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 140
Summarization of Contents
Customer Services
Technical Enquiries
Provides technical advice on product application and use from the technical team and accredited agents.
Site Assembly
Offers a service of site assembly for products where plant room area is restricted.
Commissioning
Ensures equipment operates safely and efficiently through commissioning by engineers or agents.
Maintenance Agreements
Regular routine servicing by engineers to inspect safety, integrity, and performance of plant.
Breakdown service, repair, replacement
Provides rapid response breakdown, repair, or replacement services through head office and agents.
Spare Parts
Offers a comprehensive spare parts service for current and discontinued products.
1.0 Introduction
1.8 Options
Details optional features like reverse return header kits and Milton boiler sequence control systems.
2.0 Technical Data
2.3 Screw Threads
Specifies the screw thread standards used in the Warmwell boiler, including ISO and BS standards.
3.0 General Requirements
3.1 Related Documents
Lists relevant standards and regulations for installation and safety compliance.
3.2 Feed Water Quality
Advises on water treatment to prevent scale and sludge formation in boiler waterways.
3.3 Adequate Water Flow
Discusses the importance of adequate water flow through the boiler for optimal performance and longevity.
3.4 Time Clock Control
Recommends pump overrun after time clock shutdown to prevent overheating and deposition.
3.5 Minimum System Water Pressure
Outlines minimum pressure requirements at the boiler for different installation configurations.
5.0 Gas Supply
5.1 Service Pipes
Guidance on consulting the local gas region for adequate gas supply planning.
5.2 Meters
Instructions on checking existing gas meters for adequacy and new meter connections.
5.3 Gas Supply Pipes
Specifies standards for fitting gas supply pipes, ensuring adequate size and testing.
5.4 Boosted Supplies
Requirements for gas pressure boosters, including low-pressure cut-off switches.
5.5 Boiler House Control Valve
Mandates a manual gas isolation valve for the boiler house, clearly identified and accessible.
5.6 Boiler Gas System Leak Check
Details procedures for performing gas leak checks on pipework and components after installation.
6.0 Flue System
6.1 General Requirements
Outlines general requirements for flue systems, referencing regulations and design considerations.
6.2 Design Waste Gas Volume and Temperature
Specifies design parameters for waste gas volume and temperature for flue system design.
6.3 Flue Condensation
Highlights the need to manage condensation in the flue system and channel it to drains.
6.4 Materials
Specifies requirements for flue system materials, emphasizing corrosion resistance and durability.
6.5 Disconnection
Advises on making provisions for flue pipe disconnection for servicing and inspection.
6.6 Flue Discharge
Details safe and efficient flue discharge requirements to disperse combustion products.
6.7 Surface Temperatures
Specifies maximum surface temperatures for boilers and flues near combustible materials.
6.8 Flue System Location
Provides guidance on flue system placement to avoid accidental damage and danger.
7.0 Air Supply
7.1 Air Supply by Natural Ventilation
Details requirements for permanent air vents for combustion and ventilation in the boiler room.
7.2 Air Supply by Mechanical Ventilation
Outlines specifications for mechanical ventilation systems, including inlet and extract rates.
8.0 Water Circulation System
8.1 General
Provides general recommendations for the water circulation system, referencing standards.
8.2 Pressure Relief Valve (Safety Valve)
Specifies requirements for fitting pressure relief valves to comply with safety standards.
8.3 Open Vent and Cold Feed Pipe
Details pipe sizing and installation requirements for open vent and cold feed systems.
8.4 Altitude Gauge (Water Pressure Gauge)
Mandates the provision of a water pressure gauge with an isolating cock for monitoring system pressure.
8.5 Thermometer
Recommends fitting a thermometer to indicate water flow temperature in the pipework.
8.6 Drain Valves
Specifies the need for drain valves in accessible positions for system draining.
8.7 Circulating Pump
Discusses the requirement for circulating pumps and checking their performance against boiler pressure drop.
8.8 Minimum Water Flow Rates
Details minimum water flow rates required for the boiler to operate safely and efficiently.
8.9 Water Pressure Drop
Indicates where to find information on the waterside hydraulic resistance (pressure drop) of the boiler.
8.10 Control Schemes
Covers control schemes, including temperature controls, water flow controls, and frost protection.
8.11 Unvented Pressurised Systems
Provides guidance on sizing pressurisation units and expansion vessels for unvented systems.
8.12 Modular Boiler Control Schemes
Describes optional Milton boiler sequence control systems for modular installations.
9.0 Electrical Supply
9.1 Site Wiring
Details electrical connection requirements, including cable routing and knockout provision.
9.2 Indication Signals and Volt Free Contacts
Explains the use of volt-free contacts for external indicators or alarms, and isolation requirements.
9.3 Milton Boiler Sequence Control and Sequencing Interface Module (Optional)
Describes the optional Milton system for managing multiple boilers and its interface module.
10.0 Boiler Assembly and Installation
10.1 General
Outlines the factory packaging and site assembly of the boiler components and casing.
10.2 Heat Exchanger Insulation Fitting Instructions
Provides step-by-step instructions for fitting insulation blankets to the primary and secondary heat exchangers.
10.3 Gas Pipe Fitting Instructions
Details procedures for fitting gas pipework, including union connections and clamp usage.
10.4 Connection of Boilers to the Flue System
Discusses flue system design recommendations, joint sealing, and material requirements.
10.5 Gas Connections
Specifies requirements for the incoming mains gas supply, including isolating valves and unions.
10.6 Water Connections
Guides on connecting water pipework, emphasizing avoiding stress on boiler connections.
10.7 Casing and Controls Assembly
Covers the assembly of casing panels, control panels, and associated components for single and modular units.
11.0 Commissioning and Testing
11.1 Electrical Installation
Details electrical checks, supply requirements, and wiring connections for the boiler installation.
11.2 Gas Installation
Refers to gas supply sections for inspection, testing, and purging requirements.
11.3 Water Circulation System
Outlines steps for filling the system, venting air, and checking for leaks after pump installation.
11.4 Commissioning the Boiler
Specifies prerequisites and checks required before and during the boiler commissioning process.
11.5 Boiler Checks Prior To Lighting
Lists essential checks on gas supply, electrical connections, and safety links before initial boiler lighting.
11.6 Procedure for Initial Lighting
Describes the step-by-step process for safely lighting the boiler for the first time.
11.7 Gas Pressure Adjustment and Combustion Checks
Details how to adjust gas pressures and perform combustion analysis for optimal boiler performance.
11.8 Temperature Limiter (Limit Thermostat)
Explains how to test and adjust the temperature limiter to ensure safety shutdown.
11.9 Safety Checks
Outlines checks for controller operation and safety features, including lockout conditions.
11.10 User's Instructions
Emphasizes the importance of demonstrating operation and providing user instructions to the boiler owner.
12.0 Fault Finding
12.1 Safety Features Summary
Explains the function of safety features and their indicators (neons) on the main PCB.
12.2 Fault Finding Procedures
Provides flowcharts and guidance for diagnosing and rectifying common boiler faults.
12.3 Possible Causes of Boiler Lockout
Lists potential reasons for the boiler entering a lockout state, such as ignition or gas supply issues.
13.0 Servicing
13.1 Regular Servicing Recommendations
Stresses the importance of annual servicing for controls, safety features, and efficiency checks.
13.2 Pre-Servicing Procedures
Details essential safety steps before commencing any servicing work on the boiler.
13.3 Boiler Flueway Cleaning
Describes the process for accessing and cleaning the boiler's flueways and heat exchanger surfaces.
14.0 Replacement of Failed Components
14.1 Igniter Assembly
Instructions for removing and replacing the igniter assembly, including its mounting and connections.
14.2 Pressure Switch
Details the procedure for replacing pressure switches used for monitoring fan operation.
14.3 Control Thermostat Renewal
Guides on how to replace the boiler's temperature control thermostat and its sensor.
14.4 Temperature Limiter (Limit Stat) Renewal
Outlines the process for replacing the temperature limiter, including its setting adjustment.
14.5 Main Gas Valve
Provides instructions for replacing the main gas valve assembly, emphasizing correct orientation and connections.
14.6 Fan Assembly
Details the procedure for removing and replacing the fan motor and impeller unit.
14.7 Fan Speed Controller
Explains how to replace the fan speed controller, including disconnecting and reconnecting electrical components.
Appendix A - Information Relating to Propane Firing
1.0 Introduction
Introduces differences in construction and setting for propane-fired boilers compared to natural gas.
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