Table of Contents
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Warmwell Series Boilers
Cast Iron, Atmospheric, Condensing, Modular Boilers
with Automatic Ignition for Heating and Domestic Hot
Water Installations
Installation, Commissioning
and Servicing Instructions
Warmwell 60, 80, 95 120 & 140 Models
IMPORTANT NOTE
THESE INSTRUCTIONS MUST BE READ
AND UNDERSTOOD BEFORE INSTALLING,
COMMISSIONING, OPERATING OR
SERVICING EQUIPMENT
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Table of Contents
Related Manuals for Hamworthy Warmwell 95
Summarization of Contents
Warmwell Series Boilers: Installation, Commissioning and Servicing Instructions
Important Safety Note
Crucial warning about reading instructions before installation or operation.
Customer Services
Technical Enquiries
Advice on product application and use from the technical team.
Site Assembly Service
Service for restricted plant rooms, ensuring quality build.
Commissioning Service
Ensuring safe and efficient operation by engineers or agents.
Maintenance Agreements
Benefits of regular servicing for safety and efficiency.
Breakdown, Repair, and Replacement
Rapid response service for breakdowns and repairs.
Spare Parts Availability
Service for current and discontinued product parts.
1.0 Introduction
Installation Personnel and Regulations
Requirement for competent installers and adherence to regulations.
Boiler Design and Features
Description of cast iron sections, heat exchanger, and flue system.
System Considerations and Options
Notes on unvented systems, water flow layouts, and optional controls.
2.0 Technical Data
Boiler Dimensions and Clearances
Boiler dimensions and required installation space for boilers.
Screw Thread Standards
Conformance to ISO standards for screw threads.
3.0 General Requirements
Compliance with Related Documents
Adherence to Gas Safety, Building, and IEE regulations.
Feed Water Quality Recommendations
Importance of water treatment to prevent scale and sludge.
3.3 Adequate Water Flow
Time Clock Control Considerations
Pump overrun requirements for time-controlled systems.
Minimum System Water Pressure
Pressure requirements for safe and effective boiler function.
4.0 Location
Boiler Installation Site Requirements
Space, ventilation, and surface requirements for boiler placement.
5.0 Gas Supply
Gas Service Pipes and Metering
Requirements for gas supply availability and metering.
Gas Pipework, Valves, and Leak Checks
Procedures for fitting gas pipes, control valves, and leak testing.
6.0 Flue System
General Flue System Design and Requirements
Guidelines for flue system design, support, and location.
Flue Condensation and Material Selection
Managing condensation and choosing appropriate flue materials.
7.0 Air Supply
Natural Ventilation for Air Supply
Requirements for permanent air vents in the boiler room.
Mechanical Ventilation for Air Supply
Considerations for mechanical air supply systems.
8.0 Water Circulation System
General Water System Installation
Insulation, drain valves, and header connection guidelines.
Safety Valves and Venting Requirements
Installation of pressure relief valves and vent pipes.
Pumps, Gauges, and Flow Rate Management
Circulating pumps, thermometers, and flow rate monitoring.
8.8 Minimum Water Flow Rates
Control Schemes and Frost Protection
Temperature controls, flow controls, and frost thermostat installation.
Unvented Pressurised Systems
Sizing pressurisation units and expansion vessels.
Modular Boiler Control Schemes
Optional Milton sequencing system for modular boiler control.
9.0 Electrical Supply
Site Wiring and Mains Connections
Requirements for electrical installation and mains supply isolation.
Signal Outputs and Sequencing Module
Volt-free contacts and optional sequencing interface module connections.
10.0 Boiler Assembly and Installation
General Assembly and Component Handling
Unpacking, handling, and initial assembly of boiler components.
Heat Exchanger Insulation Fitting
Instructions for fitting primary and secondary heat exchanger insulation.
10.3 Gas Pipe Fitting Instructions
Flue, Gas, and Water Connections
Connecting the boiler to flue, gas supply, and water systems.
10.7 Casing and Controls Assembly
Multi Casing Assembly Procedure
Detailed steps for assembling multi-boiler casing kits.
Single and Top Casing Assembly
Instructions for fitting single casing parts and the top casing.
11.0 Commissioning and Testing
Electrical and Gas Installation Verification
Checks for correct electrical and gas installation before operation.
Water System and Boiler Pre-Checks
Flushing, filling, and pre-lighting checks of the boiler system.
Boiler Commissioning and Initial Lighting
Step-by-step guide to commissioning and first lighting the boiler.
12.0 Fault Finding
Safety Features and Control Panel Indicators
Overview of safety features and function indicators on the PCB.
13.0 Servicing
Annual Servicing and Safety Checks
Recommended servicing frequency and pre-service isolation procedures.
Flueway Cleaning and Component Access
Steps for cleaning flueways and gaining access to internal parts.
14.0 Replacement of Failed Components
Igniter, Pressure Switch, and Thermostat Replacement
Procedures for replacing key electrical and control components.
Gas Valve and Fan Assembly Replacement
Steps for replacing the main gas valve and fan motor assembly.
15.0 Recommended Spares
Spare Parts List and Contact Information
List of electrical and mechanical spare parts and contact details.
Appendix A: Information Relating to Propane Firing
Propane Gas Data and Installation Differences
Specific gas data and requirements for propane fuel.
Propane Boiler Checks and Combustion
Pre-lighting checks and combustion parameters for propane operation.
Connect Direct: Contact Information
Hamworthy Office Contacts
Telephone and fax numbers for Hamworthy's main offices.
Accredited Agents and Website
Listing of regional agents and the company website.
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