Hamworthy Purewell, Installation, Commisioning And Maintenance Instructions

Page 1: ...OMATIC IGNITION CONTROLS Standard Draught Diverter or Low Line Draught Diverter Purewell Gas Fired Modular Boiler Systems NATURAL GAS I 2 H LPG PROPANE I3P IMPORTANT NOTE THESE INSTRUCTIONS MUST BE READ AND UNDERSTOOD BEFORE INSTALLING COMMISSIONING OPERATING OR SERVICING EQUIPMENT Homepage Register Contents ...

Page 2: ...ctive parts but does not include labour When the equipment is commissioned and routinely maintained by Hamworthy Heating under a Service Maintenance Agreement then the warranty terms will cover both parts and labour MAINTENANCE AGREEMENTS 01202 662555 Regular routine servicing by Hamworthy Heating s engineers ensures trouble free operation and optimum efficiency The frequency of visits required is...

Page 3: ... UNDERSTOOD BEFOREATTEMPTING TO INSTALL COMMISSION OR OPERATE THIS UNIT THE PUREWELL BOILER IS INTENDED FOR USE AS A COMMERCIALAPPLIANCE AND IS NOT CERTIFIED FOR USE IN DOMESTIC APPLICATIONS OR HABITABLE AREAS THIS BOILER IS 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...

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Page 5: ...tem Leak Check 6 0 FLUE SYSTEM 5 6 1 General Requirements 6 2 Design Waste Gas Volume and Temperature 6 3 Flue Condensation 6 4 Materials 6 5 Disconnection 6 6 Flue Discharge 6 7 Surface Temperature 6 8 Flue System Location 7 0 AIR SUPPLY 9 7 1 Air Supply by Natural Ventilation 7 2 Air Supply by Mechanical Ventilation 8 0 WATER CIRCULATION SYSTEM 9 8 1 General 8 2 Pressure Relief Valve Safety Valv...

Page 6: ...NENTS 17 15 0 RECOMMENDED SPARES 19 APPENDIX A INFORMATION RELATING TO PROPANE FIRING 32 FIGURES PAGE Figure No 1 Performance and General Data 2 Figure No 2 Recommended minimum water flow rates 3 Figure No 3 Gas valve integrity check 5 Figure No 4 Mechanical ventilation flow rates 6 Figure No 5 Heat Exchanger Insulation Fitting Instructions 10 Figure No 6 Gas Pipe Fitting Instructions 10 11 Figure...

Page 7: ...imum working pressure of the boiler as given in Section 2 TECHNICAL DATA Consult Hamworthy Heating Technical Department for help or assistance if in doubt 1 5 The Purewell boiler is not suitable for direct connection to domestic hot water supplies or gravity fed heating systems 1 6 The Purewell boiler can be installed with either reverse return water flow layout or with single pipe header layout S...

Page 8: ...cution 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 IEE Regulations and the byelaws of the local water undertaking Figure No 1 Performance and General Data Information NOTE Flue gas volumes are based on a gross flue gas temperature of 100 C at 1013mbar This is consid...

Page 9: ...s from the above references are emphasized since failure to comply with these requirements will almost certainly result in an unsatisfactory installation 3 2 Feed water Quality 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 re...

Page 10: ...equately 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 Further details regarding boiler location are given in BS 6644 5 0 GAS SUPPLY 5 1 Service Pipes The local gas region must be consulted at the installation planning stag...

Page 11: ...avoid compression of the draught diverter and enable its removal for boiler cleaning 4 Boilers should be located as near the chimney as possible the nearest being not more than 2m 6ft away 5 The flue system should be designed to achieve a negative suction at all times at the draught diverter outlet on all modules in a bank For optimum performance draught conditions should be between 0 05 to 0 125 ...

Page 12: ...ny other appliance 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 b...

Page 13: ...ised hot water systems 8 3 Open Vent and Cold Feed Pipe See BS 6644 for further information Every boiler or group of boilers should have an open vent pipe and cold feed pipe installed between the boiler and the first water isolating valve The minimum bore mm of these pipes per installation is as follows The vent pipe must rise continually it must not be valved except by a design which when closed ...

Page 14: ... Part 1 ISO 4126 for information See also BS 6880 Part 1 for design considerations 8 12 Modular Boiler Control Schemes For Modular applications Hamworthy Heating can supply a unique boiler management control system called the Marshall This system comprises a master control unit which houses the main interface processor and dependent on the number of boilers a slave unit for each of the other boile...

Page 15: ...nd the boiler slid into position 2 Casing including all screws fasteners etc to permit site assembly Instructions are included in each box to show method of assembly Two sizes are manufactured these are Small casing for boilers up to 80kW NOTE P70 L L utilises larger casing large casing for boilers from 95kW to 120kW NOTE When installing a multi casing set the spacing plates must be used to correc...

Page 16: ...Ensure gas pipe bracket is clear and unobstructed Figure No 5c Ensure combustion air passages are unobstructed when fully fitted 10 3 Gas Pipe Fitting Instructions With reference to Figure No 6a Remove half union and gas valve from gas train Ensure gas valve manifold bracket does not suffer undue stress movement Affix half union and gas valve assembly to gas pipe as shown using proprietary sealing...

Page 17: ...e gas 10 2 3 The top panel will require protecting to ensure no damage occurs to the plastic coating during subsequent site assembly of other components It is important for service requirements that the flue system is fully self supporting Check the flue and chimney are clear from obstruction 10 5 Gas Connection The Purewell boiler is supplied with a gas pipe which when assembled exits the casing ...

Page 18: ...line only 5 Attach side panels to the basket using items 3 12 13 and 14 Attach back panel DO NOT FULLY TIGHTEN SCREWS 6 Locate the control panel and fit using No 8 x 1 2 self tapping screws item 5 7 Locate the top panel and fit the strikers item 2 NOTE L L fit all four D D two at rear only Ensure the blade is fitted as shown Fit the U nuts to the top panel Place the top panel in position and pass ...

Page 19: ...HAMWORTHY HEATING LTD PUREWELL AUTOMATIC IGNITION 500001035 G 13 Figure No 7a Exploded View of Casing Set ...

Page 20: ...ion any boiler ensure that personnel involved are aware of what action is about to be taken and begin by making the following checks 1 Flueway passages to chimney are clear 2a Standard Diverter models If necessary remove the flue hood and baffle not fitted to the 120kW boiler to ensure the boiler flueways are clear Reposition the gas baffle ensuring that it is laying flat on the top section Re fit...

Page 21: ...a manometer suitable for 30mbar Natural Gas or 50mbar Propane Check low fire start rate against pressure shown in Figure No 1 or Appendix A If necessary adjust low fire pressure refer to Figure No 15 for relevant gas valve fitted Replace high fire link carefully to drive valve system up to high fire Check gas pressure against that shown in Figure No 1 or Appendix A If necessary adjust high fire go...

Page 22: ... made to ascertain the cause See Figure No 17 for possible corrective scenarios 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 12 2 Fault Finding Procedures General fault finding is shown in Figure No 17 If the boiler still cannot be operated satisfactorily after following the chart...

Page 23: ...adings and compare with Figure No 1 or for propane firing refer to Appendix A adjust as required Ensure no gas leaks are evident from the gas connections see Figure No 3 for procedure Check thermostat settings and adjust if required Re fit door and tidy floor around boiler as necessary 14 0 REPLACEMENT OF FAILED COMPONENTS There are a number of components listed below which can be replaced simply ...

Page 24: ...d 2 Remove the gas valve wiring plug from the socket in the controls housing by un doing both screws and pulling firmly downwards 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 relevan...

Page 25: ...n 533901030 Red Neon 533901029 Reset button 533901132 Hours Run Meter 533901067 Ignition Sequence Controller 533901169 230 Volt VFC Single Pole Relay 533901204 Mechanical Items Single Burner Bar 533301003 Heat Exchanger Nipple 330502033 Flue hood thermoseal Yarn 10mm Dia 331299233 Injector Copper Washer 339008347 Gas Valve O Ring Joint 40 80kW only 742111245 Gas Valve O Ring Joint 95 120kW only 74...

Page 26: ...HAMWORTHY HEATING LTD PUREWELL AUTOMATIC IGNITION 500001035 G 20 Figure No 8 Boiler Installation Typical Key t Thermometer or sensor p Pressure Gauge ...

Page 27: ... IGNITION 500001035 G 21 Figure No 9 Boiler Dimensions Clearances NOTE 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 ...

Page 28: ...HAMWORTHY HEATING LTD PUREWELL AUTOMATIC IGNITION 500001035 G 22 Figure No 10 General Layout Front View ...

Page 29: ...ll produce approx 1mbar pressure loss This table must be used in conjunction with losses of various fittings fitted in the gas line shown below For example 2 Purewell 120kW Boilers being fed by 21 2 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 ...

Page 30: ...lt free contact s is 3 Amperes Resistive WARNING External voltage MUST NOT be applied to remote stop start terminals 3 4 or high low control loop terminals C3 C4 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 ...

Page 31: ...HAMWORTHY HEATING LTD PUREWELL AUTOMATIC IGNITION 500001035 G 25 Figure No 13 Standard Automatic Wiring Diagram Schematic ...

Page 32: ...HAMWORTHY HEATING LTD PUREWELL AUTOMATIC IGNITION 500001035 G 26 Figure No 13a Additional Wiring Schematic for Models Fitted with Pektron 0459 Series Ignition Controls ...

Page 33: ...HAMWORTHY HEATING LTD PUREWELL AUTOMATIC IGNITION 500001035 G 27 Figure No 14 Diagram of Igniter Electrode Probe Assembly ...

Page 34: ...t gas pressure remove the link between terminals C3 and C4 nominally set the low fire start gas pressure by rotating the inner 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 the boiler should now drive to high fire Replace protective cap on Hi Lo gas valve Note The low fir...

Page 35: ...to 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 Ti...

Page 36: ...HAMWORTHY HEATING LTD PUREWELL AUTOMATIC IGNITION 500001035 G 30 Figure No 17 Fault Finding Procedures Automatic Only ...

Page 37: ...HAMWORTHY HEATING LTD PUREWELL AUTOMATIC IGNITION 500001035 G 31 Figure No 17a Fault Finding Procedures Automatic Only Cont ...

Page 38: ...he 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 Performance and General Data Information 11 5 BOILER CHECKS PRIOR TO LIGHTING Ensure that the gas supply is connected but turned to...

Page 39: ... and 11 5 or 9 0 to 4 0 O2 dependant upon model Normal CO levels should not exceed 200ppm NOTE All the above measurements refer to dry flue gas samples Gas Pressure Switch Location Key I Gas Pressure Switch II Main Gas Valves Gas Pressure Switch Wiring Schematic Gas Pressure Switch Adjustment With the cover removed turn the M3 nut clockwise to increase the set point and vice versa Seal the adjuste...

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Page 41: ...0 218 New Chester Road 92 94 Dargan Crescent Birkenhead Duncrue Industrial Estate Merseyside L41 9BG Belfast BT3 9JP Tel 0151 666 1030 Tel 01232 777788 Fax 0151 647 8101 Fax 01232 776865 North East England Southern Ireland Allison Heating Products HEVAC Limited 17 Beach Road 70 72 Lower Dorset Street South Shields Dublin 1 Ireland Tyne Wear NE33 2QH Tel 003531 830 1211 Tel 0191 455 7898 Fax 003531...

Page 42: ...d liaise individual delivery arrangements 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 Please contact our spares team providing details of product type serial number model and part requirements wherever possible SERVICE DEPARTMENT 01202 662555 At Hamworthy Heating we employ ...