flow Gas Valve Assembly (Natural Gas Only)
WARMWELL 120 and 140kW Automatic
The 'Flowshare' gas valve assembly is designed to
pass the correct quantity of gas at the nominal inlet
pressure of 20mbar and a maximum inlet pressure
of 25mbar.
Refer to Figure 2.2 to find low fire/start and high fire
gas pressures for the boiler being fired.
Fit a manometer (suitable for 30mbar) onto gas
manifold pressure tapping point.
Light the boiler. Remove protective cap from the Hi/
Lo pressure regulator.
Turn the Hi/Lo valve high fire pressure regulator
(outer nut) clockwise until the pressure stops
increasing. Loosen Throttle locking nut (if fitted) and
rotate the throttle valve adjuster screw until the
manifold pressure is a approx. 0.5mbar greater than
the required high fire gas pressure.
Tighten the locking nut (if fitted) on the throttle
adjuster screw.
Turn the Hi/Lo valve high fire rate adjuster anticlockwise to fine trim the high fire pressure.
Refer to Figure 11.6a for procedure on how to adjust
valves for correct low fire/start gas pressures.
NOTE! Honeywell valves shown in diagram.
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connection CN21 from the main PCB), the boiler
should lockout after approximately one second.
Check that the flame has been extinguished.
Remove multi-meter and replace wire link to the
plug CN21. If a sequencing interface module is fitted
set the hand/auto switch ‘SW1’ on the boiler main
PCB (refer to Figure 11.1 p26) to the ‘auto’ position.
Wait at least 15 seconds before pressing re-set
button on fascia to re-set controller. After a waiting
period the boiler will light and run normally.
11.10 User’s Instructions
When the above is complete, the boiler owner 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. In
particular, care should be taken to ensure that the
discharge from the condensate trap, at the rear of
the appliance, is free from blockage. 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
The main PCB is fitted with neons to indicate correct
operation of the boiler functions – refer to Figure
12.1 (p32).
Should the control thermostat fail, causing an
overheat condition, the temperature limiter will trip
thus creating an immediate shutdown regardless of
firing mode. An overheat neon on the controls
fascia will indicate that this condition has occurred.
The door will have to be removed to permit access
to the temperature limiter re-set pin. If, after
pushing the pin in, the light on the fascia does not
go out and the boiler does not light up, it could be
that the boiler is still too hot, i.e. the control
thermostat has not re-set. 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.
The flame is under constant supervision by the
burner logic controller. This is accomplished by
measuring the flame's ability to rectify an AC
current. If the flame diminishes for whatever reason
and the rectified current drops below the controllers
minimum (0.7µA DC), the controller will induce a
non-volatile lockout which will require a manual reset (situated on the controls fascia) to re-start the
control sequence. See Figure 12.2 (p34/35) for
possible corrective scenarios.
Pressure switches are fitted to monitor the correct
operation of the induced draught fan fitted to the
Warmwell. It ensures sufficient air is pulled through
the boiler to facilitate correct combustion. The
For Natural Gas the gas pressure governor control
system is configured for a nominal gas inlet
pressure of 20mbar with a maximum inlet pressure
of 25mbar. The Warmwell 120 and 140 boiler is
fitted with a unique flow share gas valve
arrangement. Refer to Figure 11.7b (p30) to
establish method of adjustment of the by-pass
throttle arrangement. NOTE! The by-pass valve
throttle MUST only be used as a coarse adjuster,
the main control MUST always be accomplished by
the high/low control valve.
For Propane firing boilers, the nominal gas inlet
pressure is 37mbar, with a maximum inlet pressure
of 47mbar. 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. All Propane firing boilers are
fitted with a single gas valve providing high and low
control. Refer to Figure 11.7a (p29).
Remove manometer and close pressure test point.
Record all readings for future reference on relevant
commissioning sheet. Allow system to warm up
sufficiently to check operation of control thermostat.
A combustion check must be taken when first
commissioning the boiler. A plugged sample hole is
provided in the top of the stainless steel collector
hood. NOTE! Care should be exercised if the boiler
is firing as the flue can achieve temperatures which
can produce injury if touched.
Combustion figures for Natural Gas should be as
follows: -
CO
2 = 7-8% condensing or 8-9% non-condensing
(Dry flue gas).
CO = 0-50 ppm: however figure should not exceed
200 ppm under normal operating conditions.
Details of the flue gas composition relating to
propane firing can be found in Appendix ‘A’ (p41).
11.8 Temperature Limiter (Limit Thermostat)
Reset and test the operation of the temperature
limiter by firmly pressing the button (in the controls
fascia), 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. Removing plastic
cover (unscrewing) can achieve this if fitted. Undo
holding nut and withdraw into the controls housing.
Adjust if required and replace in reverse order to
above.
11.9 Safety Checks
To check for correct operation of the controller,
break the multi-meter µA circuit (remove plug
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Figure 12.1 Boiler Function Neons
ISS.
LK13
HAMWORTHY HEATING LIMITED
AND PROVING SWITCH
FAN / LOW FIRE DAMPER
AND PROVING SWITCH
LK5
LK4
HIGH FIRE DAMPER
BOILER CONTROL PCB
CN2
CN1
SERIAL NO.
PCB MFR DATE
PCB MFR
PART NO. 563901
10 MAX
0 MIN
OFFSET
LOW FI RE
LK3
F1
F2
F3
F4
NE8
NE12
NE10
NE7
NE1
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is important that all controls and safety features are
checked for correct operation. NOTE! Measuring
flue gas CO
2
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.
13.2 Before servicing the boiler, the following
procedure must be carried out: - WARNING: Isolate
the electrical supply and turn off the gas service
cock to the boiler module being serviced.
1) Remove the front casing door by using a
screwdriver to rotate the ¼ turn latch.
2) Turn off gas service cock, (fitted upstream of
gas control valve) and carefully drop down the
fascia of the controls housing.
3) Undo both screws on gas valve gland plate,
situated under controls assembly, and carefully
disconnect the plug from the PCB. Withdraw the
cable and plug assembly.
4) Disconnect igniter and probe leads carefully. A
protective boot will require pulling back to reveal the
sensing probe connector.
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 high/
low gas solenoid.
6) Carefully remove burner assembly by pulling
burner front plate. Check condition of igniter
assembly and probe for damage. Clean as
required. Check burner bars 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 rivets
holding it on to the front plate. A replacement
burner bar will be supplied with clinch nuts and
screws to fix onto the front plate.
13.3 The boiler flueways can now be cleaned as
follows:-
1) Carefully remove sloping front panel by pulling
both edges around the centre position. Remove the
top casing front panel secured by spring latches.
Insert a screwdriver into the slot in the 7 way plug
and socket assembly connected to the fan. The plug
can then be pulled away from the socket.
Disconnect the electrical connections from the main
PCB (CN1, CN2 & CN11), and carefully withdraw
the cables from the rear of the panel. Disconnect the
float switch cable via the push fit connector. Note
the relative positions and disconnect the flexible
hoses from the pressure switches. Remove the
exhaust fan control panel from the top side panels
control circuit is configured to establish a light/dark
check thereby ensuring the switch is open (no air)
before starting the fan. Once started the circuit then
checks that the switch has changed position (full air)
thus allowing the boiler to light and continue firing.
Prior to the ignition sequence starting, the fan has to
operate the air pressure switch and prove airflow.
With the thermostat calling for heat, neon NE7 on
the main PCB will be illuminated, indicating power to
the exhaust fan.
Once the fan is running, neon NE10 on the main
PCB will be illuminated – indicating that the low fire
airflow has been detected. A 20 second pre-purge
will commence, subsequent to which the green HSI
LED on the control panel fascia will illuminate. After
approximately 10 seconds the green Low Fire LED
on the control panel fascia will illuminate, indicating
the opening of the low fire gas valve. On ignition the
green HSI LED on the fascia will be extinguished.
Should there be a demand for hi fire, neon NE8 on
the main PCB will be illuminated, indicating the
changeover to the High Fire fan speed.
Subsequently, neon NE12 on the main PCB will be
illuminated, indicating that the High Fire airflow has
been detected. Simultaneously, the green High Fire
LED on the control panel fascia will illuminate. The
boiler should now be operating at High Fire.
A float switch is fitted to monitor the level in the
condense trap. Should the trap fail to discharge
condensate, the switch will operate and cause the
boiler to shut down. The condense trap should be
inspected regularly and cleaned out if necessary.
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. Refer to Appendix ‘A’ (p41) to check
operation of the low gas pressure switch.
12.2 Fault Finding Procedures
General fault finding is shown in Figure 12.2
(p34/35). If the boiler still cannot be operated
satisfactorily after following the chart, consult your
local office of Hamworthy Heating for assistance.
12.3 Possible Causes of Boiler Lockout
1) Ignition failure due to faulty igniter.
2) Ignition failure due to faulty gas valve.
3) No or low gas supply pressure.
4) No ignition due to faulty controller.
5) Ignition failure due to faulty damper mechanism.
6) Condensate trap blocked.
13.0 SERVICING
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
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Figure 12.2a Fault Finding Procedures
Initial Start Procedure
Is the fan running ?
Yes
Yes
Continued
Yes
Yes
Yes
Yes
Ye s
Yes
Yes
No
No
No
No
No
No
No
Is mains power lamp lit
On the fascia ?
Has the ignition
controller reset ?
Has the Low Fire Air
Pressure Switch proved ?
Neon N 10 illuminated on
main PCB.
E
Is there a glow at the HSI
probe ? Green neon on
fascia panel illuminated.
Is the temperature limiter
reset ? (Indicated on the
fascia as Overheat)
Check the operation of
and the Low Gas
Press
Switch (LPG only) .
the
Condense Level
Switch
Is there a demand from the
thermostat ?
Is neon Ne7 illuminated on
the main PCB ?
Is remote control link
16 (1-2) secure ?CN
Replace ignition
controller
Check fuse(s) time clock
on/off switch etc.
Re-set ignition
controller (Lockout
button on fascia).
Check thermostats.
Check air pressure
switches, sensing pipes
and pressure switch
connecting tubes.
Check that the probe and
electrode connections are
secure and sound.
Re-set temperature
limiter (Limit Stat)
Is 230V present at pins
1 & 2 (C 11) and pins
1 & 3 (C 10) on main PCB.
N
N
Check and turn
thermostat to maximum.
Check connections to
exhaust panel and fan
motor
Check and close
remote circuit.
No
No
No
Yes
.
Float
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Figure 12.2b Fault Finding Procedures (Cont.)
Does the burner light at Low
Fire ?
Is there a demand for High
Fire ? Neon N8 illuminated
on main PCB.
E
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
No
No
Continued
No
No
No
No
No
No
Is the flame signal from the
probe above the minimum
(0.7uA) ?
Is there power at the
gas valve ?
Is there a demend from
the thermostat ?
Turn the thermostat to
maximum.
Replace the gas valve
Does the boiler operate at
High fire ?
Is the High/Low link fitted,
terminals (3 - 4)CN16 ?
Has High Fire airflow been
detected ? Neon N12
illuminated on main PCB.
E
Replace the gas valve
Is there power at the High
Fire gas valve solenoid ?
Check the probe wiring
Check the gas valve
plug and wiring
Check C16 terminal
wiring. Check B.E.M.S
load requirements
N
Check gas valve plug and
wiring to main PCB Cn12.
Check High Fire Air
Pressure Switch,
electrical connections and
sensing tubes.
Temperature control circuit
faulty
Boiler at high fire but
cycles on/off rapidly.
Yes
Poor water circulation
Yes
Check/replace temperature
sensor and/or boiler PCB
Check/replace pump, bleed
trapped air from the system
Yes
Insufficient water circulation
Boiler at high fire but
overheats while system
remains cool
Yes
Check/replace pump, bleed
air from system
Yes
Temperature control set
too high
Insufficient water circulation
Boiler at high fire but
operates noisily.
Yes
Adjust temperature control
to a lower setting
Check/replace pump, bleed
air from the system
Yes
Yes
Temperature control circuit
faulty
Check/replace temperature
sensor and/or boiler PCB
Yes
Scale build up in boiler
waterways.
Descale boiler
Yes
Gas control valve faulty
Check/replace gas valve
Yes
Boiler gas setting pressure
incorrect
Check/adjust gas pressure
at manifold
Yes
No
No
No
Boiler operates
satisfactorily
35
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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 recommended in Figure 14.1 (p37).
14.2 Pressure Switch
Two pressure switches are used to monitor the
induced draught fan at Hi/Lo operation. The
pressure switches are mounted on the exhaust fan
control panel mounted on the upper casing, and are
identified - HI/LO.
Remove the top casing front panel secured by
spring latches. Remove the pressure switch cover,
note and disconnect the electrical connections –
See Figure 11.5 (p28). Note and remove the flexible
hoses from the switch, undo the 2 screws attaching
the switch to the control panel and withdraw the
switch.
Replace the switch in the reverse order and set to
the required setting - see Figure 2.2 (p4). Seal the
adjuster once set.
14.3 Control Thermostat Renewal.
The thermostat consists of a potentiometer and
remote sensor. Part Nos. 563901258 & 533901350
NOTE! Record existing temperature setting of
thermostat for reference before removal.
Prise the top panel from the side panels (secured by
spring latches) and lift boiler top panel to reveal
thermostat pocket. Carefully remove thermostat
phials. Drop down fascia to reveal controls section.
Disconnect the sensor cable plug (CN23) from the
PCB and remove the sensor. Prise out the indicator
disc from the centre of the control knob and loosen
the collet nut securing the knob to the shaft. Pull off
the control knob and undo the securing nut on the
central spindle. Disconnect the potentiometer cable
plug (CN14) from the PCB and remove the
potentiometer. Replace components in reverse
order ensuring that the sensor is correctly located
within the pocket. Do not force the bulb into the
pocket. When replacing the potentiometer knob,
rotate the shaft fully anti-clockwise and fit the knob
with the locating pip aligned with the 20°C
graduation. Fit the indicator disc aligning the mark
with the graduation. Close fascia and re-fit top panel
correctly.
Run the boiler and turn the thermostat up and down
and ‘on’ and ‘off’ to check for correct operation. Set
thermostat to previously noted setting.
14.4 Temperature Limiter (Limit Stat) Renewal
Part No. 339011044 or 533901179
The temperature limiter renewal procedure follows
(secured by 4 screws). This will give access to the
transition duct cover. Remove nuts to gain access to
the flueways (insulation jacket should be carefully
prised open to reveal duct).
2) The boiler flueways are now exposed and can
be brushed through diagonally in both directions to
remove deposits from the cast iron finned surfaces.
Check secondary heat exchanger surfaces and
wash if required. Re-assemble the boiler in the
reverse order to that shown above. Ensure a new
seal is fitted to the cover to ensure a gas tight seal.
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. Also
clean the area under the reflector before re-placing
it in its correct location. Re-assemble the burner bar
assembly, ensuring correct location on the rear
support bracket.
3) 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.
4) Take gas pressure and exhaust gas readings
and compare with Figure 2.2 (p4) for Natural Gas or
Appendix ‘A’ (p41) for LPG Propane, adjust as
required. Ensure no gas leaks are evident from the
gas connections, see Figure 5.6 (p9) for procedure.
Check thermostat settings and adjust if required.
5) Re-fit door and tidy floor around boiler as
necessary.
6) Check the operation of the condense trap and
clean if necessary by removing the trap and flushing
through with fresh water.
14.0 REPLACEMENT OF FAILED COMPONENTS
There are a number of components listed below
which can be replaced simply and quickly by
following the given procedure. In each case
carrying out the appropriate part of the
commissioning procedure must check the operation
of each replaced component. See Section 11.0:
Commissioning and Testing (p24).
NOTE: Isolate electrical supply to the boiler and
turn off the gas supply before removing controls
cover and commencing any servicing or
component exchange procedure.
14.1 Igniter Assembly
Reference to Figure 11.0 (p25) shows position of
igniter assembly. To remove assembly disconnect
the plug/socket on the supply lead and remove the
screw securing the igniter to the burner front panel.
Figure 14.1 (p37) shows diagram of igniter
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Figure 14.1 Diagram of Hot Surface Igniter and Sensing Probe Assembly
37
6.0mm
Viewing Port
72mm REF
79mm REF
Flame Probe Electrode
(533805014)
Hot Surface Igniter Assembly
(563801010)
Burner Bar
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same direction as the arrow on the bottom of the
valve. Refit all external components. 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 Section 5.6 (p7) if necessary for valve
integrity check procedure.
5) Re-light the boiler using instructions on the
inside of the door. Check and adjust, the low fire/
start gas and high fire gas pressures, refer to Figure
2.2 (p4) for Natural Gas or Appendix ‘A’ (p41) propane firing, for correct settings. Re-set throttle
valve position, if replaced, see Figure 11.7b (p30)
for procedure. If necessary, refer to Section 11.4
Commissioning the Boiler (p24), for correct
procedures.
14.6 Fan Assembly
Ensure power supply is isolated. Access to the rear
of the boiler is required to service this item.
NOTE! The 7 way plug and socket assembly
requires a 'tool' to disengage the locking
mechanism. A screwdriver should be inserted into
the slot in the plug and socket assembly. The plug
can then be pulled away from the socket.
Undo the 4 nuts holding the motor assembly to the
fan housing and remove complete motor and
impeller unit.
Due to the aggressive media being handled, it is
recommended that the complete fan motor and
impeller assembly be replaced if a motor has failed.
If required clean fan impeller taking care not to bend
or distort assembly.
Re-assemble unit in reverse order of dis-assembly.
NOTE! All models utilise a capacitor start and run
motor. Before replacing motor due to possible
failure, ensure the capacitor is functioning correctly
(located in the exhaust fan control panel).
Ensure all screws are tightened and re-fit plug/
socket assembly.
Periodically check the fan volute, which is inside the
plenum chamber. This will require removal of the
stainless steel plenum chamber at the rear of the
boiler. Ensure flue is supported before removal.
The fan volute is fitted internally and fixed to the
plenum by the pressure tapping connection
assembly. NOTE! Connect pressure-sensing tubes
to their relevant positions to achieve correct
operation of the pressure switches.
See Figure 11.5 (p28) for tube/switch assembly
layout.
that of the control thermostat with some minor
differences. These are as below: -
Remove the 'push on' spade connections from the
temperature limiter body noting position of coloured
cables. Remove plastic cover (if fitted) and unscrew
holding nut to detach temperature limiter from
housing. Gently feed the capillary back through the
controls bulkhead. Re-set temperature limiter to
100°C. Check the operation of the device by
carefully applying a heat source to the bulb. Reassemble temperature limiter into controls housing
ensuring correct cable notation. Refer to the
thermostat diagram if terminal identification differs
from those given in Figure 9.1 (p15).
14.5 Main Gas Valve.
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.
NOTE! Only gas valves with an identical Type No.
may be used for replacement. Please contact
Hamworthy Heating spares Dept. for further
information.
Various types and manufacturers of gas valves are
used. Refer to Figure 11.7a (p29) for particular
valve(s) fitted.
1) Ensure power and gas supplies are isolated.
2) Remove the gas valve wiring plugs from the gas
valve(s) – secured by M3 screws through the plug
body. NOTE! The position of the relevant electrical
cables should be noted, especially on the 95 &
120kW boilers. 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.
3) Remove the gas valve by unscrewing cap head
screws holding valve to pipework. NOTE! The
position of the relevant electrical cables should be
noted, especially on the Warmwell 140 boiler. When
replacing the gas valve, it is advisable to renew the
`O` ring seals sealing both ends. See SECTION
15.0 Recommended Spares for Part Nos. Note
that the `O` ring fitted to the 60 & 95kW (Natural
Gas) and all propane models, is different to that
used on the 140kW (Natural Gas) model. Do not
over tighten cap head screws in gas valve body.
Ensure electrical plugs are firmly and correctly
located and holding screws are tightened.
4) Replace assembly ensuring correct orientation
of the gas valve. Ensure that the gas flow is in the
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from the rear of the panel. Disconnect the float
switch cable via the push fit connector. Note the
relative positions and disconnect the flexible hoses
from the pressure switches. Remove the exhaust
fan control panel from the top side panels (secured
by 4 screws). Remove the fan speed controller
cover (secured by 2 screws)
Note the positions of the electrical connections on
the PCB and carefully disconnect the leads from the
screw terminal rail - See Figure 9.1 (p15). From the
rear of the exhaust fan control panel, remove the 4
screws securing the PCB. Replace components in
reverse order. NOTE! The replacement speed
controller is factory set !
Re-light the boiler using instructions on the inside of
the door. and check for correct operation at both
High and Low fire. See Figure 2.2 (p4) for correct
settings. If necessary, refer to Section 11.4
Commissioning the Boiler (p24), for correct
procedures.
Re-fit the fan assembly ensuring the gasket
between the fan fixing plate and plenum is replaced
if damaged. Spin the fan to ensure the impeller is
free. Ensure the fan plug and socket assembly is
securely fitted and locked together. Re-light the
boiler and check for correct operation of pressure
switches. See Figure 2.2 (p4) for correct settings.
14.7 Fan Speed Controller
Ensure power supply is isolated. Remove the top
casing front panel secured by spring latches. Insert
a screwdriver into the slot in the 7 way plug and
socket assembly connected to the fan. The plug can
then be pulled away from the socket. Disconnect the
electrical connections from the main PCB (CN1,
CN2 & CN11), and carefully withdraw the cables
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15.0 RECOMMENDED SPARES
Please Note! To ensure the correct spare parts are despatched by our spares department, 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
Main fuse (F1) on PCB. – T6.3A ............................................................................................................... 533901221
PCB fuses (F2, F3 & F4) – T2A ................................................................................................................ 533922002
Sequencing Interface Module PCB Fuse - T250mA ................................................................................. 533922008
Relays (RL14 & RL15) .............................................................................................................................. 533901204
Flame sensing probe lead ......................................................................................................................... 533901259
Main PCB .................................................................................................................................................. 563901293
Fascia PCB ............................................................................................................................................... 563901237
Thermostat sensor (incl. 600mm long leads) ............................................................................................ 533901350
Potentiometer (incl. PCB harness) ............................................................................................................ 563901258
Ignition Sequence Controller ..................................................................................................................... 533901344
Hours Run Meter ....................................................................................................................................... 563901273
Fan speed controller ................................................................................................................................. 563901296
Fan Assembly (Complete) ......................................................................................................................... 533901229
Pressure Switch (High & Low Fire) ........................................................................................................... 747146550
Float Switch ............................................................................................................................................... 563901327
Sequencing Interface Module ................................................................................................................... 533901421
Mechanical Items
Single Burner Bar ...................................................................................................................................... 533301003
Heat Exchanger Nipple ............................................................................................................................. 330502033
Injector Copper Washer ............................................................................................................................ 339008347
Gas Valve 'O' Ring Joint (60 & 95kW only) ............................................................................................... 742111245
Gas Valve 'O' Ring Joint (140kW only) ..................................................................................................... 742122069
HSi Igniter ................................................................................................................................................. 563801010
Flame Probe .............................................................................................................................................. 533805014
Temperature Limiter (Imit) ......................................................................................................................... 533901179
Temperature Limiter (L & G) ..................................................................................................................... 339011044
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 Limited
Fleets Corner
Poole
Dorset
BH17 0HH
Phone Number ............................................................ 01202 662500
Fax Number ................................................................. 01202 665111
Service ......................................................................... 01202 662555
Spares .......................................................................... 01202 662525
Technical ...................................................... 01202 662527 / 662528
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Appendix A Warmwell Automatic Ignition
INFORMATION RELATING TO PROPANE FIRING
NOTE:LPG FUELS - IT IS STRONGLY RECOMMENDED THAT, ON LPG INSTALLATIONS, GAS DETECTION
EQUIPMENT IS 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
The operation of the Warmwell range of boilers on
LPG-Propane (3
rd
family) I3P is similar to that on
Natural Gas (2
nd
family) I2H and the design and
installation details described in the main body of the
installer’s guide should be followed. There are
however, differences in the construction and setting
of the propane fired boiler which are as follows: -
a) The main gas injectors (located in the gas
manifold) are replaced with those detailed the
Performance and General Data Information table
below.
b) The nominal gas inlet pressure for propane
should be 37mbar.
c) Relevant labels are replaced to indicate the
appropriate gas for which the boiler is set up to fire.
The following tables and paragraphs, using the
same numbering system as the main installer’s
guide, highlight the different values and procedures
to be used when firing propane, and should be used
in conjunction with the Main Installer’s Guide.
Figure 2.2 Performance and General Data Information
* NOTE! Flue gas volumes are based on a gross flue gas temperature of 15°C at 1013.25mbar
GENERAL DATA 60 95 120
Boiler Input High Fire - kW (Gross) 63.4 101.0 N/A
Boiler Input High Fire - kW (Nett) 58.4 93.0 N/A
Boiler Input Low Fire - kW (Gross) 30.3 42.3 N/A
Boiler Input Low Fire - kW (Nett) 27.8 39.0 N/A
Boiler Output High Fire (Condensing) - kW 59.0 93.0 N/A
Boiler Output High Fire (Non-Condensing) - kW 54.0 86.0 N/A
Boiler Output Low Fire (Condensing) - kW
28.1 38.9 N/A
Boiler Output Low Fire (Non-Condensing) - kW
25.8 36.0 N/A
FLUE DATA
Approx. Flue Gas Temperature (Condensing) - °C 45 50 N/A
Approx. Flue Gas Temperature (Non-Condensing) - °C 60 70 N/A
Approx. Flue Gas Volume @ 9.0% CO2 - m3/h* 85 125 N/A
CO2 - %
8.5 9.5 N/A
GAS DATA
Nominal Gas Inlet Pressure - mbar 37
Maximum Gas Inlet Pressure - mbar
Gas Manifold Pressure High Fire - mbar 15.0 17.0 N/A
Gas Manifold Pressure Low Fire - mbar 4.0 3.0 N/A
Gas Flow Rate High Fire - m3/h
- kg/h
2.4
4.6
3.8
7.2
N/A
Injector Marking / Dia. - mm 2.3 2.9 N/A
45
Pressure Switch Setting (Normal) High Fire - mbar 1.8 2.4 N/A
Pressure Switch Setting (Normal) Low Fire - mbar 1.5 1.5 N/A
140
150.0
138.1
49.8
45.8
135.0
128.0
44.8
42.4
50
70
201
8.5
24.0
2.5
3.0
0.6
5.7
10.7
2.9
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Gas Pressure Switch Location
Key: I - Gas Pressure Switch
II - Main Gas Valve
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
MECHANICAL ITEMS PART No.
Low Gas Pressure Switch................... 339009477
11.5 BOILER CHECKS PRIOR TO LIGHTING
IMPORTANT!
Check that link LK9 has been removed from the
main PCB. Refer to Figure 11.1 (p26) and Section
11.4 (p24).
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
across terminals ‘C & NO’ - to measure circuit
continuity.
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-meter.
Turn ‘OFF’ the gas supply and undo the pressure
test point on the gas valve inlet and allow the gas
pressure to fall. The switch should operate at
approximately 20mbar - noted on the multi-meter.
11.5.1 Gas Pressure Adjustment
After approximately 30 minutes of normal firing,
connecting a manometer to test point on the
manifold should check the manifold gas pressure.
Minor adjustments to the appliance governor may
be necessary to correct for site gas pressure
conditions.
NOTE: The above is a first order check. Final
setting must be made using a gas meter.
11.5.2 Combustion Checks
A flue gas sampling point is provided in the front
boiler casing (see Figure 11.0 p25). To check
combustion take a flue gas sample from each
module test point and for reference CO
2
measurements should be between 8.0% and 11.5%
or 9.0 to 4.0% O
2
(dependant upon model). Normal
CO levels should not exceed 200ppm.
NOTE: All the above measurements refer to dry
flue gas samples.
I
II
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NOTES:
INSTALLER SITE ADDRESS
BOILER TYPE BOILER SIZE(S) UNIT NO(S). SERIAL NO(S). FLUE
DATE OF COMMISSIONING:
USEFUL USER INFORMATION
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NOTES:
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Notes
Page 52
Poole Office
Hamworthy Heating Limited
Fleets Corner, Poole, Dorset BH17 0HH England
Main switchboard tel: 01202 662500
Technical enquiries 01202 662527/662528 01202 665111
Spare parts 01202 662525 01202 665111
Service department 01202 662555 01202 662522
Birmingham Office
Hamworthy Heating Limited
Shady Lane, Great Barr, Birmingham B44 9ER
Main switchboard tel: 0121 360 7000 fax: 0121 325 2309
General enquiries 0121 360 7000
• flue components
• packaged fan dilution systems
• bespoke flue components
• bespoke flue systems
• design and installation
Customer Services
Associate Companies, Offices and Agents throughout the World.
Hamworthy reserves the right to make changes and improvements which may necessitate alteration to the specification without prior notice.
Connect direct
Direct Dial Telephone and Fax Numbers
Direct Email Addresses
Hamworthy Heating Accredited Agents
Website
www.hamworthy-heating.com
• boilers
• controllers
• water heaters
• pressurisation sets
North West England
Gillies Modular Services
210-218 New Chester Road, Birkenhead, Merseyside L41 9BG
tel: 0151 666 1030 fax: 0151 647 8101
Scotland
McDowall Modular Services
14-46 Lomond Street, Glasgow, Scotland G22 6JD
tel: 0141 336 8795 fax: 0141 336 8954
Southern Ireland
HEVAC Limited
Naas Road, Dublin 12, Ireland
tel: 00 3531 141 91919 fax: 00 3531 145 84806
Northern Ireland
HVAC Supplies Limited
Unit 2, Antrim Line Business Park, Sentry Lane, Newtownabbey BT36 8XX
tel: 02890 849826 fax: 02890 847443
North East England
Allison Heating Products
17 Beech Road, South Shields, Tyne & Wear NE33 2QH
tel: 0191 455 7898 fax: 0191 455 7899
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