Hamworthy Purewell Manual

Installation, Commissioning
and Servicing Instructions
Atmospheric Cast Iron Boiler
40kW to 120kW Output
A TOMATIC IGNITION CONTROLS
Standard Draught Diverter
or
Low Line Draught Diverter
Purewell
Gas Fired
Modular Boiler Systems
NATURAL GAS I2H
LPG-PROPANE I
3P
IMPORTANT NOTE
THESE INSTRUCTIONS MUST BE READ AND UNDERSTOOD BEFORE
INSTALLING, COMMISSIONING, OPERATING OR SERVICING EQUIPMENT.
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Customer Services
TECHNICAL ENQ IRIES 01202 662527 / 662528
To supplemen he de ailed echnical brochures, echnical advice on he applica ion and use of produc s in
he Hamwor hy Hea ing range is available from our echnical eam in Poole and our accredi ed agen s.
SITE ASSEMBLY 01202 662555
Specialis eams are available for on si e assembly of he full range of Hamwor hy boilers (excluding
Lulwor h). Boiler sec ions for si e assembly mus be posi ioned wi hin he boiler house prior o he arrival
of he assembly eam and provide sufficien space for safe working. Handling sec ions in o boiler houses
o her han a ground level may be subjec o addi ional charges.
The normal assembly price does no include for he fi ing of boiler casings or he burner, however his can
be carried ou a he ime of build a addi ional cos .
Providing he facili ies are available on si e, a hydraulic es will be carried ou wi hin he erms of BS779.
Upon comple ion a cer ifica e of assembly and es will be issued.
COMMISSIONING 01202 662555
Commissioning of equipmen by Hamwor hy Hea ing’s own engineers, accredi ed agen s or specialis sub-
con rac ors will ensure ha he equipmen is opera ing safely and efficien ly. Hamwor hy commissioning
repor s provide a de ailed record of he original s a us of he plan , which is essen ial for fu ure rou ine
main enance and rouble free opera ion.
S andard warran y erms provide for he free of charge replacemen of defec ive par s, bu does no
include labour. When he equipmen is commissioned and rou inely main ained by Hamwor hy Hea ing
under a Service Main enance Agreemen hen he warran y erms will cover bo h par s and labour.
MAINTENANCE AGREEMENTS 01202 662555
Regular rou ine servicing by Hamwor hy Hea ing’s engineers ensures rouble free opera ion and op imum
efficiency. The frequency of visi s required is variable, dependen upon he equipmen ype and usage.
Annual service agreemen s are available on all Hamwor hy produc s o mee individual requiremen s.
Planned main enance of equipmen by rou ine servicing reduces opera ional cos s considerably below ha
associa ed wi h repair or breakdown approach.
BREAKDOWN SERVICE, REPAIR, REPLACEMENT 01202 662555
Even when he commissioning and rou ine servicing has been carried ou o he highes s andard here
are always occasions when he unexpec ed breakdowns occur. Hamwor hy provide a rapid response
breakdown, repair or replacemen service hrough head office a Poole and accredi ed agen s loca ed
hroughou he UK.
SPARE PARTS 01202 662525
A comprehensive spare par s service is opera ed from our fac ory in Poole, providing replacemen par s
for bo h curren and discon inued produc s. In some ins ances spares may be available from accredi ed
agen s.
Delivery of par s and componen s is normally from s ock wi hin 7 days. However, a 24 hour delivery
service is available for breakdowns and emergencies for he addi ional cos of he courier. Please con ac
our spares eam, providing de ails of produc ype, serial number, model or any o her iden ifying marks or
codes o de ermine par requiremen s wherever possible.

HAMWORTHY HEATING LTD. PUREWELL AUTOMATIC IGNITION 500001035/G
i
P REWELL ATMOSPHERIC HOT WATER BOILER FOR HEATING
AND DOMESTIC HOT WATER INSTALLATIONS
INSTALLATION, COMMISSIONING AND SERVICING INSTR CTIONS
A TOMATIC IGNITION CONTROLS
WITH STANDARD DRAUGHT DIVERTER (D/D)
0,50,60,70,80,95,105 & 120kW models
OR WITH LOW LINE DRAUGHT DIVERTER (L/L)
0,70 & 100kW models
NOTE: THESE INSTR CTIONS SHO LD BE READ AND NDERSTOOD BEFORE ATTEMPTING TO INSTALL,
COMMISSION OR OPERATE THIS NIT
THE P REWELL BOILER IS INTENDED FOR SE AS A COMMERCIAL APPLIANCE AND IS NOT CERTIFIED
FOR SE IN DOMESTIC APPLICATIONS OR HABITABLE AREAS.
THIS BOILER IS FOR SE ON GRO P H NAT RAL GAS (2ND FAMILY)I2H OR LPG-PROPANE (3RD FAMILY)I3P.
PLEASE ENS RE RELEVANT INFORMATION REQ IRED WITHIN DOC MENT IS FO ND RELATING TO
SPECIFIC GAS TO BE FIRED BEFORE FIRING BOILER.
THIS BOILER COMPLIES WITH ALL RELEVANT EUROPEAN DIRECTIVES.
EC TYPE CERTIFICATE No. BG/EC-87/93/20.
PRODUCT IDENTIFICATION No. 87AO20
PUBLICATION NO. 500001035
ISSUE ‘G’
JANUARY 2000

HAMWORTHY HEATING LTD. PUREWELL AUTOMATIC IGNITION 500001035/G
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THIS PAGE LEFT INTENTIONALLY BLANK

HAMWORTHY HEATING LTD. PUREWELL AUTOMATIC IGNITION 500001035/G
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CONTENTS
PAGE
INDEX ............................................................................. iii
1.0 INTROD CTION ................................................................................ 1
2.0 TECHNICAL DATA ............................................................................ 1
2.1 Overall Dimensions
2.2 Technical Da a Table
3.0 GENERAL REQ IREMENTS ............................................................ 1
3.1 Rela ed Documen s
3.2 Feed Wa er Quali y
3.3 Adequa e Wa er Flow
3.4 Time Clock Con rol
3.5 Minimum Sys em Pressure
4.0 LOCATION ......................................................................................... 4
5.0 GAS S PPLY..................................................................................... 4
5.1 Service Pipes
5.2 Me ers
5.3 Gas Supply Pipes
5.4 Boos ed Supplies
5.5 Boiler House Con rol Valve
5.6 Boiler Gas Sys em Leak Check
6.0 FL E SYSTEM .................................................................................. 5
6.1 General Requiremen s
6.2 Design Was e Gas Volume and Tempera ure
6.3 Flue Condensa ion
6.4 Ma erials
6.5 Disconnec ion
6.6 Flue Discharge
6.7 Surface Tempera ure
6.8 Flue Sys em Loca ion
7.0 AIR S PPLY ...................................................................................... 9
7.1 Air Supply by Na ural Ven ila ion
7.2 Air Supply by Mechanical Ven ila ion
8.0 WATER CIRC LATION SYSTEM ..................................................... 9
8.1 General
8.2 Pressure Relief Valve (Safe y Valve)
8.3 Open Ven Pipe and Cold Feed Pipe
8.4 Al i ude Gauge (Wa er Pressure Gauge)
8.5 Thermome er
8.6 Drain Taps
8.7 Circula ing Pump
8.8 Minimum Wa er Flow Ra es
8.9 Wa erside Pressure Drop
8.10 Con rol Schemes
8.11 Unven ed Pressurised Sys ems
8.12 Modular Boiler Con rol Schemes

HAMWORTHY HEATING LTD. PUREWELL AUTOMATIC IGNITION 500001035/G
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9.0 ELECTRICAL S PPLY .......................................................................... 8
9.1 Si e Wiring
10.0 INSTALLATION OF BOILERS ............................................................. 9
10.1 General
10.2 Hea Exchanger Insula ion Fi ing Ins ruc ions
10.3 Gas pipe Fi ing Ins ruc ions
10.4 Connec ion of Boilers o he Flue Sys em
10.5 Gas Connec ion
10.6 Wa er Connec ions
10.7 Casing and Con rols Assembly
11.0 COMMISSIONING AND TESTING ....................................................... 14
11.1 Elec rical Ins alla ion
11.2 Gas Ins alla ion
11.3 Wa er Circula ion Sys em
11.4 Commissioning he Boiler
11.5 Boiler Checks Prior o Ligh ing
11.6 Gas Pressure Adjus men and Combus ion Checks
11.7 Tempera ure Limi er (Limi Thermos a )
11.8 Safe y Checks
11.9 User’s Ins ruc ions
12.0 FA LT FINDING.................................................................................... 16
12.1 Safe y Fea ures Summary
12.2 Faul Finding Procedures
12.3 Possible Causes of Boiler Lockou
13.0 SERVICING........................................................................................... 16
14.0 REPLACEMENT OF FAILED COMPONENTS.................................... 17
15.0 RECOMMENDED SPARES.................................................................. 19
APPENDIX ‘A’ - INFORMATION RELATING TO PROPANE FIRING…...... 32
FIG RES PAGE
Figure No. 1 Performance and General Da a ........................................……. 2
Figure No. 2 Recommended/minimum wa er flow ra es.........................……. 3
Figure No. 3 Gas valve in egri y check...................................................……. 5
Figure No. 4 Mechanical ven ila ion flow ra es........................................…… 6
Figure No. 5 Hea Exchanger Insula ion Fi ing Ins ruc ions....................…… 10
Figure No. 6 Gas Pipe Fi ing Ins ruc ions……........................................…… 10/11
Figure No. 7 Enclosure assembly de ails................................................……. 12/13
Figure No. 8 Boiler ins alla ion ypical layou . Ven ed and Un-ven ed boilers. 20
Figure No. 9 Overall dimensions of boiler and recommended clearances .... 21
Figure No. 10 Fron assembly showing general layou .................................... 22
Figure No. 11 Maximum gas flows hrough pipes .........................................… 23
Figure No. 12 Si e wiring de ails..................................................................….. 24
Figure No. 13 Typical s andard boiler wiring diagram..................................…. 25
Figure No. 13a Wiring Diagram fi ed wi h Pek ron 0459 Series Igni er.......…… 26
Figure No. 14 Diagram of elec rode assembly.............................................…. 27
Figure No. 15 Diagram of various gas valves fi ed.....................................…. 28
Figure No. 16 Diagram of double gas valve layou ........................................... 29
Figure No. 17 General faul finding................................................................... 30/31
Page

HAMWORTHY HEATING LTD. PUREWELL AUTOMATIC IGNITION 500001035/G
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1.0 INTROD CTION
1.1 A compe en person holding ‘CORGI’ regis ra ion
or equivalen mus ins all his boiler. All ins alla ions
M ST conform o he relevan Gas Safe y and Building
Regula ions. Heal h & Safe y requiremen s mus also
be aken in o accoun when ins alling any equipmen .
Failure o comply wi h he above may lead o
Prosecu ion.
1.2 These ins ruc ions are for Group H Na ural Gas
(2nd Family) and LPG-Propane (3rd Family). The
informa ion rela ive o propane firing is o be found in
Appendix ’A’. Boilers M ST NOT use gas o her han
for which hey were designed and made for.
1.3 The Purewell is an a mospheric, gas fired boiler
manufac ured from horizon al cas iron sec ions,
nippled a al erna e ends. These sec ions are moun ed
on a fabrica ed mild s eel baske assembly, which
houses he burner bar and igni er assemblies. A
unique radian baffle is fi ed benea h he burner bars,
pro ec ing he floor below by reducing hea los from
he boiler.
The s andard version of he Purewell boiler is designed
o be connec ed o he flue via a specifically designed
draugh diver er. This diver er M ST be fi ed in o
he spigo on op of he hea exchanger as supplied.
NO modifica ion or variance is permi ed as his may
change opera ional charac eris ics. Flue ou le s from
more han one boiler may be connec ed oge her o
form a header.
Low Line versions have an in-buil draugh diver er
and can herefore be connec ed direc o a header
assembly via a sui able flue pipe.
1.4 If he boiler is o be connec ed o an un-ven ed
(pressurised) hea ing sys em, care mus be aken o
ensure all ex ra safe y requiremen s are me and ha
he relevan in erlocks will shu down he boiler(s)
should a high or low pressure faul occur.
The pressurisa ion uni mus also incorpora e a low
level wa er swi ch, which pro ec s he wa er pumps,
and will direc ly or indirec ly shu down he boiler plan
should a low wa er condi ion occur.
Considera ion should also be given o he maximum
working pressure of he boiler as given in Section
2:TECHNICAL DATA. Consul Hamwor hy Hea ing
Technical Depar men for help or assis ance if in doub .
1.5 The Purewell boiler is no sui able for direc
connec ion o domes ic ho wa er supplies or gravi y
fed hea ing sys ems.
1.6 The Purewell boiler can be ins alled wi h ei her
reverse re urn wa er flow layou or wi h single pipe
header layou . See Figure No. 8 for ypical schema ic
layou .
Hamwor hy Hea ing can supply a pre-designed
arrangemen of componen s, which will produce a
“reverse-re urn” assembly. Please con ac Hamwor hy
Hea ing for informa ion.
1.7 I is good prac ice in all hea ing ins alla ions o
use some form of wa er rea men o reduce forma ion
of lime scale and black iron oxide sludge. The high
efficiencies produced by he Purewell Boiler can easily
be reduced by lime scale forma ion. If a pressurised
uni is used, i is pruden o include an hours run me er
o give an indica ion of pump running ime and hence
raw wa er make-up. Any leaks should be a ended o
as soon as possible o avoid calcium sal build up
wi hin he boiler’s wa erways.
2.0 TECHNICAL DATA
2.1 Overall dimensions are shown in Figure No. 9.
Bo h single and mul i boiler arrangemen s are shown.
The Purewell boiler can be ins alled as a single uni
or in modular form where a ‘mul i’ casing reduces
required floor area. Each boiler has an independen
door for access o he con rols and o her working
componen s.
I is recommended ha a maximum of 6 boilers can
be posi ioned on 533mm (21") cen res if required.
Larger numbers should be spli in o wo or more banks
wi h 150mm (6") be ween each bank. NOTE! When
ins alling modular uni s on 533mm (21") cen res, he
casing suppor rail or spacing pla es should be fi ed
be ween each boiler before bol ing oge her. See
Section 10.1: General Installation of Boilers Ref.:
- spacing pla es for fur her informa ion.
2.2 General Informa ion and Technical Da a rela ing
o Na ural Gas is shown in Figure No. 1.
Technical da a rela ing o propane firing can be found
in Appendix ’A’.
2.3 Screw threads: All screw hreads used in he
Purewell boiler conform o he following: -
ISO 7/1 or ISO 228/1 for pipe hreads where
applicable.
ISO 262 for all general screw hreads.

HAMWORTHY HEATING LTD. PUREWELL AUTOMATIC IGNITION 500001035/G
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3.0 GENERAL REQ IREMENTS
3.1Related Documents.
Gas Safety Installations and se Regulations
1994, (As amended).
I is law ha compe en persons in accordance wi h
he above regula ions ins all all gas appliances.
Failure o ins all appliances correc ly
could lead o prosecu ion. I is in your own in eres ,
and ha of safe y, o ensure ha his law is complied
wi h.
The ins alla ion of he boiler M ST be in accordance
wi h he relevan requiremen s of he IEE Regula ions
and he byelaws of he local wa er under aking.
Figure No. 1 - Performance and General Data Information
* NOTE! Flue gas volumes are based on a gross flue gas empera ure of 100°C a 1013mbar. This is considered o
be he predic ed empera ure of he produc s in he secondary flue downs ream of he draugh diver er.
Related Documents - cont.

HAMWORTHY HEATING LTD. PUREWELL AUTOMATIC IGNITION 500001035/G
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The ins alla ion should also be in accordance wi h
any relevan requiremen s of he local gas region and
local au hori y and he relevan recommenda ions of
he following documen s: -
British Standards
BS 7074: Applica ion, selec ion and ins alla ion of
expansion vessels and ancillary equipmen for sealed
wa er sys ems. Par 2: Code of prac ice for low and
medium ho wa er sys ems.
BS 6891: Ins alla ion of low-pressure gas pipework
of up o 28mm in domes ic premises. (For larger
ins alla ions see IM/2, IM/5 and IM/16 below.)
BS 6644: Ins alla ion of Gas Fired Ho Wa er Boilers
- 60kW o 2MW.
BS 6700: Design, ins alla ion, es ing and
main enance of services supplying wa er for domes ic
use.
BS 6880: Part 1, 2 & 3: Code of prac ice for low
empera ure ho wa er hea ing sys ems of ou pu
grea er han 45kW.
BS EN 60335, Part 1. Safe y of Household &
Similar Elec rical Appliances. BS 3456, Part 201:
Elec rical S andards.
Figure No. 2 - Flow-rate/Pressure Drop Table
CP 342: Cen ralised ho wa er supply.
Par 2: Buildings o her han individual dwellings.
British Gas Publications
IM/2 Purging procedures for non-domes ic gas
ins alla ions.
IM/5 Soundness es ing procedures for indus rial and
commercial gas ins alla ions.
IM/11 Flues for commercial and indus rial gas fired boilers
and air hea ers.
IM/16 Guidance no es on he ins alla ion of gas pipework.
(Excluding domes ic ins alla ions of 25mm and below.)
Health and Safety Executive:-
Guidance note PM5 - Au oma ically con rolled s eam and
ho wa er boilers.
CIBSE Publications: - “CIBSE Guide”
I is imprac ical in his documen o specify all relevan
informa ion, bu he following ex rac s from he above
references are emphasized since failure o comply wi h
hese requiremen s will almos cer ainly resul in an
unsa isfac ory ins alla ion.
3.2 Feed water Quality
If he boiler feed wa er has a high degree of hardness,
i is recommended ha he wa er be rea ed o preven
precipi a ion of scale or sludge in he boiler wa er
passageways. De ails of addi ives can be ob ained
from any reliable manufac urer of wa er rea men
produc s or he local wa er au hori y. I should be
no ed however, ha even if he boiler wa er is of
average hardness, no requiring rea men ,
subsequen draining of he sys em for repair or
cons an make-up wa er due o an unde ec ed leak
will cause addi ional deposi s and gradual build-up of
scale. I is essen ial, herefore ha leaks are a ended
o promp ly and draining is kep o an absolu e
minimum.
I is recommended ha he sys em is flushed ou a
leas wice wi h ho wa er before any rea men is
added. If any doub exis s regarding he
I is recommended ha he sys em is flushed ou a leas
wice wi h ho wa er before any rea men is added. If any
doub exis s regarding in ernal cleanliness of an old
sys em, considera ion should be given o he fi ing of a
coarse fil er in he re urn pipework o he boilers.
3.3 Adequate Water Flow
The Hamwor hy Purewell boiler is designed as a quick
response, low wa er con en uni , o run con inuously wi h
maximum reliabili y. Care should be aken in he ini ial
design and layou having due regard for adequa e wa er
flow hrough he boilers and he influence of he sys em
con rols. NOTE! The S andards Au hori y recommend a
minimum re urn empera ure of 50°C in all hea ing
sys ems o her han condensing boilers.
Figure No. 2 shows recommended and minimum wa er
flows required. The con rol sys em and valves, where
fi ed, should be regula ed o avoid lower flows occurring.

HAMWORTHY HEATING LTD. PUREWELL AUTOMATIC IGNITION 500001035/G
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The flow corresponding o 22°C empera ure rise across
he boiler is he minimum recommended flow a any ime.
For boiler pressure drop see Figure No. 2.
3.4 Time Clock Control
In order o avoid local overhea ing and progressive
calcium deposi ion a zero flow condi ions where boilers
are opera ed from ime clocks, provision should be made
for a 5 minu e circula ing pump over-run af er he las
boiler has ceased firing.
NOTE! Time clocks should no in errup live, neu ral or
ear h connec ions, see Section 9.0: ELECTRICAL
S PPLY for de ails. See Figure No. 12 for wiring de ails.
3.5 Minimum System Pressure
To comply wi h guidance no e PM5 (Health and Safety
Executive), he minimum pressure requiremen s a he
boiler are given below as examples: -
1) Single ins alled boiler running a 82°C flow
empera ure. Minimum head required is no less han 2
me res or 0.2 bar.
2) Single ins alled boiler running a 95°C flow
empera ure. Minimum head required = 5.1 me res or
0.5 bar.
3) Modular boiler ins alla ion running a 82°C flow
empera ure and 11°C rise across sys em. Minimum
head required = 4.3 me res or 0.42 bar.
4) Modular boiler ins alla ion running a 82°C flow
empera ure and 22°C rise across sys em. Minimum
head required = 10.5 me res or 1.03 bar.
See Section 8.11 for Pressurised Wa er Sys ems.
4.0 LOCATION
4.1 (See Figure No. 9 for dimensions/weigh s and
clearances.) The loca ion chosen for he boiler M ST
permi he provision of a sa isfac ory flue sys em and an
adequa e air supply. The loca ion mus also provide
adequa e space for servicing and air circula ion around
each uni . This includes any elec rical runking laid along
he floor.
Allow adequa e space, his should no normally be less
han 460 mm. a he rear, for flow and re urn connec ions.
Also allow a leas 460 mm. on one side, he o her side
mus be no less han 150 mm. Allow 610mm (minimum)
in fron of he boiler for servicing.
The boiler mus be ins alled on a level non-combus ible
surface ha is capable of adequa ely suppor ing i s
weigh (when filled wi h wa er) and any ancillary
equipmen .
Any combus ible ma erial adjacen o he boiler and he
flue sys em mus be so placed or shielded o ensure
ha i s empera ure does no exceed 65°C.
Fur her de ails regarding boiler loca ion are given in
BS 6644.
5.0 GAS S PPLY
5.1 Service Pipes
The local gas region mus be consul ed a he
ins alla ion planning s age in order o es ablish he
availabili y of an adequa e supply of gas. An exis ing
service pipe mus no be used wi hou prior consul a ion
wi h he local gas region.
5.2 Meters
A new gas me er will be connec ed o he service pipe
by he local gas region, or a local gas region con rac or.
An exis ing me er should be checked, preferably by
he gas region, o ensure ha i is adequa e o deal
wi h he ra e of gas supply required.
5.3 Gas Supply Pipes
Supply pipes mus be fi ed in accordance wi h BS 6891
or IM/16 as appropria e. Pipework from he me er o
he boiler mus be of adequa e size. Do no use pipes
of a smaller size han he boiler gas connec ion. The
comple e ins alla ion mus be purged and es ed for
soundness as described in BS 6891 or IM/2 and IM/5
as appropria e.
See Figure No. 11 for recommended gas flows in pipes.
5.4 Boosted Supplies
Where i is necessary o employ a gas pressure boos er,
he con rols mus include a low-pressure cu -off swi ch
a he boos er inle . The local gas region mus be
consul ed before a gas pressure boos er is fi ed.
5.5 Boiler House Control Valve
A manual valve for boiler house isola ion shall be fi ed
in he gas supply line. I shall be clearly iden ified and
readily accessible for opera ion, preferably by an exi .
5.6 Boiler Gas System Leak Check
Al hough he boiler receives a gas leak check and gas
rain componen in egri y check prior o leaving he
fac ory, ranspor and ins alla ion may cause
dis urbance o unions, fi ings and gas valve assemblies’
e c. During commissioning a fur her es for soundness
should be carried ou on he boiler gas pipework and
componen s. A procedure guide is given below. Care
mus be aken no o allow leak de ec ion fluid on or
near any elec rical par s or connec ions (If used). See
Figure No. 3 - Gas valve/pipework leak check es
procedure.