Boiler Assembly And Installation; General; Heat Exchanger Insulation Fitting Instructions - Hamworthy Purewell Installation, Commisioning And Maintenance Instructions

10.0 BOILER ASSEMBLY AND INSTALLATION

10.1 General

Each boiler is dispatched to site as follows: -
i) Heat Exchanger & Basket including burners and gas
valve(s) etc. on a pallet.
ii) Casing complete with assembly instructions.
iii) Control Assembly with relevant control system.
iv) Primary flue & Draught diverter. (Draught Diverter
models only).
Further details of each individual assembly is given
below: -
1) Factory tested heat exchanger casting assembly
complete, including insulation wrap, gas valve assembly
including pre-wired plug assembly. The gas connection
pipe should be fitted to the boiler flue hood once the
heat exchanger is located. NOTE! Care must be taken
to ensure no damage occurs to either insulation wrap or
gas connecting pipe. NOTE! THIS PIPE MUST NOT
BE USED TO MANOEUVRE OR POSITION THE
BOILER. Consideration must be given to the weight of
the boiler (See Figure No. 9), before lifting. It is
recommended that the boiler is moved complete with
pallet and positioned correctly. The pallet can then be
dismantled and the boiler slid into position.
2) Casing including all screws, fasteners, etc. to permit
site assembly. Instructions are included in each box to
show method of assembly. Two sizes are manufactured
these are: - Small casing for boilers up to 80kW (NOTE!
P70 Low Line model utilises larger casing), large casing
for all boilers from 95kW to 120kW.
NOTE! When installing a multi-casing set the spacing
plates must be used to correctly space the boilers approx.
3mm apart prior to fitting the casing. (See label attached
to the basket fixing.)
It is recommended that all mechanical work is carried
out prior to fitting the casing assembly, this will reduce
possible damage to the panels.
The casing assembly includes a component list, which
is also shown in Figure No. 7. You should check to
ensure that all parts are supplied prior to assembly.
3) Controls assembly including fascia panel and
thermostats. This assembly will be suited to the desired
controls and include any optional extras required. Refer
to Figure No. 7 for fitting instructions. Ensure all
thermostat capillaries are inserted and correctly located
into the top of the boiler. The controls assembly also
incorporates a socket which matches the gas valve wiring
plug. Care must be taken to ensure both plug and socket
are correctly located and fixed in position by the screws
provided.
4) (Standard Diverter models only.) Primary flue
pipe and draught diverter complete with casing bezel.
Instructions are supplied with the draught diverter on
how to assemble the unit, if required. These
instructions MUST be followed correctly and fully
complied with to ensure correct operation.
HAMWORTHY HEATING LTD.
NOTE! Ensure the baffle(Not fitted to 120kW boiler)
is positioned correctly and laying flat on the heat
exchanger before fitting the flue hood onto the boiler
(if removed).

10.2 Heat Exchanger Insulation Fitting Instructions

With reference to Figure No. 5a - Unfold blanket and
offer up to the boiler as shown. Ensure gas pipe cutout
is positioned to the left and that the 'petals' are
uppermost. Sit the insulation blanket onto the basket
ensuring a snug fit.
Figure No. 5a
Reference to Figure No. 5b - Insulation should be
folded around boiler such that its rear edges meet in
the centre. Ensure flow and return connections are
clear and unobstructed. Apply foil tape down join.
9
PUREWELL PERMANENT IGNITION 500001045/F