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Hamworthy Purewell VariHeat he Installation, Commisioning And Maintenance Instructions

Cast iron, pre-mix, modular boilers with automatic ignition for heating and domestic hot water installations
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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 he

  • Page 1 IMPORTANT NOTE THESE INSTRUCTIONS MUST BE READ AND UNDERSTOOD BEFORE INSTALLING, COMMISSIONING, OPERATING OR SERVICING EQUIPMENT...
  • Page 2 Purewell VariHeat he Boilers Cast Iron, Pre-mix, Modular Boilers with Automatic Ignition for Heating and Domestic Hot Water Installations Installation, Commissioning and Servicing Instructions MODELS - PV65he, PV85he, PV105he & PV125he NATURAL GAS NOTE: THESE INSTRUCTIONS MUST BE READ AND UNDERSTOOD BEFORE INSTALLING, COMMISSIONING, OPERATING OR SERVICING EQUIPMENT.

  • Page 3: Table Of Contents

    Display Screen ..........................28 FAULT FINDING..........................33 10.0 SERVICING............................33 11.0 REPLACEMENT OF FAILED COMPONENTS ................35 11.1 Igniter and Flame Probe Assembly 11.2 Temperature Limiter 11.3 Main Gas Valve 11.4 Combustion Fan 12.0 RECOMMENDED SPARES......................39 Page HAMWORTHY HEATING LTD PUREWELL VariHeat he 500001155/F...
  • Page 4 Hot Surface Igniter and Flame Sensing Probe Positions ............36 Figure 11.3 Gas Valve Assembly ......................36 Figure 11.4 Combustion Fan Assembly ....................37 Figure 11.5 Casing Assembly ........................37 Figure 11.6 Heat Exchanger Assembly .....................38 Page HAMWORTHY HEATING LTD PUREWELL VariHeat he 500001155/F...
  • Page 5 Schematic for Single Boiler System..................51 Figure E1.3.2 Schematic for Single Boiler, Primary Circuit System ..............51 Figure E1.3.3 Schematic for Multiple Boiler (0~10V) Primary Circuit System..........52 Figure E1.3.4 Schematic for Multiple Boiler (Cascade) Primary Circuit System...........52 Page HAMWORTHY HEATING LTD PUREWELL VariHeat he 500001155/F...

  • Page 6: Introduction

    1.5 The Purewell VariHeat he boiler is not suitable for 1.0 INTRODUCTION direct connection to domestic hot water supplies or gravity fed heating systems. 1.1 A competent person holding ‘CORGI’ registration or equivalent must install this boiler. All installations 1.6 The Purewell VariHeat he boiler can be installed...

  • Page 7: Supply And Delivery

    The flue connection & condensate trap to the boiler are packaged separately to avoid damage. The flue components consist of an adaptor elbow, gasket and straight length of 150mm diameter flue pipe. The condensate trap is supplied loose beneath the front cover. HAMWORTHY HEATING LTD PUREWELL VariHeat he 500001155/F...
  • Page 8 Figure 2.3 - Boiler Packaged Dimensions Model Depth Width Height Weight Purewell VariHeat he 65 205kg Purewell VariHeat he 85 1090mm 550mm 1310mm Purewell VariHeat he 105 277kg Purewell VariHeat he 125 Delivery Verification When taking delivery please ensure that you have received the correct number of boilers and ancillary packages to fulfil your order.

  • Page 9: Size And Space Requirements

    3.0 SIZE AND SPACE REQUIREMENTS 3.1 The Purewell VariHeat he boiler range has been designed to utilise minimum floor space, therefore it is important the plantroom has sufficient ceiling height to allow for installation and connection to the flue system.
  • Page 10 P V65/85 he PV 105/ 1 25he 1650 1780 1400 1540 RE AR ELEVATION E ND ELE VATION Figure 3.2.2 – Manifold Dimensions for a 3 Purewell VariHeat he boiler installation 2358 Boiler Model D imension (mm) PV65/85he P V105/125he 1650...

  • Page 11: Site Location And Preparation

    • 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 he 500001155/F...

  • Page 12: Flues

    Refer to Appendix C - Fig C1. Connecting flue systems may be smaller in internal diameter than the boiler • connection. Refer to Hamworthy Heating Technical Dept for assistance. Flue fixing bracket Flue Pipe...

  • Page 13: Water Supply

    For minimum water pressure see Appendix ‘E’ - Water Data (Page 47) Flow Connection Return Connection Condensate Take-Off Model Type Model Type PV105he & 125he PV65he & 85he Figure 4.4 – Water Connection Points HAMWORTHY HEATING LTD PUREWELL VariHeat he 500001155/F...
  • Page 14 • 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 •...

  • Page 15: 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 230v~50Hz Volt free contacts Casca de Max 230 v 2A Figure 4.5 - Electrical Connections HAMWORTHY HEATING LTD PUREWELL VariHeat he 500001155/F...

  • Page 16: Boiler Assembly

    Rp1” Safety Valve (behind flue pipe) Gas R1” Male thread. Return R2” Male thread. Indicated by a blue dot on boiler. Condensate Trap Figure 5.2.1 - Rear Water Connections HAMWORTHY HEATING LTD PUREWELL VariHeat he 500001155/F...

  • Page 17: Electrical Connections

    Boilers must not be capable of isolation from the safety valve. Valves between boiler and safety valve to be three way type such that when boiler is isolated from safety valve it is open to atmosphere. Hamworthy Heating Ltd provide a connection on the boiler for the safety valve .

  • 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. Fol- lowing soundness tests close valve B and remove manometer connections and tighten test points. HAMWORTHY HEATING LTD PUREWELL VariHeat he 500001155/F...

  • Page 20: Checks Prior To Lighting The Boiler

    NOTE! Care should be exercised when the boiler is firing as the flue components can achieve temperatures, which could cause injury if touched. Boiler On/Off - Enter - Reset Figure 7.3.1 Boiler Facia Display HAMWORTHY HEATING LTD PUREWELL VariHeat he 500001155/F...
  • Page 21 Note: the screen will revert back to the normal Status Screen after a few seconds. Should a set point higher than 85°C be required, please contact Hamworthy Heating, as programming for a higher maximum outlet temperature is restricted by a factory set access code.

  • Page 22: Combustion Checks

    9) If the combustion readings fall outside the required range DO NOT adjust the gas valve settings . CONTACT HAMWORTHY HEATING SERVICE DEPARTMENT. 10) Tampering with any sealed component may result in loss of warranty on the appliance. Figure 7.4.2 - Combustion Analyser Probe Setting...
  • Page 23 Figure 7.4.3 - Fan Assembly PV65he & PV85he High Fire Gas / Air Adjustment Factory Sealed Low Fire Gas Adjustment Factory Sealed Outlet Gas Pressure Test Point Pressure Switch Figure 7.4.4 - Fan Assembly PV105he & PV125he HAMWORTHY HEATING LTD PUREWELL VariHeat he 500001155/F...

  • Page 24: Controls Operation

    LCD unit and 6 buttons for operation and setting of the boiler. The system is compatible with BMS (or other) external controls via an enable or 0~10V DC input signal. The op- tional outside and mixed flow sensors are supplied by Hamworthy Heating Ltd to ensure safe and reliable opera- tion.

  • Page 25: Pump Kick

    If there is a power failure during a lockout, the control will return to lockout when the power is returned. The alarm relay is only powered in the event of an alarm situation. During normal operation, the alarm relay is not powered. HAMWORTHY HEATING LTD PUREWELL VariHeat he 500001155/F...

  • Page 26: Heat Demand

    The horizontal buttons enable a position in the four digit sequence to be selected. As soon as the correct code has been entered, the Service Mode will start (refer to Hamworthy Heating Ltd for service code). To exit the Service Mode press the on/off (Enter) button.
  • Page 27 M-S1-S2-S3-S4-S5-S6-S7 S7-S6-S5-S4-S3-S2-S1-M Day n Day n+1 S1-S2-S3-S4-S5-S6-S7-M M-S7-S6-S5-S4-S3-S2-S1 Day n+2 S2-S3-S4-S5-S6-S7-M-S1 S1-M-S7-S6-S5-S4-S3-S2 Day n+3 S3-S4-S5-S6-S7-M-S1-S2 S2-S1-M-S7-S6-S5-S4-S3 - - etc.- - - - etc.- - - - etc.- - Figure 8.5.2.3 - Cascade Sequence HAMWORTHY HEATING LTD PUREWELL VariHeat he 500001155/F...
  • Page 28 1 boiler on 100% = 2 boilers on 50%. When in this example P = 60%, the first boiler will down stay on 100% and the second boiler would switch on as soon as the total power reaches 120% (2 * P HAMWORTHY HEATING LTD PUREWELL VariHeat he 500001155/F...
  • Page 29 Should the flow temperature exceed the setpoint + it’s Offset, the heat demand is ‘blocked’ and the anti-cycling timer starts. The ‘block’ is removed as soon as the flow temperature has dropped 10°C and a start will resume when the anti-cycling timer has expired. HAMWORTHY HEATING LTD PUREWELL VariHeat he 500001155/F...
  • Page 30 Running hours, with power equal to or less than 50% of its maximum setting. • Running hours with power greater than 50% of its maximum setting. • Total ignition attempts • Fault ignition • Last 10 errors/blocks HAMWORTHY HEATING LTD PUREWELL VariHeat he 500001155/F...
  • Page 31 Below the Hysteresis line, the fan speed control is based on the PI– regulation. Above the Hysteresis line, the fan speed is set to its minimum. The gradient function is determined by points A & B, by setting the relevant parameters. Figure 8.5.7.2 - Control of flow temperature gradient HAMWORTHY HEATING LTD PUREWELL VariHeat he 500001155/F...

  • Page 32: Data Logging

    Gas consumption based on fan speed and gas valve opening is logged from two points. The start point is cleared just before leaving the factory. The second start point can be cleared by the User or Service Engineer, in both HAMWORTHY HEATING LTD PUREWELL VariHeat he 500001155/F...

  • Page 33: Display Screen

    A temperature reading is normally shown in °C. By setting the relevant parameter, this can be changed to read °F. When one of the above screens is showing, pressing the Up / Down key will add a sixth screen showing the HAMWORTHY HEATING LTD PUREWELL VariHeat he 500001155/F...
  • Page 34 BLR: REM CTRL FLT Remote Control Fault Remote Control On/Off input operating too often. Message flashes. PUMP: RUN BLR: SERVICE DUE Servicing Notification Scheduled service is due. Message flashes PUMP: RUN Figure 8.7—Display Status Screens HAMWORTHY HEATING LTD PUREWELL VariHeat he 500001155/F...
  • Page 35 PUMP: ON CAS:S4NOT PRESENT Cascade without sensor The cascade sensor S4, is not present. All connected slaves will get maximum power and calculated cascade setpoint. PUMP: ON Figure 8.7.1.5 - Cascade Status Screen HAMWORTHY HEATING LTD PUREWELL VariHeat he 500001155/F...
  • Page 36 Enter key can be pressed to return to Boiler and Pump Status Screen’. Should a changed value not be stored in the EEPROM, the control will revert to the original setting at the end of the current heat demand. HAMWORTHY HEATING LTD PUREWELL VariHeat he 500001155/F...
  • Page 37 Figure 9.0 Boiler Wiring Schematic HAMWORTHY HEATING LTD PUREWELL VariHeat he 500001155/F...

  • Page 38: Fault Finding

    9.0 FAULT FINDING The Purewell VariHeat he boiler is equipped with full self diagnostic fault indication, which is displayed on the screen - refer to section 8.7 - Controls Operation. Should a fault occur which cannot be reset, or a fault repeatedly occurs, contact Hamworthy Heating for assistance.
  • Page 39 6) Take exhaust gas readings and compare with section 7.4. Ensure no gas leaks are evident from the gas connections, refer to section 7.1 for procedure. Check thermostat settings and adjust if required. HAMWORTHY HEATING LTD PUREWELL VariHeat he 500001155/F...

  • Page 40: Replacement Of Failed Components

    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. The gas valve is supplied as a factory set component & must not be tampered with.
  • Page 41 533901497 Gas Pressure Switch 533903037 Gas Valve 532418003 Venturi Clamp 531403031 Spacer 532418002 Venturi 532403148 Closing Plate Figure 11.2 - Gas Valve Assembly ( model 65 he - 85 he shown for illustration) HAMWORTHY HEATING LTD PUREWELL VariHeat he 500001155/F...
  • Page 42 748551010 1/4 Turn Screw 748551009 1/4 Turn Receptacle 530650348 LHS Panel (530650347 RHS) 530650352 Front Cover Molding 530650351 Side Rail 530650346 Lower Front Cover 530650355 Front Cover Brace Figure 11.4 - Casing Assembly HAMWORTHY HEATING LTD PUREWELL VariHeat he 500001155/F...
  • Page 43 742121186 O-Ring 532403166 Tube 524120045 Heat Exchanger 532403217 Inlet 531201122 Water Connection Gasket Water Connection 531050011 R1/4 Sensor Pocket Figure 11.5 - Heat Exchanger Assembly ( model 65he - 85he shown for illustration) HAMWORTHY HEATING LTD PUREWELL VariHeat he 500001155/F...

  • Page 44: Recommended Spares

    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 662566 HAMWORTHY HEATING LTD PUREWELL VariHeat he 500001155/F...
  • Page 45 APPENDIX A - GAS DATA Natural Gas GENERAL DATA BOILER MODEL Purewell VariHeat he Model 65 he 85 he 105 he 125 he Boiler Input (maximum) - kW (Gross) 80.1 107.5 128.0 154.3 Boiler Input (maximum) kW (Nett) 72.1 96.8 118.1...
  • Page 46 CAUTION: DO NOT FEED MAINS VOLTAGE ONTO THE TIMER TERMINALS 1.6 The mains power supply must be maintained at all times. Each Purewell VariHeat he boiler incorporates a remote stop/start loop, which can be used to operate the boiler(s) under a timed regime. The boiler controls provide a 30V DC signal that can be fed through a volt free contact for operation.
  • Page 47 Figure B1.2 - External Control Wiring for Multiple Boiler Installation HAMWORTHY HEATING LTD PUREWELL VariHeat he 500001155/F...
  • Page 48 REGARD TO TERMINAL LOCATION AND ADJACENT BUILDING FABRIC. C1.1 General Requirements The Hamworthy Purewell Variheat he series of boilers are designed to be used with natural draught flues. Flue systems should be designed in accordance with regulations and with reference to BS6644 and IG/UP/10.
  • Page 49 Check that the flue and chimney are clear from any obstruction. Purewell VariHeat he boilers are suitable for installation in a balanced compartment in accordance with the requirements of BS 6644. Consult Hamworthy Heating Technical Department for help or assistance if in doubt. C1.9. Condensate Discharge Due to the high thermal efficiency of the boiler, a condensate trap is provided to connect the boiler sump to drain so that any condensation that may occur within the boiler during start up conditions is removed.
  • Page 50 Straight tube ø100mm maximum length (m) 45° bend ø100mm Equivalent tube length (m) 90° bend ø100mm Equivalent tube length (m) Figure C1.1 - Flue Resistance Figure C1.2 - Open (Natural Draught) B23 Flue System HAMWORTHY HEATING LTD PUREWELL VariHeat he 500001155/F...
  • Page 51 The air supplied for boiler house ventilation shall be such that the maximum temperatures within the boiler house shall be as follows: At floor level (or 100mm above floor level) = 25°C. At mid-level (1.5m above floor level) = 32°C. At ceiling level (or 100mm below ceiling level) = 40°C. HAMWORTHY HEATING LTD PUREWELL VariHeat he 500001155/F...
  • Page 52 The calculated extract flow rate is the actual inlet flow rate minus the appropriate figure in the table above. HAMWORTHY HEATING LTD PUREWELL VariHeat he 500001155/F...
  • Page 53 Figure E1 - Water Data E1.1 Water Circulation System The Purewell VariHeat he boiler has a low water content and the requirements of minimum water flow are given in the above table. Recommendations for the water circulation system are given in BS 6644.
  • Page 54 Valve Circulation pump Lockshield Temporary Double Drain check fill line valv e (Primary loop) valve valv e UNVENTED SYSTEM: Primary loop, Hamworthy recommended system . Expansion pipe Pressure & Float Val v e Temperature Drain valve gauges Safety Automatic Mains water Feed &...
  • Page 55 One or more circulating pumps will be required to circulate water around the boilers and heating system. The pump should be sited to facilitate servicing. It is important that when Purewell VariHeat he boilers are used to replace boilers on an existing system, the pumps should be checked for performance against the new boiler waterside pressure loss to ensure that the minimum flow rate can be obtained.
  • Page 56 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 57 Figure E 1.3.3 - Schematic for Multiple Boiler (External 0~10V), Primary Circuit System Figure E 1.3.4 - Schematic for Multiple Boiler (Internal Cascade), Primary Circuit System HAMWORTHY HEATING LTD PUREWELL VariHeat he 500001155/F...
  • Page 58 NOTES HAMWORTHY HEATING LTD PUREWELL VariHeat he 500001155/F...
  • Page 59 USEFUL USER INFORMATION INSTALLER SITE ADDRESS BOILER TYPE BOILER SIZE(S) UNIT NO(S). SERIAL NO(S). FLUE NOTES HAMWORTHY HEATING LTD PUREWELL VariHeat he 500001155/F...
  • Page 60 Site Assembly 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.
  • Page 61 Notes...
  • Page 62 Customer Service Centre Hamworthy Heating Limited, Fleets Corner, Poole, Dorset BH17 0HH. Telephone: 0845 450 2866 Fax: 01202 662522 Email: aftersales@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:

Pv125hePv85hePv65hePv105he

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