Hamworthy Purewell Variheat mk2 70c Installation, Commissioning And Servicing Instructions
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Hamworthy Purewell Variheat mk2 70c Installation, Commissioning And Servicing Instructions

Cast iron, pre-mix, condensing, modular boilers with automatic ignition for heating and domestic hot water installations, natural gas i2h
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Purewell Variheat mk2 c Boilers
Cast Iron, Pre-mix, Condensing, Modular Boilers with
Automatic Ignition for Heating and Domestic Hot Water
Installations
Installation, Commissioning
and Servicing Instructions
MODELS - 70c, 95c, 110c, 140c & 180c
I
NATURAL GAS
2H
IMPORTANT NOTE
THESE INSTRUCTIONS MUST BE READ
AND UNDERSTOOD BEFORE INSTALLING,
COMMISSIONING, OPERATING OR
SERVICING EQUIPMENT

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Summary of Contents for Hamworthy Purewell Variheat mk2 70c

  • Page 1 Purewell Variheat mk2 c Boilers Cast Iron, Pre-mix, Condensing, Modular Boilers with Automatic Ignition for Heating and Domestic Hot Water Installations Installation, Commissioning and Servicing Instructions MODELS - 70c, 95c, 110c, 140c & 180c NATURAL GAS IMPORTANT NOTE THESE INSTRUCTIONS MUST BE READ AND UNDERSTOOD BEFORE INSTALLING, COMMISSIONING, OPERATING OR SERVICING EQUIPMENT...
  • Page 2 Site Assembly Hamworthy offer a service if site assembly for many of our products where plant room access is restricted. Using our trained staff we offer a high quality of build and assurance of a boiler built and tested by the manufacturer.
  • Page 3 BEFORE FIRING BOILER. COUNTRY OF DESTINATION : UNITED KINGDOM & REPUBLIC OF IRELAND THIS BOILER COMPLIES WITH ALL RELEVANT EUROPEAN DIRECTIVES. PRODUCT IDENTIFICATION No. 86CN70 PUBLICATION NO. 218612 ISSUE ‘A03’ 12/2018 Page HAMWORTHY HEATING LTD PUREWELL Variheat mk2 218612 A03...

  • Page 4: Table Of Contents

    SERVICING ............................26 11.0 REPLACEMENT OF FAILED COMPONENTS ................28 11.1 Igniter and Flame Probe Assembly 11.2 Temperature Limiter 11.3 Main Gas Valve 11.4 Combustion Fan 12.0 RECOMMENDED SPARES ......................37 Page HAMWORTHY HEATING LTD PUREWELL Variheat mk2 218612 A03...
  • Page 5 GAS DATA ..........................38 APPENDIX B ELECTRICAL CONNECTIONS AND CONTROLS ............... 39 APPENDIX C FLUE DATA ........................... 41 APPENDIX D VENTILATION........................44 APPENDIX E WATER DATA ........................45 APPENDIX F ADDITIONAL KITS ........................ 50 Page HAMWORTHY HEATING LTD PUREWELL Variheat mk2 218612 A03...

  • Page 6: Introduction

    Safety and Building Regulations. Health & Safety working pressure of the boiler as per Appendix ‘E’. requirements must also be taken into account when Consult Hamworthy Heating Technical Department installing any equipment. Failure to comply with the for help or assistance if in doubt.

  • Page 7: Supply And Delivery

    6. Position the boiler for installation and using a sprit level check the appliance is level to ensure no air pockets when transporting the boiler. can collect in the boiler and the condensate can fully  Observe transport instructions drain. packaging. HAMWORTHY HEATING LTD PUREWELL Variheat mk2 218612 A03...
  • Page 8 Figure 2.1 - Boiler Packaged Dimensions Model Depth Width Height Weight Purewell Variheat mk2 70c 195kg Purewell Variheat mk2 95c 195kg Purewell Variheat mk2 110c 195kg 1200mm 800mm 1320mm Purewell Variheat mk2 140c 250kg Purewell Variheat mk2 180c 250kg Note: The above values include the pallet the boiler is supplied upon.

  • Page 9: Size And Space Requirements

    Figure 3.1 - Dimensions and Clearances 3.2 The Hamworthy Heating Ltd water manifold kit is designed to provide a compact solution for connecting the boilers to the gas supply and flow and return water connections. (Refer to the Manifold Kit Installer’s Guide for specific details.) Figure 3.2.1 –...
  • Page 10 However, each boiler has a Rp1” connection (plugged) in the rear of the boiler heat exchanger assembly for use on applications where module isolating valves are not of the 3 port type.. HAMWORTHY HEATING LTD PUREWELL Variheat mk2 218612 A03...

  • Page 11: Site Location And Preparation

    Inlet gas pressure to boiler should be nominal 20mbar (minimum 17.5mbar) dynamic at the connection to the boiler.  Boiler house gas isolation valve must be clearly identified and installed close to the entrance / exit. R 1” Gas Connection Figure 4.2 – Gas Connection Point HAMWORTHY HEATING LTD PUREWELL Variheat mk2 218612 A03...

  • Page 12: Flues

     Connecting flue systems may be smaller in internal diameter than the boiler connection and must be designed to deliver the necessary condition at the connection to the boiler. Refer to Hamworthy Heating Technical dept. for assistance. HAMWORTHY HEATING LTD...
  • Page 13 Figure 4.3 – Flue Connection Point Flue fixing bracket Flue Pipe Elbow Flue Connection as delivered Flue Connection fitted HAMWORTHY HEATING LTD PUREWELL Variheat mk2 218612 A03...

  • Page 14: Water Supply

    For minimum water pressure see Appendix ‘E’ - Water Data (Page 45) Flow Connection Model Type Model Type Return Connection PV70c, 95c & 110c PV140c & 180c Figure 4.4 – Water Connection Points HAMWORTHY HEATING LTD PUREWELL Variheat mk2 218612 A03...

  • Page 15: Condensate Connections

     Condense is mildly acidic, typically pH 3 - pH 5.  Condense pipework must be non-corrosive and not copper. Hamworthy recommend 32mm dia. Plastic waste pipe.  Condense may be discharged to a standard drain subject to National or Local regulations.

  • Page 16: Electrical Supply

    NOTE: The appliance MUST be isolated from the electrical supply if electric arc welding is carried out on connecting pipework. FOR DETAILED WIRING INSTRUCTIONS SEE SECTIONS 5.3, 9.0 & APPENDIX B Figure 4.6 - Electrical Connections HAMWORTHY HEATING LTD PUREWELL Variheat mk2 218612 A03...

  • Page 17: Boiler Assembly

    The boiler is provided with a connection on the boiler for the safety valve . Where using Hamworthy Heating Ltd pipework kits, assembly of these is detailed in the Instruction manual supplied with kit.

  • Page 18: Pre-Commissioning

    6.3 Pipework, Valves and Pump Ensure that;  Pipework and valve arrangement is installed to Hamworthy Heating recommendations.  Circulating system is full of water, vented and pressurised appropriately.  Circulation pump is fitted, working and interlocked where required.

  • Page 19: Checks Prior To Lighting

    5) 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. HAMWORTHY HEATING LTD PUREWELL Variheat mk2 218612 A03...

  • Page 20: Checks Prior To Lighting The Boiler

    5) Ensure the heating system circulation / shunt pump is operational and that the pipework is free of air. Figure 7.2.1 Location Gas Isolating Valve/Safety Temperature Limiter Air Inlet Position Of Safety Tem- perature Limiter Reset Isolating Valve Gas Pressure Test Point Location of Thermostat Fixing Screws HAMWORTHY HEATING LTD PUREWELL Variheat mk2 218612 A03...

  • Page 21: Initial Lighting

    DURING WHICH THE ABOVE PROCEDURES WILL BE REPEATED. AT THE END OF THE RESTART PROCEDURE, IF NO FLAME IS DETECTED AFTER THE FLAME PROVING PERIOD, THE BOILER WILL LOCKOUT. THE BOILER WILL NOT OPERATE UNTIL THE LOCKOUT HAS BEEN MANUALLY RESET. HAMWORTHY HEATING LTD PUREWELL Variheat mk2 218612 A03...
  • Page 22 Scroll to Heat Circuit 1 Press OK vii) Scroll to Heating Circuit 1 (Prog No 741) viii) Press OK and adjust using wheel Press OK to confirm Press ESC twice to return to Menu HAMWORTHY HEATING LTD PUREWELL Variheat mk2 218612 A03...

  • Page 23: Combustion Checks

    Nat Gas 9.5% ±0.25% CO If combustion readings are outside target range use Torx Bit to make adjustments To increase the CO level, turn the adjustment clockwise. Figure 7.4.3.1b —Adjusting gas valve offset HAMWORTHY HEATING LTD PUREWELL Variheat mk2 218612 A03...
  • Page 24 Nat Gas 8.5% ±0.25% CO If combustion readings are outside target range use Torx Bit to make adjustments To increase the CO level, turn the adjustment clockwise. Figure 7.4.5.1b —Adjusting gas valve offset HAMWORTHY HEATING LTD PUREWELL Variheat mk2 218612 A03...
  • Page 25 Figure 7.4.6 - Example Fan Assembly PV70c PV95c/110c/140c 205 - Gas Pressure Switch 206 - Gas Valve 209 - Fan 214 - Gas Valve Mounting Bracket 207 - Gas/Air Mixer (Venturi) Figure 7.4.8 - Example Fan Assembly PV180c HAMWORTHY HEATING LTD PUREWELL Variheat mk2 218612 A03...

  • Page 26: User Instructions

    This pressure should be noted on the commissioning checklist at both high & low fire. This can then be compared on each yearly service to assess burner resistance. Burner pressure test point Figure 7.7.1 - Burner pressure test point HAMWORTHY HEATING LTD PUREWELL Variheat mk2 218612 A03...

  • Page 27: Boiler Controls

    307 - IEC Mains 309 - Air Outlet Socket Pressure Switch 303 - Ignition Lead 308 - LMS Clip In 302 - LMS Controller Figure 8.1.2 - General Overview of Controls 304 - Spark Generator HAMWORTHY HEATING LTD PUREWELL Variheat mk2 218612 A03...

  • Page 28: Display

    Error messages Process running – please wait Info level activated Change battery Programming activated Burner operating (only oil/gas boiler); Heating temporarily switched off active burner stage. ECO function active Compressor operating (HP only). HAMWORTHY HEATING LTD PUREWELL Variheat mk2 218612 A03...

  • Page 29: Functions

    This boiler has the ability for 0-10V Control, for more information please refer to page 60. 8.3.6 Cascade Operation This boiler has the ability for Cascade Operation, for more information please refer to page 59. HAMWORTHY HEATING LTD PUREWELL Variheat mk2 218612 A03...
  • Page 30 Figure 9.0 Boiler Wiring Schematic HAMWORTHY HEATING LTD PUREWELL Variheat mk2 218612 A03...

  • Page 31: Fault Finding

    - see Section 4. 10.1 Regular servicing is recommended, preferably by a Hamworthy appointed person, and at least annually, to ensure trouble free operation.
  • Page 32  Disconnect the ignitor and flame probe leads.  Check the condition of the ignitor and probe (replace as required).  Carefully remove the power and control cable from the fan. HAMWORTHY HEATING LTD PUREWELL Variheat mk2 218612 A03...

  • Page 33: Replacement Of Failed Components

     Check the condition of the non-return valve. gaskets and seals disturbed and are available in a service kit from Hamworthy, part number Inspection of the fan impellor can normally be 563605569. checked at this point.

  • Page 34: Main Gas Valve

    Refer to Figure 9.0. 11.3 Main Gas Valve. NOTE! Hamworthy Heating strongly recommend that a new gas valve assembly is fitted to ensure safe, reliable operation of the boiler. 1) Disconnect the gas valve electrical plug.
  • Page 35 Figure 11.1—Ignition Electrode and Flame Sensing Probe Positions 205 - Gas Pressure Switch 208 - Venturi Seal 207 - Venturi 206 - Gas Valve Figure 11.2.1 - Gas Valve Assembly Models PV70c HAMWORTHY HEATING LTD PUREWELL Variheat mk2 218612 A03...
  • Page 36 Figure 11.2.2 - Combustion System Assembly Model PV70c 208 - Venturi Seal 205 - Gas Pressure Switch 207 - Venturi 206 - Gas Valve Figure 11.3.1 - Gas Valve Assembly Models PV95c/110c/140c HAMWORTHY HEATING LTD PUREWELL Variheat mk2 218612 A03...
  • Page 37 209 - Fan 211 - Burner Elbow Gasket 210 - Fan Elbow Seal 203 - Spark 212 - Flapper Valve Ignitor Assembly 201 - Burner Figure 11.3.3 - Combustion System Assembly PV70c/95c/110c/140c HAMWORTHY HEATING LTD PUREWELL Variheat mk2 218612 A03...
  • Page 38 Figure 11.4 .1 – Gas Valve Assembly PV180c 205 - Gas Pressure Switch 209 - Fan 206 - Gas Valve 214 - Gas Valve Mounting Bracket 207 - Gas/Air Mixer (Venturi) Figure 11.4.2 - Combustion System Assembly Model PV180c HAMWORTHY HEATING LTD PUREWELL Variheat mk2 218612 A03...
  • Page 39 Washer 501 - Control Cover Assembly 504 - Back Cover 507 - Side Cover 510 - Retaining Washer 502 - Front Cover 510 - Screw Assembly 510 - Screw Figure 11.6—Casing Assembly HAMWORTHY HEATING LTD PUREWELL Variheat mk2 218612 A03...
  • Page 40 Temp Sensor 410 - Water Connection 405 - Heat Assembly Exchanger (Fins) 409 - 2 Section Flexible Connector 415 - Water Connection Gasket Figure 11.8- Heat Exchanger Assembly (model 70c—110c shown for illustration) HAMWORTHY HEATING LTD PUREWELL Variheat mk2 218612 A03...
  • Page 41 407 - Tie Rod 405 - Heat Exchanger (Fins) 409 - 3 Section Flexible Connector 415 - Water Connection Gasket Figure 11.9 - Heat Exchanger Assembly (model 140c - 180c shown for illustration) HAMWORTHY HEATING LTD PUREWELL Variheat mk2 218612 A03...

  • Page 42: Recommended Spares

    12.0 RECOMMENDED SPARES Please refer to www.hamworthy-heating.com for spare parts using the key numbers shown in this manual. Please Note:- To ensure the correct spare parts are despatched by our spares department, it is imperative that the complete Boiler/Module/Control Panel Serial Numbers are given. The Boiler and Module Serial Numbers are located on the Data Plates affixed to the front of the heat exchanger base casting.
  • Page 43 HAMWORTHY HEATING LTD PUREWELL Variheat mk2 218612 A03...
  • Page 44 Low Gas Pressure Switch………………………………………………………205 Set of Gaskets (Routine Service - combustion system) ………………………601 Set of Gaskets (Major Service - combustion system plus heat exchanger)..602 For service or spares please contact :- Hamworthy Heating Limited Wessex House New Fields Business Park Stinsford Road...
  • Page 45 Dry NOx Emissions European Class 6 mg/kWh Noise Emission Max dB (A) 9.5 / 9.5 9.5 / 8.5 Target CO % at High / Low fire ±0.25 Figure A1 - Gas Data HAMWORTHY HEATING LTD PUREWELL Variheat mk2 218612 A03...

  • Page 46: Appendix Belectrical Connections And Controls

    FOR ELECTRICAL CONNECTIONS TO BOILER SEE FIGURE 4.6 FOR BOILER WIRING SCHEMATIC SEE FIGURE 9.0 FOR MULTIPLE BOILER WIRING SEE FIGURE B1.2 & B1.3 FOR CONTROL WIRING SEE FIGURE E1.3.1 TO E1.3.4 HAMWORTHY HEATING LTD PUREWELL Variheat mk2 218612 A03...
  • Page 47 Figure B1.2 - External Control Wiring for Multiple Module Installation HAMWORTHY HEATING LTD PUREWELL Variheat mk2 218612 A03...

  • Page 48: Appendix Cflue Data

    Consideration must be given to the correct calculation of the required flue size. If in any doubt consult Hamworthy Heating Ltd who can supply a full flue design and installation service. C1.2 Waste Gas Volume and Temperature.
  • Page 49 A drain with an integral trap is fitted to the rear of each module suitable for connection to a 32mm plastic waste pipe (not Hamworthy Heating Ltd supply), which must be connected to a tundish (not Hamworthy Heating Ltd supply). Discharge piping from a tundish should be of synthetic material due to the mild acidity of the condensate (pH 3-5), with all discharge piping having a minimum fall of 30mm/m away from the boiler.
  • Page 50 Straight tube ø150mm maximum length (m) 45° bend ø150mm Equivalent tube length (m) 90° bend ø150mm Equivalent tube length (m) Figure C1.1 - Flue Resistance Figure C1.2 - Open (Natural Draught) B23 Flue System HAMWORTHY HEATING LTD PUREWELL Variheat mk2 218612 A03...

  • Page 51: Appendix Dventilation

    Flow rate per kW total rated heat input (net) Boilers Difference between inlet and Without Inlet air (Combustion extract air (Inlet minus Draught ventilation) extract ventilation) Diverters m³/h m³/h 1350 +/- Volume 2600 1.35 +/- 0.18 HAMWORTHY HEATING LTD PUREWELL Variheat mk2 218612 A03...

  • Page 52: Appendix Ewater Data

    Boiler Output Feed mm Vent mm 60 - 150kW 150 - 300 kW Figure E1.1 Cold Feed and Vent Pipe Sizes 300 - 600 kW HAMWORTHY HEATING LTD PUREWELL Variheat mk2 218612 A03...
  • Page 53 Figure E1.2 - Typical Piping Layouts HAMWORTHY HEATING LTD PUREWELL Variheat mk2 218612 A03...
  • Page 54 If boiler / system pump(s) are not controlled by the boiler, a pump overrun (not Hamworthy Heating Ltd supply) should be fitted which must run for a minimum of 5 minutes on shutdown of the last boiler.
  • Page 55 Maximum flow temperature (°C) Maximum system hot working pressure, generally given in bar gauge. From the parameters given, Hamworthy Heating can size the pressurisation unit and also the expansion vessel required. Care must be taken in sizing expansion vessels to ensure maximum acceptance factors are not exceeded.
  • Page 56 Figure E 1.3.3 - Schematic for Single Boiler (External 0~10V), Multi Circuit System MERLEY CONTROLLER MERLEY) Optional individual Shunt Pump controlled by LMS Figure E 1.3.4 - Schematic for Multiple Boiler (Cascade), Primary Circuit System HAMWORTHY HEATING LTD PUREWELL Variheat mk2 218612 A03...

  • Page 57: Appendix Fadditional Kits

    APPENDIX F - ADDITIONAL KITS Additional kits available from Hamworthy Heating :  Additional zone heating circuit kit AGU2.550A109 - 219357  Additional 2 zone heating circuit kit AGU2.550A109 - 219358  Outside air temperature sensor QAC34 - 533901457 ...
  • Page 58 Hydraulic Schemes 1 & 2 These schematics are available to download at www.hamworthy-heating.com HAMWORTHY HEATING LTD PUREWELL Variheat mk2 218612 A03...
  • Page 59 Hydraulic Schemes 3 & 4 These schematics are available to download at www.hamworthy-heating.com HAMWORTHY HEATING LTD PUREWELL Variheat mk2 218612 A03...
  • Page 60 Hydraulic Schemes 5 & 6 These schematics are available to download at www.hamworthy-heating.com HAMWORTHY HEATING LTD PUREWELL Variheat mk2 218612 A03...
  • Page 61 Hydraulic Schemes 7 & 8 These schematics are available to download at www.hamworthy-heating.com HAMWORTHY HEATING LTD PUREWELL Variheat mk2 218612 A03...
  • Page 62 QX23—Switched live—Heating circuit pump (Contactor required for pump) BX21—Flow temperature sensor—Heating circuit H2—Heating circuit room thermostat—Basic type no/nc switch vfc (Only use if optional room sensor QAA55 or QAA74 are not specified) HAMWORTHY HEATING LTD PUREWELL Variheat mk2 218612 A03...
  • Page 63 Optional extras required for this configuration: External air sensor – QAC34 Part number 533901457 Room sensor choice – QAA55—Offset adjustable room sensor Part number 533901589 – QAA74—Programmable room sensor Part number 533901587 HAMWORTHY HEATING LTD PUREWELL Variheat mk2 218612 A03...
  • Page 64 Heating mode Auto symbol Hot water mode Optional extras required for this configuration: Heating sensor kit – QAZ36 Part number 563605674 LPB bus communication module OCI345—one per boiler module Part number 563605667 HAMWORTHY HEATING LTD PUREWELL Variheat mk2 218612 A03...
  • Page 65 Function valve 2 H1 800 (800 = 80°C) 5890 Relay output QX1 Boiler pump Q1 Note: Use H1 wiring connection for 0-10V analog input from B.M.S. Optional extras required for this configuration: None HAMWORTHY HEATING LTD PUREWELL Variheat mk2 218612 A03...
  • Page 66 LPB bus communication module OCI345—one per boiler module Part number 563605667 Note: 2x LPB bus communications modules are supplied with each Merley boiler sequence controller, therefore addi- tional modules are only required for boiler module 3 upwards. HAMWORTHY HEATING LTD PUREWELL Variheat mk2 218612 A03...
  • Page 67 USEFUL USER INFORMATION INSTALLER SITE ADDRESS BOILER TYPE BOILER SIZE(S) UNIT NO(S). SERIAL NO(S). FLUE NOTES HAMWORTHY HEATING LTD PUREWELL Variheat mk2 218612 A03...
  • Page 68 NOTES: HAMWORTHY HEATING LTD PUREWELL Variheat mk2 218612 A03...
  • Page 69 NOTES: HAMWORTHY HEATING LTD PUREWELL Variheat mk2 218612 A03...
  • Page 70 NOTES: HAMWORTHY HEATING LTD PUREWELL Variheat mk2 218612 A03...
  • Page 71 NOTES:...
  • Page 72 Wessex House, New Fields Business Park, Stinsford Road, Poole, Dorset, BH17 0NF Telephone: 01202 662500 Fax: 01202 662522 Email: service@hamworthy-heating.com Website: www.hamworthy-heating.com Hamworthy reserves the right to make changes and improvements which may necessitate alteration to the specification without prior notice.

This manual is also suitable for:

Purewell variheat mk2 95cPurewell variheat mk2 140cPurewell variheat mk2 110cPurewell variheat mk2 180c

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