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Hamworthy Purewell VariHeat 65he Installation, Comissioning And Servicing Instructions

Purewell variheat he series boilers
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Heat he
Purewell Vari
Boilers
Cast Iron, Pre-mix, High Efficiency, Modular Boilers with
Automatic Ignition for Heating and Domestic Hot Water
Installations
Installation, Commissioning
and Servicing Instructions
MODELS - 65he, 85he, 105he, 125he
I
NATURAL GAS
2H
IMPORTANT NOTE
THESE INSTRUCTIONS MUST BE READ
AND UNDERSTOOD BEFORE INSTALLING,
COMMISSIONING, OPERATING OR
SERVICING EQUIPMENT

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Summary of Contents for Hamworthy Purewell VariHeat 65he

  • Page 1 Cast Iron, Pre-mix, High Efficiency, Modular Boilers with Automatic Ignition for Heating and Domestic Hot Water Installations Installation, Commissioning and Servicing Instructions MODELS - 65he, 85he, 105he, 125he NATURAL GAS IMPORTANT NOTE THESE INSTRUCTIONS MUST BE READ AND UNDERSTOOD BEFORE INSTALLING,...
  • Page 3 Automatic Ignition for Heating and Domestic Hot Water Installations Installation, Commissioning and Servicing Instructions MODELS - 65he, 85he, 105he, 125he NATURAL GAS NOTE: THESE INSTRUCTIONS MUST BE READ AND UNDERSTOOD BEFORE INSTALLING, COMMISSIONING, OPERATING OR SERVICING EQUIPMENT. THE PUREWELL BOILER IS INTENDED FOR USE AS A COMMERCIAL APPLIANCE AND IS NOT CERTIFIED FOR USE IN DOMESTIC APPLICATIONS.

  • Page 4: Table Of Contents

    Fault Error Code Display........................30 FAULT FINDING..........................36 10.0 SERVICING............................36 11.0 REPLACEMENT OF FAILED COMPONENTS................38 11.1 Igniter and Flame Probe Assembly 11.2 Temperature Limiter 11.3 Main Gas Valve 11.4 Combustion Fan 12.0 RECOMMENDED SPARES ......................44 Page HAMWORTHY HEATING LTD PUREWELL VariHeat he 500001170/K...
  • Page 5 Combustion System Assembly PV105he/PV125he............40 Figure 11.5 Gas Train Assembly ......................40 Figure 11.6 Casing Assembly ........................41 Figure 11.7 Secondary Heat Exchanger Assembly ..................42 Figure 11.8 Heat Exchanger Assembly PV65he/PV85he................42 Figure 11.9 Heat Exchanger Assembly PV105he/PV125he..............41 Page HAMWORTHY HEATING LTD PUREWELL VariHeat he 500001170/K...
  • Page 6 Gas Data ..........................45 Figure B1.1 Electrical Supply ........................46 Figure B1.2 External Control Wiring for Multiple Boiler Installation............47 Figure B1.3 Configuration of Hamworthy—Trend IQ3 Remote Monitoring Unit (RMU) .....48 Figure C1 Flue Data..........................49 Figure C1.1 Flue Resistance ........................51 Figure C1.2 Open Flue (Natural Draught) B23 Flue System..............51 Figure D1 Mechanical Ventilation Flow Rates..................52...

  • Page 7: Introduction

    2, 3 & 4 boiler configuration covering a single chimney. No draught diverter is fitted to the models 65he, 85he, 105he, 125he. These kits boiler nor is a fixed diverter required in the flue incorporate all necessary valves and interconnecting system.

  • 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 he 500001170/K...
  • Page 9 65 - 85 he 4 boilers 2318 105 - 125 he 2 boilers 1250 105 - 125 he 3 boilers 1784 105 - 125 he 4 boilers 2318 Figure 2.3 - Header Kit Packaged Dimensions HAMWORTHY HEATING LTD PUREWELL VariHeat he 500001170/K...

  • 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.)
  • 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 he 500001170/K...

  • 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 he 500001170/K...

  • Page 13: Flues

    Refer to Appendix C - Fig C1. • Connecting flue systems may be smaller in internal diameter than the boiler connection. Refer to Hamworthy Heating Technical Dept for assistance. Flue fixing bracket Flue Pipe...

  • Page 14: Water Supply

    For minimum water pressure see Appendix ‘E’ - Water Data (Page 48) Flow Connection Return Connection Condensate Take-Off Model Type Model Type PV105he & 125he PV65he & 85he Figure 4.4 – Water Connection Points HAMWORTHY HEATING LTD PUREWELL VariHeat he 500001170/K...

  • Page 15: 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 16: 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 he 500001170/K...

  • Page 17: Boiler Assembly

    Return R2” Male thread. Indicated (behind flue pipe) by a blue dot on boiler. Gas R1” Male thread. Condense 32mm dia. Male plain. Offset and below return connection. Figure 5.2.1 - Rear Water Connections HAMWORTHY HEATING LTD PUREWELL VariHeat he 500001170/K...

  • Page 18: Electrical Connections

    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. Fol- lowing soundness tests close valve B and remove manometer connections and tighten test points. HAMWORTHY HEATING LTD PUREWELL VariHeat he 500001170/K...

  • 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 he 500001170/K...
  • 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 he 500001170/K...
  • 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

    9) If the combustion readings fall outside the required range DO NOT adjust the gas valve settings . CONTACT HAMWORTHY HEATING SERVICE DEPARTMENT. (Contact details on page 36) 10) Tampering with any sealed component may result in loss of warranty on the appliance.
  • Page 25 Figure 7.4.3 - Fan Assembly PV65he & PV85he High Fire Gas Adjustment Factory Sealed Low Fire Gas Adjustment Factory Sealed Outlet Gas Pressure Test Point Pressure Switch Figure 7.4.4 - Fan Assembly PV105he & PV125he HAMWORTHY HEATING LTD PUREWELL VariHeat he 500001170/K...

  • Page 26: 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 27: Controls Operation

    Bu ilding Automation / Remote Management OCI420 AGU2.50 0 AGU2.51xx OCI /ACS Clip-in Auxiliary mod ules Service Tool 0.. 10 V 4.. 20 mA Figure 8.2 - System configuration of boiler control (LMU) & system peripherals HAMWORTHY HEATING LTD PUREWELL VariHeat he 500001170/K...

  • Page 28: Standby

    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 he 500001170/K...

  • Page 29: Figure 8.2.12 Info Display Parameters

    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 he 500001170/K...
  • Page 30 Figure 8.2.1.3 - Operation and display philosophy HAMWORTHY HEATING LTD PUREWELL VariHeat he 500001170/K...

  • Page 31: Figure 8.2.2 Screen Legend

    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 he 500001170/K...

  • Page 32: Figure 8.2.3.1 Default Display

    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 he 500001170/K...

  • Page 33: Figure 8.2.4 Display Of Lockout Code

    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 he 500001170/K...

  • Page 34: Figure 8.2.6 Overview Of End User Parameters

    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 he 500001170/K...

  • Page 35: Fault Error Code Display

    - 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 he 500001170/K...
  • Page 36 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 he 500001170/K...
  • Page 37 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 he 500001170/K...
  • Page 38 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 he...
  • Page 39 In the event of a nonvolatile LMU... lockout position, fault is continually displayed. In addition, the diagnostic code on the display flashes (refer to figure 8.3.9). To cancel the lockout position, press lockout reset button 10 for at least 2 seconds. HAMWORTHY HEATING LTD PUREWELL VariHeat he 500001170/K...

  • Page 40: Figure 8.3.11 Operating Phases

    Figure 8.3.11 - Operating phases HAMWORTHY HEATING LTD PUREWELL VariHeat he 500001170/K...
  • Page 41 Figure 9.0 Boiler Wiring Schematic HAMWORTHY HEATING LTD PUREWELL VariHeat he 500001170/K...

  • Page 42: 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 43 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 he 500001170/K...

  • Page 44: 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 45 531201105 Fan/Airbox O/Side Seal 533901497 Gas Pressure Switch 533903037 Gas Valve 532418003 Venturi Clamp 531403031 Spacer 532418002 Venturi 532403148 Closing Plate Figure 11.2 - Gas Valve Assembly ( model 65he - 85he shown for illustration) HAMWORTHY HEATING LTD PUREWELL VariHeat he 500001170/K...
  • Page 46 531201123 Burner Elbow Gasket 53301016 Burner 533805015 Flame Probe 563801016 HSI Figure 11.3 - Combustion System Assembly ( model 65he - 85he shown for illustration) 533925004 Gas Pressure Switch 533704003 Fan 533903036 Gas Valve 741083676 M5x 12 Screw 532403170 Gas Valve Mounting Bracket...

  • Page 47: Figure 11.6 Casing Assembly

    748551010 1/4 Turn Screw 748551009 1/4 Turn Receptacle 530650348 LHS Panel (530650347 RHS) 530650352 Front Cover Moulding 530650351 Side Rail 530650346 Lower Front Cover 530650355 Front Cover Brace Figure 11.6 - Casing Assembly HAMWORTHY HEATING LTD PUREWELL VariHeat he 500001170/K...
  • Page 48 742121186 O-Ring 532403166 Tube 524120045 Heat Exchanger 532403217 Inlet 531201122 Water Connection Gasket Water Connection 531050011 R1/4 Sensor Pocket Figure 11.7 - Heat Exchanger Assembly ( model 65he - 85he shown for illustration) HAMWORTHY HEATING LTD PUREWELL VariHeat he 500001170/K...
  • Page 49 531201120 Section Seal 532403214 Outlet Connection 524120044 Heat Exchanger 524120045 Heat Exchanger 524120045 Heat Exchanger 532403215 Inlet Water Connection Figure 11.8 - Heat Exchanger Assembly ( model 105he - 125he shown for illustration) HAMWORTHY HEATING LTD PUREWELL VariHeat he 500001170/K...

  • Page 50: Recommended Spares

    Control panel on the maximum power rating label. These numbers MUST be quoted when ordering spare parts. SPARES ITEM PART No. ELECTRICAL ITEMS LMU 64 Boiler Controller - 65he............................533901517 LMU 64 Boiler Controller - 85he............................533901518 LMU 64 Boiler Controller - 105he..........................533901519 LMU 64 Boiler Controller - 125he..........................533901520 AGU2.310A109 Display PCB............................533901437...

  • Page 51: Appendix A Gas Data

    Maximum Gas Inlet Pressure mbar 7.63 10.24 12.49 14.79 Gas Flow Rate (maximum) Target CO % at High / Low fire ±0.25% 8.5/8.5 9.5/9.0 9.0 /8.5 9.0/9.0 Figure A1 - Gas Data HAMWORTHY HEATING LTD PUREWELL VariHeat he 500001170/K...

  • Page 52: Appendix B Electrical Connections And Controls

    NOTE: FOR ELECTRICAL CONNECTIONS TO BOILER SEE FIGURE 4.6 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 he 500001170/K...

  • Page 53: Figure B1.2 External Control Wiring For Multiple Boiler Installation

    This equipment allows remote access for monitoring operational performance and real time operating status of Hamworthy boiler(s), using the Siemens LMU boiler control system, and other specific heating equipment. Refer to the Remote Monitoring Unit (RMU) instructions for specific details. The device allows integration within a TCP/ IP Ethernet network system, providing local or remote access to boiler operational information via intergrated web server software resident in the device see figure B1.3.
  • Page 54 Figure B1.3 - Configuration of Hamworthy—Trend IQ3 Remote Monitoring Unit (RMU) HAMWORTHY HEATING LTD PUREWELL VariHeat he 500001170/K...

  • Page 55: Figure C1 Flue Data

    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 56 Check that the flue and chimney are clear from any obstruction. Purewell VariHeat he boilers are suitable for installation in a balanced compartment in accordance with the requirements of BS 6644. Consult Hamworthy Heating Technical Department for help or assistance if in doubt. C1.9. Condensate Discharge Consideration should be given to possible freezing of condense water traps and pipework.

  • Page 57: Figure C1.1 Flue Resistance

    Straight tube ø100mm maximum length (m) 45° bend ø100mm Equivalent tube length (m) 90° bend ø100mm Equivalent tube length (m) Figure C1.1 - Flue Resistance Figure C1.2 - Open (Natural Draught) B23 Flue System HAMWORTHY HEATING LTD PUREWELL VariHeat he 500001170/K...

  • Page 58: Figure D1 Mechanical Ventilation Flow Rates

    Figure D1 Mechanical Ventilation Flow Rates Flow rate per total rated heat input (net) Difference between Boilers Inlet air inlet and extract air Without (Combustion (Inlet minus extract Draught ventilation) ventilation) Diverters m³/h m³/h 1.35 +/- 0.18 HAMWORTHY HEATING LTD PUREWELL VariHeat he 500001170/K...

  • Page 59: Figure E1 Water Data

    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 he 500001170/K...

  • Page 60: Figure E1.2 Typical Piping Layouts

    Temporary Doubl e Drain check fill line va l v e (Pri m ary l o op) valve valve UNVENTED SYSTEM: Prim ary loop, Hamworthy recommended system. Expansion pipe Pressure & Float Val v e Temperature va lve Drain gauges...
  • Page 61 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 62: Figure E1.3.1 Schematic For Single Boiler System

    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 63: Figure E1.3.3 Schematic For Single Boiler (External 0~10V) Multi Circuit System

    Figure E 1.3.3 - Schematic for Single Boiler (External 0~10V), Multi Circuit System Figure E 1.3.4 - Schematic for Multiple Boiler (Cascade), Primary Circuit System HAMWORTHY HEATING LTD PUREWELL VariHeat he 500001170/K...
  • Page 64 USEFUL USER INFORMATION INSTALLER SITE ADDRESS BOILER TYPE BOILER SIZE(S) UNIT NO(S). SERIAL NO(S). FLUE NOTES HAMWORTHY HEATING LTD PUREWELL VariHeat he 500001170/K...

This manual is also suitable for:

Purewell variheat 85hePurewell variheat 105hePurewell variheat 125he

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