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The header must be suitably supported when
screwing in and tightening pipework to this header.
It is recommended that unions be fitted locally to the
boiler to permit future servicing requirements. Fully
closing valves must not be connected to both flow
and return pipes unless the boiler is fitted with an
individual, correctly sized safety valve.
recommended that a 3-way 'L' port valve is fitted in
the flow connection to allow an open vent situation
should the boiler need to be fully isolated from the
system.
The secondary & primary heat exchangers can be
dispatched separately if required, and will require
assembly on site. Refer to Figure 10.6 (p20).
This is achieved as follows: -
1) Carefully unpack secondary heat exchanger
assembly. A flexible pipe assembly connects both
heat
exchangers
together
dispatched fitted onto the primary heat exchanger.
2) Ensure rope seal is aligned within rope groove
on the top casting.
washers onto the tie rods.
transition duct onto the top casting - ensure rope
seal does not move.
restrain the assembly, DO NOT TIGHTEN AT THIS
STAGE.
3) Connect the flexible pipe to the secondary heat
exchanger and tighten - TAKE CARE NOT TO
DAMAGE OR PLACE UNDUE STRESS ON THE
COPPER TUBES OR HEADERS.
onto the transition duct.
otherwise lugs will be distorted. Lock M8 nuts
together. Remove transition duct cover and visually
inspect rope seal integrity.
4) Ensure all connections are watertight starting at
the base. Re-fit transition duct cover and continue
installation.
10.7 Casing and Controls Assembly
For assembly of casing and controls refer to Figure 10.7
(p22/23).
10.7.1 Multi casings
Note: Where boilers are in Modular form, i.e.
MW420 (3 x 140kW), a multi-casing pack is
provided for each additional boiler. For example: a
triple boiler module will require: - 1 off single casing
pack plus 2 off multi-casing packs. If the bottom
support rail (item 19) has not been pre-assembled,
the following procedure must be taken: -
1) Loosen the nuts that clamp the basket
assemblies of the 2 boilers together, (1 front and 1
rear). Remove the bolt, spacer and nut assembly.
HAMWORTHY HEATING LTD
and
is
normally
Screw on four M8 nuts &
Gently lower the
Fit M8 nuts & washers to
Tighten nuts
Do not over tighten
2) Position the bottom support rail (item 19)
between the boiler baskets. Assemble to boiler
baskets using 2off M6 screws, nuts and shake proof
washers (items 18, 9 & 10).
3) Select the rear support rail (item 21) and fit 6off
It is
'U' nuts (item 15), 4off in the 2 lower pairs of holes
and 2off in the angle bracket at the top. Fix the rear
support rail to the bottom support rail, using 2off M6
screws and washers (items 18 and 10).
4) Select the front support rail (item 22) and fit the
2off door location brackets (item 5) using 4off M6
screws and spring washers (items 13 and 14). Fit
2off 'U' nuts (item 15) to the top 45° return. Fix the
front support rail to the bottom support rail, using
2off M6 screws and washers (items 18 and 10).
5) Select the top support rail (item 20) and fit 2off 'U'
nuts (item 15) to the pair of holes at the rear end. Fix the
top support rail to the front and rear support rails using
6off No.8 self tapping screws (item 16).
10.7.2 Single and multi-casings.
6) Select the side panels (items 1 and 2) and fit the
2off door location brackets (item 5) using 4off M6
screws and spring washers (items 13 and 14). Fit
'U' nuts (item 15) to the 2 holes at the rear of each
panel as shown. Fix the side panels to the boiler
basket using M6 nuts and shake proof washers
(items 9 and 10).
7) Fit the back panel (item 3) using 4off No.8 self
tapping screws (item 16). DO
TIGHTEN THE SCREWS.
8) Select the control panel (item 6). Permanent
pilot boilers only, fit the door catch bracket to the
control panel using the 2off M6 screws, nuts and
washers supplied with the panel as shown. Loosely
fit 4off M6 nuts and washers (items 9 & 10) to the
pressed-in studs at the top front end of the side
panels (or multi-casing frame set) as shown. Fit the
control panel by passing the right hand side behind
the pressed-in studs and pulling the panel forwards
to engage the studs into the slots in the right hand
side of the panel. Push the left of the control panel
backwards to engage the studs on that side into the
slots in the panel. Tighten the 4off M6 nuts.
10.7.3 Warmwell top casing.
1) Tighten the 4off screws fixing the back panel to
the side panels.
2) Select the appropriate side panel support (item
34 or 35) dependent on boiler model. Discard the
unused item. Fit 'U' nuts (item 15) to the holes at
each end of the side panel support. Fit 2off M6 nuts
and plain washers (items 9 and 36) to the M6 studs
located on the top of the Warmwell boiler secondary
19
WARMWELL
NOT
FULLY
500001091/F
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