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Hamworthy Purewell Installation, Commisioning And Maintenance Instructions

Gas fired modular boiler systems atmospheric cast iron boiler 40kw to 120kw output automatic ignition controls standard draught diverter or low line draught diverter
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Installation, Commissioning
and Servicing Instructions
Atmospheric Cast Iron Boiler
40kW to 120kW Output
AUTOMATIC IGNITION CONTROLS
Standard Draught Diverter
Low Line Draught Diverter
Purewell
Gas Fired
Modular Boiler Systems
IMPORTANT NOTE
THESE INSTRUCTIONS MUST BE READ AND UNDERSTOOD BEFORE
INSTALLING, COMMISSIONING, OPERATING OR SERVICING EQUIPMENT.
Register
or
NATURAL GAS
LPG-PROPANE
Contents
I
2 H
I
3P

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Summary of Contents for Hamworthy Purewell

  • Page 1 Servicing Instructions Atmospheric Cast Iron Boiler 40kW to 120kW Output AUTOMATIC IGNITION CONTROLS Standard Draught Diverter Low Line Draught Diverter Purewell Gas Fired Modular Boiler Systems NATURAL GAS LPG-PROPANE IMPORTANT NOTE THESE INSTRUCTIONS MUST BE READ AND UNDERSTOOD BEFORE...
  • Page 2 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 Specialist teams are available for on site assembly of the full range of Hamworthy boilers (excluding Lulworth).
  • Page 3 NOTE: THESE INSTRUCTIONS SHOULD BE READ AND UNDERSTOOD BEFORE ATTEMPTING TO INSTALL, COMMISSION OR OPERATE THIS UNIT THE PUREWELL BOILER IS INTENDED FOR USE AS A COMMERCIAL APPLIANCE AND IS NOT CERTIFIED FOR USE IN DOMESTIC APPLICATIONS OR HABITABLE AREAS.
  • Page 4 THIS PAGE LEFT INTENTIONALLY BLANK HAMWORTHY HEATING LTD. PUREWELL AUTOMATIC IGNITION 500001035/G...

  • Page 5: Table Of Contents

    8.4 Altitude Gauge (Water Pressure Gauge) 8.5 Thermometer 8.6 Drain Taps 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 HAMWORTHY HEATING LTD. PUREWELL AUTOMATIC IGNITION 500001035/G...

  • Page 6: Table Of Contents

    Figure No. 14 Diagram of electrode assembly..........…. 27 Figure No. 15 Diagram of various gas valves fitted........…. 28 Figure No. 16 Diagram of double gas valve layout........... 29 Figure No. 17 General fault finding..............30/31 HAMWORTHY HEATING LTD. PUREWELL AUTOMATIC IGNITION 500001035/G...

  • Page 7: Technical Data ............................................................................ 1

    A The Purewell boiler can be installed as a single unit unique radiant baffle is fitted beneath the burner bars, or in modular form where a ‘multi’ casing reduces protecting the floor below by reducing heat lost from required floor area.

  • Page 8: General Requirements ............................................................ 1

    * NOTE! Flue gas volumes are based on a gross flue gas temperature of 100°C at 1013mbar. This is considered to be the predicted temperature of the products in the secondary flue downstream of the draught diverter. Related Documents - cont. HAMWORTHY HEATING LTD. PUREWELL AUTOMATIC IGNITION 500001035/G...

  • Page 9: Feed Water Quality

    It should be The Hamworthy Purewell boiler is designed as a quick noted however, that even if the boiler water is of response, low water content unit, to run continuously with average hardness, not requiring treatment, maximum reliability.

  • Page 10: Time Clock Control

    Figure No. 3 - Gas valve/pipework leak check test procedure. 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. HAMWORTHY HEATING LTD. PUREWELL AUTOMATIC IGNITION 500001035/G...

  • Page 11: Flue System .................................................................................. 5

    British Gas publication IM/11 “Flues for Commercial and Industrial Gas Fired Boilers and Air Heaters”. 6) Purewell 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.

  • Page 12: Flue Discharge

    Grilles or louvres must be so designed that high velocity air streams do not occur within the space housing the boiler. HAMWORTHY HEATING LTD. PUREWELL AUTOMATIC IGNITION 500001035/G...

  • Page 13: Water Circulation System ..................................................... 9

    8.0 WATER CIRCULATION SYSTEM 8.1 General The Purewell Cast Iron Boiler has a low water content and the requirements of minimum water flow are given in Section 8.8: Minimum Water Flow Rates and Figure No. 2. Recommendations for the water circulation system are given in BS 6644 and CP 342.

  • Page 14: Control Schemes

    3) Maximum flow temperature, i.e. most systems run at switched by a time clock, especially if a single header 82°C. pump kit is utilised. The Purewell boiler has a remote 4) Maximum system hot working pressure, generally given stop/start loop which can be used to operate the boiler(s) in barg.

  • Page 15: Figure No

    Refer to Figure No. 7 for fitting instructions. Ensure all thermostat capillaries are inserted and A gland plate is supplied with every Purewell boiler having correctly located into the top of the boiler. The controls two 20mm dia. holes for electrical cable anchorage. A...
  • Page 16 Bracket’s position will be dependent on boiler size. Figure No. 6a Reference to Figure No. 5c - Fold down petals as shown. Use foil tape to affix edges. Fold as HAMWORTHY HEATING LTD. PUREWELL AUTOMATIC IGNITION 500001035/G...

  • Page 17: Servicing

    Figure No. 6b shows the pipe clamp fitted to Purewell 10.4.2 Low Line models: - 60, 70, 80 and 120 kW boilers. The Low Line model incorporates its own draught Figure No. 6b diverter and care must taken to ensure the seal between the outlet spigot and flue pipe is sound to avoid the escape of flue gas.
  • Page 18 Turn the turn latch in the centre brackets (item 7) as shown opposite. of the door to lock. NOTE ! * = Single casing set ** = Multi casing set = Lowline only HAMWORTHY HEATING LTD. PUREWELL AUTOMATIC IGNITION 500001035/G...
  • Page 19 Figure No. 7a - Exploded View of Casing Set. HAMWORTHY HEATING LTD. PUREWELL AUTOMATIC IGNITION 500001035/G...
  • Page 20 5) The pipework and valve arrangement is installed to The whole of the gas installation including the meter must Hamworthy Heating recommendations in such a way that be inspected and tested for soundness and purged in water flow rates will be in accordance with Figure No. 1.
  • Page 21 120kW) are fitted with a unique flow share gas valve arrangement. Refer to Figure No. 16 to establish 5) The Purewell fully automatic boiler utilises a low fire method of adjustment of the by-pass throttle start gas rate ignited by direct spark ignition (DSI), see arrangement.
  • Page 22 General fault finding is shown in Figure No. 17. If the boiler still cannot be operated satisfactorily after following Details of flue gas composition relating to propane the chart, consult your local office of Hamworthy Heating firing can be found in Appendix ‘A’. for assistance.
  • Page 23 Alternative thermostat manufacturers may be used in surfaces. Re-assemble the boiler in the reverse order the Purewell boiler controls assembly. However, the to that shown above. Ensure a new rope seal is fitted fitting and wire spade connections are physically to the flue hood to maintain a gas tight seal, (see identical.
  • Page 24 Switch on gas and power supply and without completely removing the whole assembly from check for integrity of all joints using a proprietary leak the boiler. However, Hamworthy Heating strongly detector. recommend that a new gas valve assembly is fitted to ensure safe, reliable operation of the boiler.
  • Page 25 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 Ltd. Fleets Corner Poole Dorset BH17 OHH Phone No. 01202 662500 Fax No. 01202 665111 HAMWORTHY HEATING LTD. PUREWELL AUTOMATIC IGNITION 500001035/G...
  • Page 26 Figure No 8 - Boiler Installation (Typical) Key: t - Thermometer or sensor p - Pressure Gauge HAMWORTHY HEATING LTD. PUREWELL AUTOMATIC IGNITION 500001035/G...
  • Page 27 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). HAMWORTHY HEATING LTD. PUREWELL AUTOMATIC IGNITION 500001035/G...
  • Page 28 Figure No. 10 - General Layout (Front View) HAMWORTHY HEATING LTD. PUREWELL AUTOMATIC IGNITION 500001035/G...
  • Page 29 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 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.
  • Page 30 Figure No. 12 - Purewell Boiler Site Wiring Diagram (Automatic) NOTE!..Maximum rating of a volt 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.
  • Page 31 Figure No. 13 - Standard Automatic Wiring Diagram Schematic HAMWORTHY HEATING LTD. PUREWELL AUTOMATIC IGNITION 500001035/G...
  • Page 32 Figure No. 13a - Additional Wiring Schematic for Models Fitted with Pektron 0459 Series Ignition Controls HAMWORTHY HEATING LTD. PUREWELL AUTOMATIC IGNITION 500001035/G...
  • Page 33 Figure No 14 - Diagram of Igniter Electrode/Probe Assembly HAMWORTHY HEATING LTD. PUREWELL AUTOMATIC IGNITION 500001035/G...
  • Page 34 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. HAMWORTHY HEATING LTD. PUREWELL AUTOMATIC IGNITION 500001035/G...
  • Page 35 Figure No. 16 - Diagram of ‘Hi’ Flow Gas Valve Assembly (Natural Gas Only) PUREWELL 95, 100 (L/L), 105 & 120kW Automatic & WARMWELL HE 140 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.
  • Page 36 Figure No. 17 – Fault-Finding Procedures (Automatic Only) HAMWORTHY HEATING LTD. PUREWELL AUTOMATIC IGNITION 500001035/G...
  • Page 37 Figure No. 17a – Fault-Finding Procedures (Automatic Only) (Cont.) HAMWORTHY HEATING LTD. PUREWELL AUTOMATIC IGNITION 500001035/G...
  • Page 38 AND LOW LEVEL. REFER TO MAIN INSTALLER’S GUIDE. 1.0 INTRODUCTION Performance and General Data Information table below. The operation of the Purewell range of boilers on LPG- b) The nominal gas inlet pressure for propane should Propane (3 family)I is similar to that on Natural Gas be 37mbar.
  • Page 39 Seal the adjuster after setting. Key: I - Gas Pressure Switch II - Main Gas Valves 15.0 RECOMMENDED SPARES MECHANICAL ITEMS PART No. Low Gas Pressure Switch....339009477 HAMWORTHY HEATING LTD. PUREWELL AUTOMATIC IGNITION 500001035/G...
  • Page 40 THIS PAGE LEFT INTENTIONALLY BLANK HAMWORTHY HEATING LTD. PUREWELL AUTOMATIC IGNITION 500001035/G...
  • Page 41 Tyne & Wear NE33 2QH Tel: 003531 830 1211 Tel: 0191 455 7898 Fax: 003531 830 1990 Fax: 0191 455 7899 For all other areas, or for further advice, please contact Hamworthy Heating head office service department in Poole, telephone 01202 662500.
  • Page 42 DELIVERY ENQUIRIES ......... 01202 662515/662504 Deliveries from Hamworthy Heating arrive direct from the factory on a vehicle equipped with a tail-lift for ease of off-loading to ground level. Our contracts team will progress despatch and liaise individual delivery arrangements. SPARE PARTS ............

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