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.
Homepage Register Contents

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
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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.

HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001045/F
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Note: -
Main Gas Supply Pressure: G20 - 20mbar
G31 - 37mbar
TO CHECK VALVE A
1) Open C.
2) Open B o produce he main gas supply pressure
be ween A and B.
3) Close B
4) Sys em may be considered sound if over a period
of 2 minu es any drop in pressure is less han 0.5mbar
(0.2" wg.).
NOTE: Allow a manome er s abilisa ion period of
approxima ely 1 minu e before each 2 minu e check
period. Following soundness es s close valve B and
remove manome er connec ions and igh en es
poin s.
6.0 FLUE SYSTEM
De ailed recommenda ions for flue sys ems are given
in BS 6644 Bri ish Gas Publica ion, IM/11 “Flues for
Commercial and Indus rial Gas-Fired Boilers and Air
Hea ers”.
The following no es are in ended o give general
guidance only.
6.1 General Requirements
The Hamwor hy Purewell Series of boilers are
designed o be used wi h na ural draugh flues. Flue
sys ems should be designed in accordance wi h
curren regula ions and wi h reference o he Bri ish
Gas publica ion IM/11 “Flues for Commercial and
Indus rial Gas Fired Boilers and Air Hea ers”. The
following poin s should be no ed: -
1) Each boiler MUST have i s correc draugh diver er
fi ed in an unmodified condi ion before connec ion o
he flue sys em.
2) The bo om of he flue header should be a leas
500 mm above he draugh diver er skir bo om.
3) The flue sys em mus be self-suppor ing in he
correc posi ion o avoid compression of he draugh
diver er and enable i s removal for boiler cleaning.
4) Boilers should be loca ed as near he chimney as
possible he neares being no more han 2m (6 f )
away.
5) The flue sys em should be designed o achieve a
nega ive suc ion a all imes a he draugh diver er
ou le on all modules in a bank. For op imum
performance, draugh condi ions should be be ween
-0.05 o -0.125mbar. In he case of a single boiler
ins alla ion, he minimum ver ical flue heigh is 2m
above he draugh diver er skir . For mul iple boiler
ins alla ions consul Hamwor hy Hea ing Technical
Depar men . In some ins ances, mechanical
assis ance may be necessary. The boilers are sui able
for connec ion o a fan dilu ed flue sys em, refer o
Bri ish Gas publica ion IM/11 “Flues for Commercial
and Indus rial Gas Fired Boilers and Air Hea ers”.
6) Purewell boilers are sui able for ins alla ion in a
balanced compar men in accordance wi h he
requiremen s of BS 6644. Consul Hamwor hy
Hea ing Technical depar men for help or assis ance
if in doub .
6.2 Design Waste Gas Volume and Temperature
I is recommended ha he volume and empera ure
of he was e gases used for design of he flue sys em
be as shown in Figure No. 1 for Na ural Gas.
Informa ion rela ing o propane firing can be found in
Appendix ‘A’.
6.3 Flue Condensation
Care should be aken o ensure ha he flue is ins alled
in such a way ha any condensa ion produced on s ar
up will drain away na urally.
6.4 Materials
Ma erials used for he flue sys em mus be
mechanically robus , resis an o in ernal and ex ernal
corrosion, non-combus ible and durable under he
condi ions o which hey are likely o be subjec ed.
6.5 Disconnection
Draugh diver er models have been designed o
enable he primary flue o be lif ed clear of he boiler
o ease disconnec ion. The flue mus be correc ly
reconnec ed when servicing is comple e ensuring
loca ing bol s are securely fi ed. See Section 13:
SERVICING for fur her informa ion.
6.6 Flue Discharge
The flue sys em mus ensure safe and efficien
opera ion of he boiler o which i is a ached, pro ec
he combus ion process from wind effec s and
disperse he produc s of combus ion o he ex ernal
air.
Figure No. 3 Gas Valve Leak Check rocedure

HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001045/F
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The flue mus ermina e in a freely exposed posi ion
and be so si ua ed as o preven he produc s of
combus ion en ering any opening in a building.
Where he flue diame er is less han 200mm (8") a
erminal mus be fi ed. Where he flue is of a larger
size considera ion should be given o he fi ing of a
flue discharge erminal or grill o s op ingress of birds,
e c.
6.7 Surface Temperatures
Combus ible ma erials in he vicini y of he boiler and
flue shall no exceed 65°C during boiler opera ion. The
flue shall no be closer han 50mm o any combus ible
ma erial, excep where i passes hrough such ma erial
wi h a non-combus ible sleeve when he air gap may
no be less han 25mm.
6.8 Flue System Location
The flue sys em mus no be placed or fi ed where here
is undue risk of acciden al damage o he flue pipe or
undue danger o persons in he vicini y. NOTE! The
flue MUST be self-suppor ing. Check ha he flue and
chimney are clear from any obs ruc ion.
7.0 AIR SU LY
De ailed recommenda ions for air supply are given in
BS 6644. The following no es are in ended o give
general guidance. In all cases here mus be provision
for an adequa e supply of air for bo h combus ion and
general ven ila ion, in addi ion o ha required for any
o her appliance.
7.1 Air Supply by Natural Ventilation
The boiler room mus have, or be provided wi h,
permanen air ven s direc ly o he ou side air, a high
level and a low level. For an exposed boiler house, air
ven s should be fi ed preferably on all four sides, bu a
leas on wo sides. Air ven s should have negligible
resis ance and mus no be si ed in any posi ion where
hey are likely o be easily blocked or flooded or in any
posi ion adjacen o an ex rac ion sys em which is
carrying flammable vapour. Grilles or louvres mus be
so designed ha high veloci y air s reams do no occur
wi hin he space housing he boiler.
The air supplied for boiler house ven ila ion shall be
such ha he maximum empera ures wi hin he boiler
house shall be as follows:
1) A floor level (or 100mm above) = 25°C.
2) A mid-level (1.5m above floor level) = 32°C.
3) A ceiling level (or 100mm below) = 40°C.
Where bo h low and high level openings are used, he
grilles shall have a o al minimum free area of:-
Low Level (inle ): 540cm2 plus 4.5cm2 per Kilowa in
excess of 60kW o al ra ed inpu .
High Level (ou le ): 270cm_ plus 2.25cm_ per Kilowa
in excess of 60kW o al ra ed inpu .
7.2 Air Supply by Mechanical Ventilation
Air supplied o he boiler room by Mechanical means
should be as follows: -
1) Mechanical inle and mechanical ex rac can be
u ilised providing design ex rac ion ra e does no
exceed one hird of he design inle ra e.
2) Mechanical ex rac ven ila ion wi h na ural inle
ven ila ion MUST NOT be used.
Figure No. 4 - Mechanical Ventilation Flow Rates
NOTE: For Mechanical ven ila ion sys ems an
au oma ic con rol should be provided o cu off he
gas supply o he boiler, in he even of failure of air
flow in ei her inle or ex rac fans.
8.0 WATER CIRCULATION SYSTEM
8.1 General
The Purewell Cas Iron Boiler has a low wa er con en
and he requiremen s of minimum wa er flow are given
in Section 8.8:Minimum Water Flow Rates and
Figure No. 2. Recommenda ions for he wa er
circula ion sys em are given in BS 6644 and C 342.
The following no es are of par icular impor ance: -
1) In a combined cen ral hea ing and ho wa er sys em,
he ho wa er s orage vessel mus be of he indirec
cylinder or calorifier ype. The ho wa er s orage vessel
should be insula ed preferably wi h no less han 75mm
(3in) hick mineral fibre, or i s hermal equivalen .
2) Circula ing pipework no forming par of he useful
hea ing surface should be insula ed o help preven
hea loss and possible freezing, par icularly where
pipes are run hrough roof spaces and ven ila ed
cavi ies. Cis erns si ua ed in areas, which may be
exposed o freezing condi ions, should also be
insula ed. Insula ion exposed o he wea her should
be rendered wa erproof.
3) Draining aps mus be loca ed in accessible
posi ions, which permi he draining of he whole
sys em, including he boiler and ho wa er s orage
vessel.
4) Each boiler has one 2" BSP female flow and one
2" BSP female re urn apping. Flow and re urn
headers should connec boilers bu sufficien leng h

HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001045/F
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of connec ing pipe should be allowed o clear he
casing before connec ing in o he headers. The
headers should be connec ed o he sys em in a
“reverse re urn” arrangemen ( he wa er flow in each
header is in he same direc ion) o ensure equal flow
in each module. Figure No. 8 shows ypical layou .
8.2 ressure Relief Valve (Safety Valve)
Each boiler, or in he case of a modular ins alla ions,
each bank of boilers, mus be fi ed wi h a pressure
relief valve o BS 759 or BS 6759 art 1 (ISO 4126)
and sized as shown in BS 6644.
BS 6644 provides comprehensive informa ion for he
selec ion and loca ion of safe y valves and a en ion
is drawn o he higher capaci y requiremen s of safe y
valves for pressurised ho wa er sys ems.
8.3 Open Vent and Cold Feed ipe
(See BS 6644 for fur her informa ion.)
Every boiler or group of boilers should have an open
ven pipe and cold feed pipe ins alled be ween he
boiler and he firs wa er isola ing valve. The minimum
bore (mm) of hese pipes per ins alla ion is as follows:
The ven pipe mus rise con inually, mus no be valved
excep by a design which when closed for
main enance ensures he boiler is open o
a mosphere. The pipe shall be pro ec ed agains
freezing where his migh occur.
8.4 Altitude Gauge (Water ressure Gauge)
Every boiler or group of boilers should be provided
wi h a gauge comple e wi h isola ing cock. See Figure
No. 8 for ypical posi ion.
8.5 Thermometer
See Figure No. 8 for ypical posi ion.
A hermome er comple e wi h pocke should be fi ed
in he pipework o indica e wa er flow empera ure.
8.6 Drain Valves
Each boiler should have a 1/2 in NB drain valve (no
H.H.L. supply) fi ed o drain he boiler only. The
hea ing sys em in o al should have drain valves as
recommended by BS 6644. See Figure No. 8 for
recommended posi ions.
8.7 Circulating ump
One or more circula ing pumps will be required o
circula e wa er around he boilers and hea ing sys em.
Figure No. 1 shows he hydraulic resis ance of he
boiler. The pump should be si ed o facili a e servicing.
I is impor an o no e ha when Purewell boilers are
used o replace boilers on an exis ing sys em, he
pumps should be checked for performance agains he
new boiler wa erside pressure drop o ensure ha he
minimum flow ra e can be ob ained. I is also impor an
ha he exis ing sys em be flushed hrough wice o
remove any loose ma er, which may have
accumula ed. If in any doub regarding he cleanliness
of he sys em, a coarse fil er should be fi ed in he
re urn pipework o he boilers.
8.8 Minimum Water Flow Rates
Minimum wa er flow ra es are shown in Figure No. 2.
These flow ra es mus be main ained hrough he boiler
a all imes whils he boiler is firing. If he flow ra e is
allowed o fall below he minimum, he boiler hea
exchanger could fail due o he resul an scale
forma ion. Par icular a en ion should be paid o he
res ric ion of ex ernal flow circui s during periods of
low hea demand.
8.9 Waterside ressure Drop
The wa erside hydraulic resis ance (Pressure drop) is
shown in Figure Nos.1 & 2.
NOTE: If boilers are run off ime clock con rol, a pump
overrun (no H.H.L. supply) should be fi ed which mus
run for a minimum of 5 minu es on shu -down of he
las boiler.
8.10 Control Schemes
8.10.1 Temperature Controls
An adjus able con rol hermos a is supplied for each
boiler and should be se o opera e wi hin he range
65-90°C for s andard applica ions.
If a higher wa er empera ure is required (and providing
sufficien head on he wa er sys em is available) he
hermos a may be adjus ed o opera e up o 95°C. A
empera ure limi er, (hand rese limi hermos a ) is also
fi ed o he boiler and is normally se a 100°C. The
minimum difference be ween con rol hermos a and
empera ure limi er MUST NOT be less han 10°C.
8.10.2 Water Flow Controls
Any ex ernal mixing valves or similar con rols should
always ensure ha he minimum wa er flow ra e shown
in Figure No. 2 is main ained.
8.10.3 Frost rotection
Considera ion should be given o fi ing a fros
hermos a se a approxima ely 4°C.

HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001045/F
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8.11 Unvented ressurised Systems
See Figure No. 8 for ypical layou of a Pressurised (Un-
ven ed) Ho Wa er Sys em.
In order o correc ly size a Pressurisa ion Uni for any
Hea ing Sys em cer ain parame ers are required. These
are: -
1) S a ic heigh of highes componen in sys em.
2) Sys em volume - if no known a general rule of humb
of 10 li res/kW ins alled boiler power can be used.
3) Maximum flow empera ure, i.e. mos sys ems run a
82°C.
4) Maximum sys em ho working pressure, generally
given in barg.
From he above informa ion Hamwor hy Hea ing can size
he pressure uni and also he expansion vessel required.
Care mus be aken in sizing expansion vessels o ensure
maximum accep ance fac ors are no exceeded.
Normally manufac ures of vessels impose a limi of 0.5.
This value mus no be exceeded a any ime during he
opera ion of he boiler: his includes he over pressure
condi ion should a safe y valve lif .
Considera ion should also be given o sizing of he safe y
valve(s) in he sys em. See BS 6759: Par 1(ISO 4126)
for informa ion.
See also BS 6880: Par 1 for design considera ions.
8.12 Modular Boiler Control Schemes
For Modular applica ions Hamwor hy Hea ing can supply
a unique boiler managemen con rol sys em called he
‘Marshall’ - see Figure No. 8. This sys em comprises: a
mas er con rol uni , which houses he main in erface
processor and, dependen on he number of boilers, a
slave uni for each of he o her boilers. Each uni plugs
in o he previous one by a low vol age signal wire. All
he sensors are connec ed o he las ‘slave’ by a single
cable, which is simple o a ach. Bo h mas er and slave(s)
are incorpora ed in o he con rols fascia for ease of
applica ion. For fur her informa ion con ac Hamwor hy
Hea ing for de ails.
9.0 ELECTRICAL SU LY
WARNING: THIS A LIANCE MUST BE EARTHED.
Wiring ex ernal o he boiler mus be ins alled in
accordance wi h he IEE Regula ions and any local
regula ions, which apply. Wiring mus be comple ed in
hea resis an 3-core cable. (Size 1.0mm_ csa). Boilers
are normally supplied sui able for 230 vol s, 50Hz. Fascia
fuse ra ing is 2A. Ex ernal fuses should be 6A for all
single boiler sizes.
The me hod of connec ion o he mains elec rici y
supply mus facili a e comple e elec rical isola ion of
he single boiler wi h a con ac separa ion of a leas
3mm in all poles.
This appliance must be isolated from the mains
electricity supply in the event of electric arc
welding being carried out on any connecting
pipework.
A mains isola or mus be provided adjacen o he
boiler in a readily accessible posi ion. The supply
should only serve he boiler. NOTE! Vol free con ac
elec rical supplies mus also be isola ed when fi ed
(See no e on fascia). Fur her de ails regarding
connec ion o he elec rici y supply are given in BS
EN 60335, art 1 or BS 3456, art 201.
The power supply should no be swi ched by a ime
clock, especially if a single header pump ki is u ilised.
The Purewell boiler has a remo e s op/s ar loop which
can be used o opera e he boiler(s) under a imed
regime. This remo e loop requires a vol free con ac
for opera ion. Power is supplied by he boiler for his
circui o func ion. The vol age will herefore be he
same as he boiler’s power supply.
Refer o Figure No. 12 for ypical si e wiring
connec ions. See BS 6644 for fur her informa ion.
9.1 Site Wiring
Access o he con rols is achieved by ro a ing he 1/4
urn la ch and removing he door. A 20mm dia.
knockou is provided in each side panel if required for
elec rical connec ions. Any o her rou ing of si e cables
should ensure ha cables do no pass close o he
boiler flue hood or ha any cable runking does no
in erfere wi h normal air circula ion and supply duc s.
A gland pla e is supplied wi h every Purewell boiler
having wo 20mm dia. holes for elec rical cable
anchorage. A plug and socke arrangemen is u ilised
for he si e erminal connec ions. Care mus be aken
o ensure correc connec ions are made o he relevan
erminals before applying power.
Refer o Figure No. 13 for ypical wiring diagram of
s andard Permanen pilo boiler.

HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001045/F
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10.0 BOILER ASSEMBLY AND INSTALLATION
10.1 General
Each boiler is dispa ched o si e as follows: -
i) Hea Exchanger & Baske including burners and gas
valve(s) e c. on a palle .
ii) Casing comple e wi h assembly ins ruc ions.
iii) Con rol Assembly wi h relevan con rol sys em.
iv) Primary flue & Draugh diver er. (Draugh Diver er
models only).
Fur her de ails of each individual assembly is given
below: -
1) Fac ory es ed hea exchanger cas ing assembly
comple e, including insula ion wrap, gas valve assembly
including pre-wired plug assembly. The gas connec ion
pipe should be fi ed o he boiler flue hood once he
hea exchanger is loca ed. NOTE! Care mus be aken
o ensure no damage occurs o ei her insula ion wrap or
gas connec ing pipe. NOTE! THIS I E MUST NOT
BE USED TO MANOEUVRE OR OSITION THE
BOILER. Considera ion mus be given o he weigh of
he boiler (See Figure No. 9), before lif ing. I is
recommended ha he boiler is moved comple e wi h
palle and posi ioned correc ly. The palle can hen be
disman led and he boiler slid in o posi ion.
2) Casing including all screws, fas eners, e c. o permi
si e assembly. Ins ruc ions are included in each box o
show me hod of assembly. Two sizes are manufac ured
hese are: - Small casing for boilers up o 80kW (NOTE!
P70 Low Line model u ilises larger casing), large casing
for all boilers from 95kW o 120kW.
NOTE! When ins alling a mul i-casing se he spacing
pla es mus be used o correc ly space he boilers approx.
3mm apar prior o fi ing he casing. (See label a ached
o he baske fixing.)
I is recommended ha all mechanical work is carried
ou prior o fi ing he casing assembly, his will reduce
possible damage o he panels.
The casing assembly includes a componen lis , which
is also shown in Figure No. 7. You should check o
ensure ha all par s are supplied prior o assembly.
3) Con rols assembly including fascia panel and
hermos a s. This assembly will be sui ed o he desired
con rols and include any op ional ex ras required. Refer
o Figure No. 7 for fi ing ins ruc ions. Ensure all
hermos a capillaries are inser ed and correc ly loca ed
in o he op of he boiler. The con rols assembly also
incorpora es a socke which ma ches he gas valve wiring
plug. Care mus be aken o ensure bo h plug and socke
are correc ly loca ed and fixed in posi ion by he screws
provided.
4) (Standard Diverter models only.) Primary flue
pipe and draugh diver er comple e wi h casing bezel.
Ins ruc ions are supplied wi h he draugh diver er on
how o assemble he uni , if required. These
ins ruc ions MUST be followed correc ly and fully
complied wi h o ensure correc opera ion.
NOTE! Ensure he baffle(No fi ed o 120kW boiler)
is posi ioned correc ly and laying fla on he hea
exchanger before fi ing he flue hood on o he boiler
(if removed).
10.2 Heat Exchanger Insulation Fitting Instructions
Wi h reference o Figure No. 5a - Unfold blanke and
offer up o he boiler as shown. Ensure gas pipe cu ou
is posi ioned o he lef and ha he ‘pe als’ are
uppermos . Si he insula ion blanke on o he baske
ensuring a snug fi .
Figure No. 5a
Reference o Figure No. 5b - Insula ion should be
folded around boiler such ha i s rear edges mee in
he cen re. Ensure flow and re urn connec ions are
clear and unobs ruc ed. Apply foil ape down join.

HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001045/F
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Figure No. 5b
Reference o Figure No. 5c - Fold down pe als as
shown. Use foil ape o affix edges. Fold as required.
Ensure gas pipe bracke is clear and unobs ruc ed.
Figure No. 5c
Ensure combus ion air passages are unobs ruc ed
when fully fi ed.
10.3 Gas ipe Fitting Instructions
Wi h reference o Figure No. 6a - Remove half union and
gas valve from gas rain. Ensure gas valve/manifold
bracke does no suffer undue s ress/movemen . Affix
half union and gas valve assembly o gas pipe as shown
using proprie ary sealing compound. Ensure gas valve
lever is correc ly orien a ed. Offer gas pipe o boiler as
shown. Bracke should be moun ed as shown. Bracke ’s
posi ion will be dependen on boiler size.
Figure No. 6a
Figure No. 6b shows he pipe clamp fi ed o Purewell 60,
70, 80 and 120 kW boilers.
Figure No. 6b
Figure No. 6c shows he pipe clamp fi ed o Purewell
40, 50, 95 and 105 kW boilers.
Figure No. 6c
Tigh en screws ensuring ‘U’ clamp hreads do no
damage insula ion. I may be necessary o remove he
bo om hread of he ‘U’ clamp wi h he bracke in lower
posi ion as i may foul he draugh hood. Ensure no
undue s ress is placed on he gas pipe/manifold and
ensure pipe is ver ical/horizon al before clamping in
posi ion.

HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001045/F
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10.4 Connection to the Flue System
No es on he recommenda ion for design of he flue
sys em are given in Section 6:FLUE SYSTEM.
10.4.1 Standard Diverter models: -
When supplied wi h a draugh diver er, i mus be fi ed
o he boiler as supplied, NO modifica ions are permi ed
on si e. Prior o fi ing he assembly o he boiler, he
op casing panel should be removed from i s packing
and placed in posi ion. Fi ing his panel af er he flue is
fi ed is no recommended. Care should be aken o
ensure he seal be ween primary flue pipe (S andard
Diver er model) and boiler spigo is sound, as a leak
may affec he boiler’s opera ion.
10.4.2 Low Line models: -
The Low Line model incorpora es i s own draugh
diver er and care mus be aken o ensure he seal
be ween he ou le spigo and flue pipe is sound o avoid
he escape of flue gas.
10.4.3
The op panel will require pro ec ing o ensure no
damage occurs o he plas ic coa ing during subsequen
si e assembly of o her componen s.
I is impor an , for service requiremen s, ha he flue
sys em is fully self-suppor ing. Check he flue and
chimney are clear from obs ruc ion.
10.5 Gas Connection
The Purewell boiler is supplied wi h a gas pipe which,
when assembled, exi s he casing a he rear. See
Figure No. 9 for posi ion. The incoming mains gas
supply mus be capable of supplying gas o he boiler
a he required pressure, under all firing condi ions. For
sizing informa ion see Figure No. 11. An approved
isola ing valve & union should be ins alled for each boiler
in a convenien and safe posi ion and be clearly marked.
10.6 Water Connections
See Figure No. 9 for posi ion of wa er connec ions (flow
and re urn). A 1/2” BSP plug is fi ed local o he re urn
connec ion for he fi ing of a drain cock, NOTE! (No
HHL supply.) Care mus be aken when ins alling wa er
sys em pipework ha undue s ress is avoided on he
boiler flow and re urn connec ions. I is recommended
ha unions are fi ed local o he boiler o permi fu ure
servicing requiremen s.
Fully closing valves mus no be connec ed o bo h flow
and re urn pipes unless he boiler is fi ed wi h an
individual, correc ly sized safe y valve. I is
recommended ha a 3-way ‘L’ por valve is fi ed in he
flow connec ion o allow an open ven si ua ion should
he boiler need o be fully isola ed from he sys em.
10.7 Casing and Controls Assembly
For assembly of casing componen s and con rols uni
see Figure No. 7.

HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001045/F
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Multi-casing.
Note: Where boilers are in Modular form, i.e. MP360
(3 x 120kW), a mul i-casing pack is provided for each
addi ional boiler. For example: a riple boiler module
will require: - 1 off single casing pack plus 2 off mul i-
casing packs. If he suppor bar (bo om rail of i em
22) has no been pre-assembled, he following
procedure mus be aken: -
1) Loosen he nu s ha clamp he boilers oge her, (1
fron and 1 rear). Remove he bol , spacer and nu
assembly.
2) Posi ion he suppor bar (i em 22) be ween he boiler
baske s. Assemble using he “pozi-pan head” screws
(i em 13) and M6 nu s (i em 3).
3) Selec he remainder of i em 22: fron , op, and rear
bars and fi he ‘U‘ nu s (10 off i em 4), he la ch (2 off
i em 2) and door loca ion bracke s (2 off i em 7). The
rear member uses 6 off ‘U‘ nu s (4 off in he wo lower
pairs of holes and 2 off in he angle bracke a he
op).
Assemble he frame using he No 8 self- apping
screws (i em 5), he M6 pan head screws and washers
(i ems 12 and 13).
Single and multi-casings.
4) Selec he bo h side panels (i ems 17 & 18) and fi
he la ches (i em 2), ‘U‘ nu s (i em 4) and loca ion
bracke s (i em 7) as shown opposi e.
Figure No. 7 - Assembling the Casing/Multi-Casing Set.
NOTE ! * = Single casing set ** = Multi casing set # = Lowline only
5) A ach side panels o he baske using i ems 3, 12,
13 and 14. A ach back panel. DO NOT FULLY
TIGHTEN SCREWS.
6) Loca e he con rol panel, and fi using No. 8 x _”
self apping screws (i em 5).
7) Loca e he op panel and fi he s rikers (i em 2)
NOTE! L/L fi all four, D/D wo a rear only. Ensure
he blade is fi ed as shown. Fi he ‘U‘ nu s o he op
panel. Place he op panel in posi ion and pass he
draugh diver er hrough o loca e in o boiler spigo .
Fi he draugh diver er in o he boiler hood spigo and
ensure a comple e seal is made be ween hood and
diver er. For Low Line models he flue is connec ed
direc ly in o he boiler spigo . Ensure he seal is made
be ween flue pipe and spigo . Refer o section 10.2:
Connection of Boilers to the Flue System for fur her
informa ion. Wi h he flue correc ly fi ed, lower he
op panel and press he la ch and s rikers oge her
and secure a he fron wi h 2 off No. 8 self apping
screws (i em 5) hrough he con rol panel op edge.
8) Tigh en he back panel screws (i em 5) and fi screw
covers (par of i em 14) o i em 13 on side panels.
9) A ach he loca ion pins (i em 8) o he wo holes in
he 25mm re urn on he door by using M4 x 20 pan
head screws (i em 9), washers (i em 11) and nu s (i em
10). To fi he door, loca e he slo ed holes in he
bo om on o he loca ion bracke s (i em 7). Close he
door agains he con rol panel fascia ensuring he
loca ing pins en er he holes. Turn he 1/2 urn la ch
in he cen re of he door o lock.

HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001045/F
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Figure No. 7a - Exploded View of Casing Set.

HAMWORTHY HEATING LTD. PUREWELL PERMANENT IGNITION 500001045/F
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11.0 COMMISSIONING AND TESTING
11.1 Electrical Installation
A sui ably compe en person MUST check wiring. Power
supply required is 230 vol s AC single phase 50Hz. An
isola or correc ly fused a 6A should be si ed close o
he boiler.
Access o he con rols is achieved by ro a ing he _ urn
la ch and removing he door. Connec ions o he boiler
should pass hrough he 2 x 20mm wiring gland pla e. If
a single header pump ki is used hen his power source
mus be cons an and no swi ched by any ime clock.
The boiler is supplied wi h a remo e s op/s ar circui for
ime clock opera ion.
Any other interlocks, i.e. ressurisation unit, BEM
System should be wired in series with the remote
stop/start loop.
The si e wiring erminal rail is marked wi h Live, Neu ral
and Ear h connec ions. See Figure No. 10 for de ails.
IM ORTANT: READ THE WARNING NOTE
REGARDING EXTERNAL VOLTAGES. This rail is of
he plug/socke ype and can be unplugged for wiring if
required. A schema ic of he circui is shown in Figure
No. 13, op ional ex ras (if fi ed) are also shown.
11.2 Gas Installation
For design see Section 5:GAS SU LY.
The whole of he gas ins alla ion including he me er mus
be inspec ed and es ed for soundness and purged in
accordance wi h he recommenda ions of BS 6891 or
IM/2 or IM/5 as appropria e.
11.3 Water Circulation System
For design see Section 8:WATER SYSTEM.
The sys em should be horoughly flushed ou wi h cold
wa er wi hou he pump in posi ion. Ensure all he valves
are open.
Wi h he pump fi ed he sys em should be filled and air
locks cleared. Ven he radia ors and check for leaks.
If he sys em is unven ed he pressurisa ion uni should
no be u ilised for he ini ial filling. This should be carried
ou using a WRC approved double check valve and
emporary-filling loop.
In order o comply wi h local Wa er Au hori y Regula ions,
his loop mus be disconnec ed when filling is comple e.
Wa er rea men s should no be fed hrough he
Pressurisa ion uni unless permi ed by he manufac urer.
Check he expansion vessel cushion pressure as
de ailed by he manufac urer’s Ins aller’s Guide.
11.4 Commissioning The Boiler
Before a emp ing o commission any boiler, ensure ha
personnel involved are aware of wha ac ion is abou o
be aken and begin by making he following checks: -
1) Flueway passages o chimney are clear.
2a) Standard Diverter models: - If necessary, remove
he flue hood and baffle, (no fi ed o he 120kW boiler),
o ensure he boiler flueways are clear. Reposi ion he
gas baffle ensuring ha i is lying fla on he op sec ion.
Re-fi he flue hood. Ensure boiler draugh diver er
passages are clear and clean.
2b) Low Line models: - The Low line draugh diver er
incorpora es an in egral inspec ion cover. To gain access,
remove insula ion and he M6 bol s on he sloping fron
of he hood assembly. This will reveal he inner par of
he boiler, if fur her access is required, remove primary
flue pipe (ensure i is correc ly suppor ed), and remove
comple e op of he draugh diver er assembly. Af er
cleaning he boiler re-assemble draugh diver er in he
reverse of dis-assembly. Ensure all join s are correc ly
sealed.
3) Adequa e ven ila ion as per Section 7:AIR SU LY
exis s in he boiler house.
4) The sys em is fully charged wi h wa er, ready o receive
hea . All necessary valves are open and he pump is
circula ing wa er.
5) The pipework and valve arrangemen is ins alled o
Hamwor hy Hea ing recommenda ions in such a way ha
wa er flow ra es will be in accordance wi h Figure No. 1.
6) The gas supply pipework is clear of any loose ma er,
es ed for soundness and purged o C : 331/3.
11.5 Boiler Checks rior To Lighting
NOTE! Refer o Figure No. 1 for Na ural Gas maximum
inle pressure for normal opera ion. Informa ion rela ing
o propane firing can be found in Appendix ‘A’.
Note: - all propane firing boilers are fi ed wi h a low gas
pressure swi ch (se a 20mbar). Should he pressure
fall below his level, he boiler will not opera e.
1) Gas supply is connec ed bu urned o he “off” posi ion.
Any unions or fi ings are correc ly igh ened, es poin s
are closed, burners correc ly posi ioned, injec ors are in
place (of correc size) and igh and ha he pilo is
connec ed o he gas valve.
2) Ensure elec rici y is connec ed bu 2A fuse on boiler
is removed, he plug/socke gas valve connec ion is
correc ly loca ed and fully igh ened wi h screws provided
and ha he hermos a bulbs are fully inser ed in o he
boiler pocke . Ensure he hermocouple is correc ly
connec ed be ween gas valve and pilo burner.
3a) All Models: - Re-se empera ure limi er by firmly
pressing pin on uni .
3b) Non- ilotstat models: - Ensure energy cu -off
(ECO) connec or is correc ly loca ed be ween valve and
hermocouple. Check he leads for damage and