Hamworthy Purewell Manual

Installation, Commissioning
and Servicing Instructions
Atmospheric Cast Iron Boiler
40kW to 120kW Output
ERMANENT IGNITION CONTROLS
Standard Draught Diverter
or
Low Line Draught Diverter
urewell
Gas Fired
Modular Boiler Systems
NATURAL GAS I2H
LPG-PROPANE I
3P
IM ORTANT NOTE
THESE INSTRUCTIONS MUST BE READ AND UNDERSTOOD BEFORE
INSTALLING, COMMISSIONING, OPERATING OR SERVICING EQUIPMENT.
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Customer Services
TECHNICAL ENQUIRIES 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, RE AIR, RE LACEMENT 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.
S ARE ARTS 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 PERMANENT IGNITION 500001045/F
i
UREWELL ATMOS HERIC HOT WATER BOILER FOR HEATING
AND DOMESTIC HOT WATER INSTALLATIONS
INSTALLATION, COMMISSIONING AND SERVICING INSTRUCTIONS
ERMANENT IGNITION CONTROLS (ECO CONTROL)
ERMANENT IGNITION CONTROLS
( ILOTSTAT CONTROL- NATURAL GAS ONLY)
WITH STANDARD DRAUGHT DIVERTER (D/D)
0,50,60,70,80,95,105 & 120 kW models
OR WITH LOW LINE DRAUGHT DIVERTER (L/L)
0,70 & 100 kW models
NOTE: THESE INSTRUCTIONS SHOULD BE READ AND UNDERSTOOD BEFORE ATTEM TING TO INSTALL,
COMMISSION OR O ERATE THIS UNIT
THE UREWELL BOILER IS INTENDED FOR USE AS A COMMERCIAL A LIANCE AND IS NOT CERTIFIED
FOR USE IN HABITABLE AREAS.
THIS BOILER IS FOR USE ON GROU H NATURAL GAS (2ND FAMILY)I2H OR L G- RO ANE (3RD FAMILY)I3 .
LEASE ENSURE RELEVANT INFORMATION REQUIRED WITHIN DOCUMENT IS FOUND RELATING TO
S ECIFIC 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. 500001045
ISSUE ‘F’
JANUARY 2000

HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001045/F
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THIS PAGE LEFT INTENTIONALLY BLANK

HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001045/F
iii
CONTENTS
PAGE
INDEX ................................................................................ iii
1.0 INTRODUCTION ................................................................................ 1
2.0 TECHNICAL DATA ............................................................................ 1
3.0 GENERAL REQUIREMENTS ............................................................ 2
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 Wa er Pressure
4.0 LOCATION ......................................................................................... 4
5.0 GAS SU LY..................................................................................... 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 FLUE 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 ures
6.8 Flue Sys em Loca ion
7.0 AIR SU LY ...................................................................................... 6
7.1 Air Supply by Na ural Ven ila ion
7.2 Air Supply by Mechanical Ven ila ion
8.0 WATER CIRCULATION SYSTEM ..................................................... 6
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 Valves
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 PERMANENT IGNITION 500001045/F
iv
AGE
9.0 ELECTRICAL SU LY ...................................................................... 8
9.1 Si e Wiring
10.0 BOILER ASSEMBLY AND INSTALLATION..................................... 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 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 hermos a )
11.8 Users ins ruc ions
12.0 FAULT 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 RE LACEMENT OF FAILED COM ONENTS................................. 17
15.0 RECOMMENDED S ARES.............................................................. 19
A ENDIX ‘A’ - INFORMATION RELATING TO RO ANE FIRING....... 32
FIGURES AGE
Figure No. 1 Performance and General Da a................................................ 2
Figure No. 2 Flow Ra es/Pressure Drop Table…………................................ 3
Figure No. 3 Gas Valve Leak Check Procedure............................................ 5
Figure No. 4 Mechanical Ven ila ion Flow Ra es.............................................. 6
Figure No. 5 Hea Exchanger Insula ion Fi ing Ins ruc ions............................. 9/10
Figure No. 6 Gas Pipe Fi ing Ins ruc ions……................................................ 10
Figure No. 7 Enclosure Assembly De ails....................................................... 12/13
Figure No. 8 Boiler Ins alla ion Typical Layou (Ven ed and Un-ven ed)…… 20
Figure No. 9 Overall Dimensions of Boiler and Recommended Clearances . 21
Figure No. 10 Fron Assembly Showing General Layou .............................. 22
Figure No. 11 Gas Flow in Pipes.......................................………………….. 23
Figure No. 12 Si e Wiring Diagram................................................................ 24
Figure No. 13 Typical boiler wiring diagram (inc. Op ions)............................ 25
Figure No. 14 Pilo s a boiler wiring diagram................................................. 26
Figure No. 15 Diagram of igni er assembly.................................................... 27
Figure No. 16 Diagram of Various gas valves fi ed...................................... 28
Figure No. 17 Pilo s a valve assembly.......................................................... 29
Figure No. 18 General Faul Finding.............................................................. 30/31

HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001045/F
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1.0 INTRODUCTION
1.1 A compe en person holding ‘CORGI’ regis ra ion
or equivalen mus ins all his boiler. All ins alla ions
MUST 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 MUST 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. The draugh diver er MUST 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 PERMANENT IGNITION 500001045/F
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Figure No. 1 - erformance and General Data information.
* NOTE! Flue gas volumes are based on a gross flue gas empera ure of 100∞C a 1013mbar. This is consid-
ered o be he predic ed empera ure of he produc s in he secondary flue downs ream of he draugh diver er.
3.0 GENERAL REQUIREMENTS
3.1 Related Documents.
Gas Safety Installations and Use 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 MUST be in accordance
wi h he relevan requiremen s of he Gas Safe y
Regula ions, Building Regula ions, IEE Regula ions
and he byelaws of he local wa er under aking.

HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001045/F
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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. art 2: Code of prac ice for low and
medium empera ure 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: art 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, art 1. Safe y of Household & similar
elec rical appliances. BS 3456, art 201: Elec rical
S andards.
C 342: Cen ralised ho wa er supply.
Par 2: Buildings o her han individual dwellings.
British Gas ublications
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 M5 - Au oma ically con rolled s eam and
ho wa er boilers.
CIBSE ublications: -”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 would
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 be flushed ou a leas
wice wi h ho wa er before any wa er rea men is added.
If any doub exis s regarding he 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 , able 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.
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.
Figure No. 2 - Flow-rate ressure Drop Table.

HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001045/F
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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
SU LY for de ails. See Figure No. 10 for wiring de ails.
3.5 Minimum System Water ressure
To comply wi h guidance no e M5 (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 MUST
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 460mm a he rear, for flow and re urn connec ions.
Also allow a leas 460mm on one side, he o her side
mus be no less han 150mm. 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 SU LY
5.1 Service ipes
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 ipes
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 shown in Figure No. 3. 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.
TO CHECK VALVE B
1) Turn off he elec rical power and gas o he appliance.
2) Connec he manome er o gas valve es poin .
3) Wi h A, B closed open C and moni or manome er over
a 2 minu e period, a rise indica es a leak on valve B.