Hamworthy Purewell VariHeat 70c Installation, Commissioning And Servicing Instructions
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Hamworthy Purewell VariHeat 70c Installation, Commissioning And Servicing Instructions

Hamworthy Purewell VariHeat 70c Installation, Commissioning And Servicing Instructions

Cast iron, pre-mix, condensing, modular boilers with automatic ignition for heating and domestic hot water
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Heat c
Purewell Vari
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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  • Page 1 Heat c Purewell Vari 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 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. 500001169 ISSUE ‘T’ MARCH 2015 Page HAMWORTHY HEATING LTD PUREWELL VariHeat c 500001169/T...

  • Page 4: Table Of Contents

    10.0 SERVICING ............................37 11.0 REPLACEMENT OF FAILED COMPONENTS ................39 11.1 Igniter and Flame Probe Assembly 11.2 Temperature Limiter 11.3 Main Gas Valve 11.4 Combustion Fan 12.0 RECOMMENDED SPARES ......................45 Page HAMWORTHY HEATING LTD PUREWELL VariHeat c 500001169/T...
  • Page 5 Combustion system Assembly Models PV95c/110c/140c(exploded view).……….……..….45 Figure 11.4.2 Combustion system Assembly Models PV95c/110c/140c………………………………...…….45 Figure 11.5 Gas Train Assembly ....................... 46 Figure 11.6 Casing Assembly ........................46 Figure 11.7 Secondary Heat Exchanger Assembly .................. 47 Page HAMWORTHY HEATING LTD PUREWELL VariHeat c 500001169/T...
  • Page 6 Schematic for Single Boiler, Primary Circuit System ............. 57 Figure E1.3.3 Schematic for Single Boiler (External 0~10V) Multi Circuit System ........58 Figure E1.3.4 Schematic for Multiple Boiler (Cascade) Primary Circuit System .......... 58 Page HAMWORTHY HEATING LTD PUREWELL VariHeat c 500001169/T...

  • Page 7: Introduction

    Consult Hamworthy Heating Technical Department 1.0 INTRODUCTION for help or assistance if in doubt. 1.1 A competent person holding ‘GAS SAFE’ 1.5 The Purewell VariHeat boiler is not suitable for registration or equivalent must install this boiler. All direct connection to domestic hot water supplies or installations MUST conform to the relevant Gas gravity fed heating systems.

  • Page 8: 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 c 500001169/T...
  • Page 9 Figure 2.2 - Boiler Packaged Dimensions Model Depth Width Height Weight Purewell VariHeat 70c 170kg Purewell VariHeat 95c 170kg Purewell VariHeat 110c 170kg 1090mm 550mm 1190mm Purewell VariHeat 140c 230kg Purewell VariHeat 180c 230kg Delivery Verification When taking delivery please ensure that you have received the correct number of boilers and ancillary packages to fulfil your order.

  • Page 10: 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 11 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 c 500001169/T...

  • Page 12: 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 c 500001169/T...

  • Page 13: 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 14 Figure 4.3 – Flue Connection Point Flue fixing bracket Flue Pipe Elbow Flue Connection as delivered Flue Connection fitted HAMWORTHY HEATING LTD PUREWELL VariHeat c 500001169/T...

  • Page 15: Water Supply

    For minimum water pressure see Appendix ‘E’ - Water Data (Page 54) Flow Connection Model Type Model Type Return Connection PV70c, 95c & 110c PV140c & 180c Figure 4.4 – Water Connection Points HAMWORTHY HEATING LTD PUREWELL VariHeat c 500001169/T...

  • Page 16: 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 17: 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 c 500001169/T...

  • Page 18: 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 19: 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 20: 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 c 500001169/T...

  • Page 21: Checks Prior To Lighting The Boiler

    A combustion check must be taken when first commissioning the boiler. A sampling point is provided in the base of 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. HAMWORTHY HEATING LTD PUREWELL VariHeat c 500001169/T...
  • Page 22 10) Check the flame ionisation signal generated whilst the boiler is firing. This can be viewed directly from the display by accessing information level C1. The value is set to read dc μA. Refer to section 8.2 - Controls Operation. HAMWORTHY HEATING LTD PUREWELL VariHeat c 500001169/T...
  • Page 23 7.3.4.4 After changing the set-point to the desired value the ’Mode’ key must be pressed to store this value and return to the boiler’s default display. Should a set point higher than 80°C be required, please contact Hamworthy Heating, as programming for a higher maximum outlet temperature is restricted by a factory set access code.

  • Page 24: Combustion Checks

    If combustion level is outside of this range use the Cross Head Throttle Screw to adjust the mixture. HIS SETTING MUST BE CORRECT BEFORE CONTINUING To increase the CO level, turn the adjustment anti-clockwise. Figure 7.4.3.1 - Adjusting gas valve throttle HAMWORTHY HEATING LTD PUREWELL VariHeat c 500001169/T...
  • Page 25 Low Fire Target 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 7.4.4.1—Adjusting gas valve offset HAMWORTHY HEATING LTD PUREWELL VariHeat c 500001169/T...

  • Page 26: User Instructions

    Switch Set Point mbar low fire  High Fire  10.6 70c  0.34 mbar  1.39 mbar  95c  0.46 mbar   1.94 mbar  10.2 110c   0.54 mbar  2.46 mbar  140c  0.87 mbar  5.73 mbar  180c                                                  7.5 ‐ 8.5 mbar  Burner pressure test point Figure 7.4.5 - Burner pressure test point HAMWORTHY HEATING LTD PUREWELL VariHeat c 500001169/T...
  • Page 27 Figure 7.4.3 - Example Fan Assembly PV70c High Fire Gas Adjustment Factory Sealed Low Fire Gas Adjustment Factory Sealed Pressure Switch Outlet Gas Pressure Test Point Figure 7.4.4 - Example Fan Assembly PV140c & PV180c HAMWORTHY HEATING LTD PUREWELL VariHeat c 500001169/T...

  • Page 28: Boiler Controls

    LCD unit and 10 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 29 LMU64 Controller ( For Part No’s See Page 44 ) 532496004 Air Pressure Switch 533901441 Igniter Transformer 533901437 Display Screen 533901179 Safety Temperature Limiter 530801029 Perspex Cover Figure 8.1.2 - General Overview of Controls HAMWORTHY HEATING LTD PUREWELL VariHeat c 500001169/T...

  • Page 30: Controls Operation

    Water Pressure ◄ ◄ ◄ Operating phase - refer to section 8.2.15 Outside temperature Error code - refer to section 8.2.14 Boiler temperature Press one of these buttons to return to the default display HAMWORTHY HEATING LTD PUREWELL VariHeat c 500001169/T...
  • Page 31 Adjustment of dhw temperature setpoint - not used Line selection (down / up) Selection of operating parameter Adjustment of settings Adjustment of parameter settings Information Select information display screens Enable Maintenance mode Press buttons simultaneously to select HAMWORTHY HEATING LTD PUREWELL VariHeat c 500001169/T...
  • Page 32 Press Info button Press buttons for at least 3 seconds Press button twice Choose the relevant parameter with buttons Note after about 8 minutes, the display will automatically change to the default display. HAMWORTHY HEATING LTD PUREWELL VariHeat c 500001169/T...
  • Page 33 Figure 8.2.1.3 - Operation and display philosophy HAMWORTHY HEATING LTD PUREWELL VariHeat c 500001169/T...
  • Page 34 Operating mode is, or changes to: Automatic Continuous ‘Normal’ operation Continuous ‘Reduced’ operation Standby Operating mode of dhw. On or Off - not used Time bar Display of time program of heating circuit HAMWORTHY HEATING LTD PUREWELL VariHeat c 500001169/T...
  • Page 35 3 seconds. The internal error code will be displayed. Example “4975” Press the info button to return to the info display. Press to return to the default display. Figure 8.2.3.2 - Display of Status Code HAMWORTHY HEATING LTD PUREWELL VariHeat c 500001169/T...
  • Page 36 The room temperature setpoint or boiler temperature setpoint will be changed depending on the plant’s configuration ( with or without outside sensor). If no button is pressed for about 8 minutes, the screen will automatically return to the default display. Changes will be stored. HAMWORTHY HEATING LTD PUREWELL VariHeat c 500001169/T...
  • Page 37 When a new startup is made, or after power-On, the previous settings will be stored in the LMU. Also, the software version number of the operator module and that of the connected type of LMU... will be deliv- ered. HAMWORTHY HEATING LTD PUREWELL VariHeat c 500001169/T...

  • Page 38: Functions

    - figure 8.2.9 The operating modes are selected by pressing button On the LCD, a pointer below the respective symbol points to the selected heating circuit operating mode. HAMWORTHY HEATING LTD PUREWELL VariHeat c 500001169/T...
  • Page 39 Fault air pressure switch (does not close) Fault heating circuit flow switch / pressure switch Fault air pressure switch (does not open) Chimney sweep function active Controller stop function active LMU... in parameter setting mode HAMWORTHY HEATING LTD PUREWELL VariHeat c 500001169/T...
  • Page 40 PH_THL2_2 PH_TN_2 Home run PH_TNB PH_TLO PH_TNN Lockout position (display of the current PH_STOER error code) Note: -If operating phases are passed very quickly or skipped, the relevant display code will not appear. HAMWORTHY HEATING LTD PUREWELL VariHeat c 500001169/T...
  • Page 41 The automatic mode must obviously be activated on the boiler as well as on the QAA73, for the function to oper- ate. The function is automatically activated by a default setting in the QAA73. HAMWORTHY HEATING LTD PUREWELL VariHeat c...
  • Page 42 The Albatros code is the ‘E’ display code supported by the internal code. See figure 8.2.9 Note : When connecting to a QAA73 unit refer to Hamworthy OEM manual 500001140 When connecting to a Merley control unit refer to Hamworthy OEM manual 500001210 HAMWORTHY HEATING LTD PUREWELL VariHeat c...
  • Page 43 Figure 8.3.11 - Operating phases HAMWORTHY HEATING LTD PUREWELL VariHeat c 500001169/T...
  • Page 44 Figure 9.0 Boiler Wiring Schematic HAMWORTHY HEATING LTD PUREWELL VariHeat c 500001169/T...

  • Page 45: Fault Finding

    - refer to section 8.2.1 - Controls Operation. Should a fault occur which cannot be reset, or a fault repeatedly occurs, contact Hamworthy Heating for assistance. Do not continue to operate or use the boiler as this may cause damage to the boiler or controls.
  • Page 46 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. 7) Re-fit casing panels and tidy floor around boiler as necessary. HAMWORTHY HEATING LTD PUREWELL VariHeat c 500001169/T...

  • Page 47: 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 48 Figure 11.1 - Hot Surface Igniter and Flame Sensing Probe Positions 533901497 Gas Pressure Switch 531201067 Venturi Seal 532418005 Venturi 533903037 Gas Valve Figure 11.2 - Gas Valve Assembly Models PV70c HAMWORTHY HEATING LTD PUREWELL VariHeat c 500001169/T...
  • Page 49 Figure 11.3 - Combustion System Assembly PV70c 533901497 Gas Pressure Switch 533901376 Fan 533903037 Gas Valve 748010342 M5x 12 Screw 532418005 Gas/Air Mixer (Venturi) 748010342 M8x20 Screw Figure 11.4 - Combustion System Assembly Model PV70c HAMWORTHY HEATING LTD PUREWELL VariHeat c 500001169/T...
  • Page 50 748520218 M8x20 Screw Figure 11.4 .1- Combustion System Assembly Models PV180c 742121238 Venturi Seal 533901497 Gas Pressure Switch 532418007 Venturi 533903044 Gas Valve Figure 11.2.1 - Gas Valve Assembly Models PV 95c/ 110c/ 140c HAMWORTHY HEATING LTD PUREWELL VariHeat c 500001169/T...
  • Page 51 Figure 11.3 .1- Combustion System Assembly PV 95c/ 110c/ 140c 533901497 Gas Pressure Switch 533706076 Fan 533903044 Gas Valve 74813870 M6x16 Screw 532418007 Gas/Air Mixer (Venturi) Figure 11.4.2 - Combustion System Assembly Model PV 95c/ 110c/ 140c HAMWORTHY HEATING LTD PUREWELL VariHeat c 500001169/T...
  • Page 52 Fastener Clip 533901492 Cable Clip 748551009 1/4 Turn Receptacle 748551010 1/4 Turn Screw 748551010 1/4 Turn Screw 530650351 Side Rail 530650355 Front 530650352 Front Cover Cover Brace Moulding Figure 11.6 - Casing Assembly HAMWORTHY HEATING LTD PUREWELL VariHeat c 500001169/T...
  • Page 53 Section Seal NTC Temp Sensor 562403165 Water Con- 5324120043 nection Assembly Heat Exchanger 562403167 2 Section Flexible Connector 531201122 Water Connection Gasket Figure 11.8- Heat Exchanger Assembly ( model 70c—110c shown for illustration) HAMWORTHY HEATING LTD PUREWELL VariHeat c 500001169/T...
  • Page 54 742121186 O-Ring 5324120044 Heat Exchanger 532012014 Tie 5324120043 Heat Exchanger 562403166 3 Section Flexible Connector 531201122 Water Connection Gasket Figure 11.9 - Heat Exchanger Assembly ( model 140c - 180c shown for illustration) HAMWORTHY HEATING LTD PUREWELL VariHeat c 500001169/T...

  • Page 55: Recommended Spares

    Low Gas Pressure Switch (180c) ..........................533925004 Set of Gaskets (Routine Service - combustion system) ....................563605569 Set of Gaskets (Major Service - combustion system plus heat exchanger) .............. 563605570 For service or spares please contact :- Hamworthy Heating Limited Fleets Corner Poole Dorset BH17 0HH Phone Number ................
  • Page 56 Maximum Gas Inlet Pressure mbar Gas Flow Rate (maximum) 10.9 14.4 18.5 9.5 / 9.5 Target CO % at High / Low fire ±0.25% 9.5 / 8.5 Figure A1 - Gas Data HAMWORTHY HEATING LTD PUREWELL VariHeat c 500001169/T...
  • Page 57 NOTE: FOR ELECTRICAL CONNECTIONS TO BOILER SEE FIGURE 4.5 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 c 500001169/T...
  • Page 58 Figure B1.2 - External Control Wiring for Multiple Module Installation HAMWORTHY HEATING LTD PUREWELL VariHeat c 500001169/T...
  • Page 59 B2.0 below. The condition of the fuse should be checked when investigating a possible LMU malfunction. HHL part number for spare T1A 5x20 fuse……………………………………………………………………..533922013 Figure B2.0 In-line Fuse HAMWORTHY HEATING LTD PUREWELL VariHeat c 500001169/T...
  • Page 60 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 61 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 62 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 c 500001169/T...
  • Page 63 Flow rate per kW total rated heat input (net) Boilers Difference between Inlet air Without inlet and extract air (Combustion Draught (Inlet minus extract ventilation) Diverters ventilation) m³/h m³/h Volume 1.35 +/- 0.18 HAMWORTHY HEATING LTD PUREWELL VariHeat c 500001169/T...
  • Page 64   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 c 500001169/T...
  • Page 65 Figure E1.2 - Typical Piping Layouts HAMWORTHY HEATING LTD PUREWELL VariHeat c 500001169/T...
  • Page 66 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 67 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 68 QAC34 (HHL 533901457) Figure E 1.3.3 - Schematic for Single Boiler (External 0~10V), Multi Circuit System MERLEY CONTROLLER MERLEY) 533901457 533901593 Figure E 1.3.4 - Schematic for Multiple Boiler (Cascade), Primary Circuit System HAMWORTHY HEATING LTD PUREWELL VariHeat c 500001169/T...
  • Page 69 USEFUL USER INFORMATION INSTALLER SITE ADDRESS BOILER TYPE BOILER SIZE(S) UNIT NO(S). SERIAL NO(S). FLUE NOTES HAMWORTHY HEATING LTD PUREWELL VariHeat c 500001169/T...
  • Page 70 NOTES: HAMWORTHY HEATING LTD PUREWELL VariHeat c 500001169/T...
  • Page 72 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:

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

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