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PERMANENT IGNITION CONTROLS
Purewell
Gas Fired
Modular Boiler System
IMPORTANT NOTE
THESE INSTRUCTIONS MUST BE READ AND UNDERSTOOD BEFORE
INSTALLING, COMMISSIONING, OPERATING OR SERVICING EQUIPMENT.
BS EN ISO 9001:1994
Certificate No. FM 10082
Installation, Commissioning
and Servicing Instructions
Atmospheric Cast Iron Boiler
40kW to 120kW Output
Classic and Integra Models
NATURAL GAS
LPG-PROPANE
I
2H
I
3P
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Summary of Contents for Hamworthy Purewell Series
- Page 1 Installation, Commissioning and Servicing Instructions Atmospheric Cast Iron Boiler 40kW to 120kW Output PERMANENT IGNITION CONTROLS Classic and Integra Models Purewell Gas Fired Modular Boiler System NATURAL GAS LPG-PROPANE IMPORTANT NOTE THESE INSTRUCTIONS MUST BE READ AND UNDERSTOOD BEFORE INSTALLING, COMMISSIONING, OPERATING OR SERVICING EQUIPMENT. BS EN ISO 9001:1994 Certificate No.
- 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 WITHIN DOCUMENT IS FOUND RELATING TO SPECIFIC GAS TO BE FIRED BEFORE FIRING BOILER. THIS BOILER COMPLIES WITH ALL RELEVANT EUROPEAN DIRECTIVES. EC TYPE CERTIFICATE No. BG/EC-93/20 PRODUCT IDENTIFICATION No.87AO20 PUBLICATION NO. 500001090 ISSUE ‘B’ NOVEMBER 2001 HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001090/B...
- Page 4 HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001090/B...
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Page 5: Table Of Contents
8.4 Altitude Gauge (Water Pressure Gauge) 8.5 Thermometer 8.6 Drain Valves 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 PERMANENT IGNITION 500001090/B... - Page 6 Typical Boiler Wiring Diagram (inc. Options)......Figure No. 13 Diagram of Igniter Assembly............ Figure No. 14 Diagram of Various gas valves fitted........Figure No. 15 General Fault Finding.............. 27/28 Figure No. 16 Damper Actuator Motor ……………………………………………. HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001090/B...
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Page 7: Introduction
1.2 These instructions are for Group H Natural Gas (2nd Family) and LPG-Propane (3rd Family). Hamworthy Heating can supply a pre-designed information relative to propane firing is to be found in arrangement of components, which will produce a Appendix ‘A’. Boilers MUST NOT use gas other than "reverse-return"... -
Page 8: General Requirements
It is recommendations of the following documents: - in your own interest, and that of safety, to ensure that this law is complied with. HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001090/B... -
Page 9: Feed Water Quality
CP 342: Centralised hot water supply. Part 2: Buildings other than individual dwellings. 3.3 Adequate Water Flow I. Gas E. Publications The Hamworthy Purewell boiler is designed as a quick response, low water content unit, able to run IGE/UP/1 Soundness... -
Page 10: Time Clock Control
TO CHECK VALVE B Further details regarding boiler location are given in 1) Turn off the electrical power and gas to the BS 6644. appliance. 2) Connect the manometer to gas valve test point. HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001090/B... -
Page 11: Flue System
6.1 General Requirements 6.5 Disconnection The Hamworthy Purewell Series of boilers are designed to be used with natural draught flues. Flue On ‘Classic’ models, the draught diverter is systems should be designed in accordance with designed to enable separation from the primary flue current regulations and with reference to the I. -
Page 12: Flue Discharge
The air supplied for boiler house ventilation shall be cavities. Cisterns situated in areas, which may be such that the maximum temperatures within the exposed to freezing conditions, should also be boiler house shall be as follows: HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001090/B... -
Page 13: Pressure Relief Valve (Safety Valve)
A thermometer complete with pocket should be fitted of 110°C. The minimum difference between control in the pipework to indicate water flow temperature. thermostat and temperature limiter MUST NOT be less than 10°C. HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001090/B... -
Page 14: Unvented Pressurised Systems
From the above information Hamworthy Heating can NOTE! When an optional On/Off Primary Flue size the pressure unit and also the expansion vessel Damper is fitted, there is a facility for the connection required. - Page 15 The controls assembly also incorporates a socket which matches the gas valve wiring plug. 4) (‘Classic’ models only.) Primary flue duct and draught diverter complete with flue bezel. HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001090/B...
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Page 16: 10.3 Gas Pipe Fitting Instructions
It may be necessary to remove the bottom thread of the ‘U’ clamp with the bracket in lower position as it may foul the draught hood. Ensure no undue stress is placed on the gas HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001090/B... -
Page 17: 10.4 Connection To The Flue System
It is recommended that unions are fitted local to the boiler to permit future servicing requirements. HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001090/B... - Page 18 Figure No. 7 - Assembling the Casing/Multi-Casing Set. LOWLINE BOILER CASING TOP DETAIL 'A' REF. DETAIL 'A' STANDARD BOILER CASING TOP REF. DETAIL 'A' AUTOMATIC BOILER 6 PERMANENT PILOT BOILER HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001090/B...
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Page 19: 11.1 Electrical Installation
BS 6891 or IGE/UP/1, rear of the bezel, and fit to the door aperture as IGE/UP/1A and IGE/UP/2 as appropriate. shown ensuring correct orientation and a strong HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001090/B... - Page 20 5) The pipework and valve arrangement is installed to Hamworthy Heating recommendations in such a Hold the button in for a further 20 seconds once the way that water flow rates will be in accordance with pilot is seen to light.
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Page 21: 12.1 Safety Features Summary
Remove plug and insert sampling satisfactorily after following the chart, consult your probe. Replace plug when test is complete. local office of Hamworthy Heating for assistance. NOTE! Care should be exercised if the boiler is HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION... - Page 22 Also clean area under the reflector before re- The boiler flueways can now be cleaned as follows: placing it in its correct location. Re-assemble the HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001090/B...
- Page 23 Renew of the boiler. Please refer to Hamworthy Heating components as required and generally remove any Technical Department before attempting to remove loose sooty deposits and clean as required. components from the gas valve.
- Page 24 No. 16. Rotate the damper blade into the horizontal position, refit the motor and tighten the ‘U’ clamp. Note: The damper shaft passing through the motor clamp, has a hole through, indicating the position of HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001090/B...
- Page 25 533901168(L&G) 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.
- Page 26 'Marshall HE’ Room Feed Hamworthy Modular Boilers Temperature Sensor pipe Valve Circulation pump Drain valve VENTED SYSTEM: Reverse return pipework, Hamworthy recommended system. ‘Marshall HE’ Boiler Sequence Pressure & Mains water Automatic Control System Temperature Double Air Vent Temporary...
- Page 27 150mm should be allowed between casings. (Space baskets 200mm apart). INTEGRA 460 RECOMMENDED 150 MIN 610 MIN 460 MIN 35 APPROX FLOW FLOW Rc2" 62.5 62.5 RET'N RETURN 533 CRS FRONT VIEW SIDE VIEW HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001090/B...
- Page 28 ASSEMBLY TEMPERATURE CONTROLS (OVERHEAT HOUSING CONTROL THERMOSTAT FUSED 3 PIN IEC SUPPLY PLUG GAS PIPE ECO CONNECTOR GAS COCK BOILER INSULATION PIEZO IGNITER VIEWING PORT GAS VALVE BURNER TEST POINT BURNER PILOT ASSEMBLY HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001090/B...
- Page 29 For example: - 2 Purewell 120kW Boilers being fed by 65mm NB 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. HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001090/B...
- Page 30 SCREWED TERMINAL IN IEC FREE PLUG AND SOCKET YELLOW YELLOW PUSH ON SPADE CRIMP TERMINAL BULKHEAD CONNECTOR NOTE! Ensure all power supplies are completely isolated prior to working on the electrical circuits of this appliance. HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001090/B...
- Page 31 Figure No. 13 - Diagram of Igniter Assembly HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001090/B...
- Page 32 Figure No. 14 - Various Gas Valves Fitted to Purewell Boilers a - Honeywell V4400 Series b - Honeywell V4600 Series c - Robertshaw 7000 Series d - SIT NOVA Series HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001090/B...
- Page 33 To Hold in Thermocouple ? Approximately 12mm. Check Thermocouple Operation by Inserting a mVolt (DC) Multi-Meter in Replace Thermocouple Parallel with ECO Lead. Reading Should be at least 8mVolts. Continued on next page HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001090/B...
- Page 34 System remains Cool ? Circulation. Pump Failure. Insufficient Circulation. Thermostat Set too High. Faulty Thermostat. Boiler Boiler Noisy? Waterways Scaled Up. Gas Valve Faulty. Gas Pressure Incorrect, Check Manifold Pressure. Boiler is Operating Satisfactorily ! HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001090/B...
- Page 35 Figure No. 16 – Damper Actuator Motor ACTUATOR END STOP MANUAL OPERATION PUSH-BUTTON POSITION SWITCH DIAL SHOWING SETTING POSITION ACTUATOR REVERSING SWITCH HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001090/B...
- Page 36 NOTE: The above is a first order check. Final Turn ‘OFF’ the gas supply and undo the pressure setting must be made using a gas meter. test point on the gas valve inlet and allow the gas HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001090/B...
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Page 37: Recommended Spares
NOTE: All the above measurements refer to dry flue gas samples. Gas Pressure Switch Location With the cover removed, turn the M3 nut clockwise HAMWORTHY HEATING LIMITED PUREWELL PERMANENT IGNITON BOILER CONTROL PANEL to increase the set point and vice-versa. Seal the 230V ~ 50Hz 35W MAX. - Page 38 USEFUL USER INFORMATION INSTALLER SITE ADDRESS DATE OF COMMISSIONING: BOILER BOILER UNIT SERIAL NO(S). FLUE TYPE SIZE(S) NO(S). NOTES: HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001090/B...
- Page 39 Unit 2 Antrim Line Business Park Naas Road Sentry Lane Dublin 12 Newtownabbey Ireland BT3 8XX Tel: 003531 14191919 Tel:02890849826 Fax: 00353114584806 Fax:02890847443 For all other areas, or for further advice, please contact Hamworthy Heating head office service department in Poole, telephone 01202 6625...
- Page 40 01202 662555 At Hamworthy Heating we employ our own skilled service engineers who are trained to work on all of our products. Our National coverage of all UK mainland sites is supported by a network of Authorised Service Agents who can provide the same high level of service and product expertise.
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