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1. 533922008 Flame sensing probe lead tete et ice a da dh cete nigel an td 533901259 Maint PCB PET 563901293 563901237 Thermostat sensor incl 600mm long leads 533901350 Potentiometer incl Harness Jouine aea Ee eene nennen nennen nn nnne nnn nnne 563901258 Ignition Sequence Controller 533901344 Primary Flue Damper Motor incl Leads sssssssseeenn ennemi n nennen 563901281 Hours Run ete ee vd aee eve Qe 563901273 Sequencing Interface Module cmo Lon re ue ree tes rtt ede e e ae dee epa ad et e aa ade Dea dag de 533901421 Mechanical Items Single Bu fner eet t ep Pie t tdem A dnte 533301003 Heat ExchangerNIpple 5 1 etre eee tit atte 330502033 Flue hood thermoseal Yarn 10mm Dia sse nemen 331299233 Injector Copper Washer 2 m Re rh e Ee P ee CER d e acta tend e ed ee 339008347 Gas Valve O Ring Joint 40 80KW a keai nnns 742111245 Gas Valve O Ring Joint 95 120kW only en nennen nnns 742122069 alice 563801010 Flame Probe m 533805014 Temperature Limiter drei eoe eerte ed e dm eene d 533901179 Temperature Limiter L amp GG eee robe ev pae e eiA tbe eet nee eoa dva eas 33901
2. gt 2 HOLMS SNIAO ld e i Ud QO 000000000 C HAMWORTHY HEATING LIMITED BOILER CONTROL PCB HOLMS ONIAOUd ANY 4 3015 MOT j x x ov 21 HAMWORTHY HEATING LTD PUREWELL AUTOMATIC IGNITION 500001089 F 1 Gas supply is connected but turned to the off position Any unions or fittings are correctly tightened test points are closed burners correctly positioned injectors are in place of correct size and tight and that the ignition and probe leads are connected correctly Ensure Hot Surface igniter and sensing probe assembly are not cracked or broken 2 Ensure electricity is connected the gas valve PCB connection is correctly located and that the sensor and thermostat bulbs are fully inserted into the boiler pocket Reset temperature limiter by firmly pressing pin in controls housing 3 If a sequencing interface module is fitted to the boiler control panel locate and the hand auto switch SW1 on the boiler main PCB refer to Figure 11 1 p21 and set it to the hand position to override operation of the sequencing interface module for the purpose
3. 5 1 Classic only 1 Classic only studs spacers M5 screws and shake proof washers items 7 8 11 and 12 Should the flue already be fitted to the boiler the top panel can be split by removing screws and washers items 11 amp 12 Place the top panel in position and press the ball studs into the matching latches in the top edge of the side panels or multi casing frame set Classic boilers only if a damper is fitted remove the screws item 16 and discard the top panel insert item 28 if required Should the damper motor assembly sit above the top panel discard the blanking plug from the top panel insert Fit the edging strip to the hole and route the damper cable assembly through the hole into the control panel securing the cables to the casing side panel using the self adhesive clips supplied Note The damper must be fitted with the motor assembly at the front of the boiler 10 The 4off screws fixing the back panel to the side panels can now be tightened 11 Select the door panel item 4 and fit the 2off location pins M4 screws nuts and shake proof washers items 23 24 25 amp 26 to the 2 holes in the rear return Select the fascia bezel item 27 supplied with the control panel Remove the paper liner from the self adhesive foam tape affixed to the rear of the bezel and fit to the door aperture as shown ensuring correct orientation and a strong bond to the surface of the door panel To fit the
4. ead adden eevee 27 14 0 REPLACEMENT OF FAILED COMPONENTS sse eene nnns 30 15 0 RECOMMENDED SPARES ene baies EENE 36 APPENDIX A INFORMATION RELATING TO PROPANE FIRING 37 iii HAMWORTHY HEATING LTD PUREWELL AUTOMATIC IGNITION 500001089 F FIGURES PAGE Figure 1 1 Boller Installation a etu Sera erate inated 2 Figure 2 1 Boiler Dimensions Clearances eene nente kun trennen tenen e uan Earn 3 Figure 2 2 Performance amp General Data Information sssssssssenee eene 4 Figure 5 3 Gas Flow Ini Pipes e eue 8 Figure 5 6 Gas Valve Pipework Leak Test Procedure eene emen 7 Figure 7 2 Mechanical Ventilation Flow Rates sssssssseeeem eene 10 Figure 8 3 Cold Feed and Vent Pipe Sizes 10 Figure 8 10 1 Temperature Controls and Boiler On Off Switch ssssseeee em 11 Figure 8 12 Site Iu To rz aper 13 Figure 9 1 Wiring E 14 Figure 10 2 Heat Exchanger Insulation Fitting Instructions ssssen enn 16 Figure 10 3 Gas Pipe Fitting INStructions eene nee 16 17 Figure 10 7 Casing Kit and Assembly nennen nnns 18 19 Figure 11 1 Main PCB RR E
5. 5 0 GAS SUPPLY 5 1 Service Pipes The local gas region must be consulted at the installation planning stage in order to establish the availability of an adequate supply of gas An existing service pipe must not be used without prior consultation with the local gas region 5 2 Meters A new gas meter will be connected to the service pipe by the local gas region or a local gas region contractor An existing meter should be checked preferably by the gas region to ensure that it is adequate to deal with the rate of gas supply required 5 3 Gas Supply Pipes Supply pipes must be fitted in accordance with BS 6891 or IGE UP 2 as appropriate Pipework from the meter to the boiler must be of adequate size Do not use pipes of a smaller size than the boiler gas 500001089 F connection The complete installation must be purged and tested for soundness as described in BS 6891 or IGE UP 1 and IGE UPMA as appropriate See Figure 5 3 p8 for recommended gas flows in pipes 5 4 Boosted Supplies Where it is necessary to employ a gas pressure booster the controls must include a low pressure cut off switch at the booster inlet The local gas region must be consulted before a gas pressure booster is fitted 5 5 Boiler House Control Valve A manual valve for boiler house isolation shall be fitted in the gas supply line It shall be clearly identified and readily accessible for operation preferably by an exit 5 6 Boiler Gas System L
6. 8 IMPORTANT PRIOR TO LIGHTING UP THE BOILER THE SAFETY LINKS ON THE MAIN PCB MUST BE REMOVED AS DETAILED TO ENSURE SAFE OPERATION OF THE BOILER REFER TO FIGURE 11 1 p21 THE LINKS MUST BE CAREFULLY CUT USING A SMALL PAIR OF ELECTRICAL SIDE CUTTERS AND THE HAMWORTHY HEATING LTD 22 PUREWELL AUTOMATIC IGNITION RESULTANT LOOSE LINKS MUST BE REMOVED FROM THE PCB SO AS NOT TO CAUSE AN ELECTRICAL SHORT 8 1 All models check that LK1 LK6 have been factory removed 8 2 For optional high flow temperature 120 C cut LK1 amp LK2 8 3 Classic high low with flue damper models cut LK3 check that LK4 LK5 amp LK13 have been factory removed 8 4 Classic and Integra on off without flue damper models fit 6way and way link connectors supplied loose with control panel to sockets CN1 6way and CN2 7way The link connectors MUST be fitted to enable correct boiler operation 8 5 For optional sequencing control cut LK7 amp LK12 8 6 For low gas pressure switch Propane boilers cut LK9 interface module 11 6 Procedure for Initial Lighting Ensure gas service cock is in the off position Press the control thermostat knob to switch on the boiler Press lockout button on fascia to re set timer wait at least 15 seconds before pressing again if lockout neon does not go out After a delay the HSI neon should illuminate on the fascia and the igniter should be visible through the viewi
7. Note Optional Hamworthy Heating Ltd Sequencing Interface Modules will be required to be installed within the control panel of each boiler to enable sequence control of the boilers by the Milton boiler sequence control Refer to Milton and Sequence Interface Module kit instructions for details 500001089 F Figure 1 1 Boiler Installation Typical Expansion pipe Pressure amp Temperature Float Drain auges Mains water valve Saf iN S valve Feed amp Valve expansion r or r i Module Module Module Automatic Air Vent 1 2 3 Circulation pump System Feed grec eee ud Boilers pipe 2 pla Heating load Circulation pump loz Primary loop 7 Drain valve V VENTED SYSTEM Primary loop Hamworthy recommended system Mains water Automatic Drain Pressure amp L Air Vent Safety Temperature valve gauges Val Lockshield HX valve t sa i gt Expansi Automatic Air Vent 1 Module Module Module Circulation pump vessel System Hamworthy Modular Boilers Drain l J J Lockshield Tvalve 5 valve Heating load Double Circulation pump a Lockshield Temporary check Drain valve UNVENTED SYSTEM Primary loop Hamworthy recommended system Primary loop valve fill line val
8. Purewell Series Boilers Cast Iron Atmospheric Modular Boilers with Automatic Ignition for Heating and Domestic Hot Water Installations Installation Commissioning and Servicing Instructions CLASSIC MODELS 40 50 60 70 80 95 105 120 kW INTEGRA MODELS 40 70 amp 100 kW NATURAL GAS LPG PROPANE IMPORTANT NOTE THESE INSTRUCTIONS MUST BE READ AND UNDERSTOOD BEFORE INSTALLING COMMISSIONING OPERATING OR SERVICING EQUIPMENT J Hamworthy HEATING amp HOT WATER PRODUCTS Customer Services Technical Enquiries 01202 662527 662528 To supplement the detailed technical brochures technical advice on the application and use of products in the Hamworthy Heating range is available from our technical team in Poole and our accredited agents Site Assembly 01202 662555 Hamworthy offer a service of site assembly for many of our products in instances where plant room area is restricted Using our trained staff we offer a higher quality of build and assurance of a boiler built and tested by the manufacturer Commissioning 01202 662555 Commissioning of equipment by our own engineers accredited agents or specialist sub contractors will ensure the equipment is operating safely and efficiently Maintenance Agreements 01202 662555 Regular routine servicing of equipment by Hamworthy service engineers inspects
9. Select the top support rail item 20 and fit 2off U nuts item 15 to the pair of holes at the rear end Fix the top support rail to the front and rear support rails using No 8 self tapping screws item 16 Single and multi casings 6 Select the side panels items 1 and 2 and fit the door location brackets item 5 using 4off M6 screws and spring washers items 13 and 14 Fit U nuts item 15 to the 2 holes at the rear of each panel as shown Fix the side panels to the boiler basket using M6 nuts and shake proof washers items 9 and 10 7 Fit the back panel item 3 using 4off No 8 self tapping screws item 16 DO NOT FULLY TIGHTEN THE SCREWS 8 Select the control panel item 6 Permanent pilot boilers only fit the door catch bracket to the control panel using the 2off M6 screws nuts and washers supplied with the panel as shown Loosely fit 4off M6 nuts and washers items 9 amp 10 to the pressed in studs at the top front end of the side panels or multi casing frame set as shown Fit the control panel by passing the right hand side behind the pressed in studs and pulling the panel forwards to engage the studs into the slots in the right hand side of the panel Push the left of the control panel backwards to engage the studs on that side into the slots in the panel Tighten the 4off M6 nuts 9 Select the top panel item17 and fit 4off ball HAMWORTHY HEATING LTD PUREWELL AUTOMATIC IGNITION Nh
10. be positioned on 533mm 21 centres if required Larger numbers should be split into two or more banks with 150mm 6 between each bank NOTE When installing modular units on 533mm 21 centres the casing support rail or spacing plates should be fitted between each boiler before bolting together See Section 10 1 General Installation of Boilers p15 Ref spacing plates for further information 2 2 General Information and Technical Data relating to Natural Gas is shown in Figure 2 2 Technical data relating to propane firing can be found in Appendix A p37 2 3 Screw threads All screw threads used in the Purewell boiler conform to the following ISO 7 1 or ISO 228 1 for pipe threads where applicable ISO 262 for all general screw threads 3 0 GENERAL REQUIREMENTS 3 1 Related Documents Gas Safety Installations and Use Regulations 1994 As amended It is law that competent persons in accordance with the above regulations install all gas appliances Failure to install appliances correctly could lead to prosecution It is in your own interest and that of safety to ensure that this law is complied with The installation of the boiler MUST be in accordance with the relevant requirements of the IEE Regulations and the byelaws of the local water undertaking The installation should also be in accordance with any relevant requirements of the local gas region and local authority and the relevant recommendations of
11. door locate the slotted holes in the bottom onto the location brackets item 5 Pivot the door backwards until the location pins engage fully into the mating holes in the front edge of the side panels or multi casing frame set Turn the quarter turn latch in the centre of the door panel to lock it in place 500001089 F 11 0 COMMISSIONING AND TESTING 11 1 Electrical Installation A suitably competent person MUST check wiring Normal supply required is 230 volts AC single phase 50 Hz An isolator correctly fused at 10A should be sited close to the boiler Access to the controls is achieved by rotating the 1 4 turn latch and removing the door Connections to the boiler should pass through the 3 x 20mm wiring gland plate If a single header pump kit is used then this power source must be constant and not Switched by any time clock The boiler is supplied with a remote stop start circuit for time clock operation Any other interlocks i e Pressurisation unit BEM System should be wired in series with the remote stop start loop The site wiring terminal rail is marked with Live Neutral and Earth connections See Figure 9 1 for details IMPORTANT READ THE WARNING NOTE REGARDING EXTERNAL VOLTAGES This rail is of the plug socket type and can be unplugged for wiring if required The main PCB is provided with four T rated fuses to protect the following circuits see Figure 11 1 Main PCB F1 T6 3A Boiler controls F2 T2A S
12. 3 1 3 75 4 2 No Burner Bars Injectors WATER DATA Water Connections Flow Rc2 Return Rc2 Maximum Water Pressure bar g 6 Water Content litres 37 1 37 1 442 Maximum Flow Rate 11 C AT Rise litre s Tones TSN Waterside Pressure Loss 11 C AT Rise mbar 20 59 26 47 37 25 Design Flow Rate 15 C AT Rise litre s d Waterside Pressure Loss 44 90 15 AT Rise mbar i Minimum Flow Rate 0 87 22 C AT Rise litre s Waterside Pressure Loss 7 06 22 C AT Rise mbar ELECTRICAL DATA Normal Supply Voltage 230V 50Hz Power Consumption maximum W 90 Shunt Pump Output optional 230V 50Hz fused 2A NOTE Flue gas volumes are based on a gross flue gas temperature of 100 C at 1013mbar This is considered to be the predicted temperature of the products in the secondary flue downstream of the draught diverter 4 HEATING LTD PUREWELL AUTOMATIC IGNITION 500001089 F 2 0 TECHNICAL DATA 2 1 Overall dimensions are shown in Figure 2 1 p3 Both single and multiple boiler arrangements are shown The Purewell boiler can be installed as a single unit or in modular form where a multi casing reduces required floor area Each boiler has an independent door for access to the controls and other working components It is recommended that a maximum of 6 boilers can
13. NE10 illuminated Check Low Fire damper main pcb electrical connections and mechanism Check and replace as required Reset limit thermostat Adjust temperature set point to create demand Secure link 15 there power at the ignition Replace ignition control Continued 28 HAMWORTHY HEATING LTD PUREWELL AUTOMATIC IGNITION 500001089 F Figure 12 26 Fault Finding Procedures Cont Continued Boiler goes to high fire 15 remote high low control link Secure link check wiring check g 9 d Secure B E M control check system load Classic models ony 7 Check High Fire ls dun er electrical connections and mechanism Is there power on the high fire m Check gas valve plug and wiring Replace valve Boiler at high fire but cycles on off rapidly Temperature control circuit faulty Check replace temperature sensor and or boiler PCB Check replace pump bleed trapped air from the system z o Poor water circulation Boiler at high fire but overheats while system remains cool Check replace pump bleed air Insufficient water circulation from the system z o Boiler at high fire but operates noisily Check replace pump bleed air Insufficient water circulation from the system Adjust temperature control to a lower setting z o Temperature control set too high Check replace temperature Temperature control circuit faulty sensor and or boiler PCB Sca
14. NUMBER 1 BOILER NUMBER 2 SEQUENCING INTERFACE MODULE TERMINALS SEQUENCING INTERFACE MODULE TERMINALS BOILER PCB TO SIM LOW VOLTAGE BOILER PCB TO SIM LOW VOLTAGE INTERFACE TERMINALS INPUTS OUTPUTS 1 INTERFACE TERMINALS INPUTS OUTPUTS WIRING HARNESS NOT WIRING HARNESS NOT TO BOILER MAIN PCB UTILISED TO BOILER MAIN PCB UTILISED CONNECTOR CN7 CONNECTOR CN7 BOILER PCB PLUG BOILER MAIN SITE BOILER PCB PLUG BOILER MAIN SITE SOCKET TERMINALS WIRING TERMINALS SOCKET TERMINALS WIRING TERMINALS 230V AC 50Hz 230V AC 50Hz 230V AC 50Hz 230V AC 50Hz OUTPUT SUPPLY OUTPUT SUPPLY SAFETY SAFETY INTERLOCK INTERLOCK BI 0 0 CONTROLS NOTE SHUNT PUMP AND VOLT FREE CONTACT TERMINALS NOT SHOWN FOR CLARITY MILTON BOILER SEQUENCE CONTROL REFER TO MILTON INSTALLATION MANUAL FOR FURTHER DETAILS n HAMWORTHY HEATING LIMITED 3 MULTIPLE BOILER INSTALLATION ON OFF OR HIGH LOW CLASSIC WITH FLUE HIGH LOW FLUE DAMPER MODELS ONLY OPERATION VIA NON HAMWORTHY HEATING LIMITED BOILER SEQUENCE CONTROL BOILER NUMBER 1 BOILER NUMBER 2 BOILER NUMBER 3 BOILER SITE WIRING TERMINALS BOILER SITE WIRING TERMINALS BOILER SITE WIRING TERMINALS BOILER PCB PLUG BOILER MAIN SITE BOILER PCB PLUG BOILER MAIN S BOILER PCB PLUG BOILER MAIN SITE SOCKET TERMINALS WIRING TERMINALS SOCKET TERMINALS WIRING TERMIN SOCKET TERMINALS WIRING TERMINALS 230V AC 50Hz 230V AC 50Hz 230V 50Hz 230V AC 50H 230V AC 50
15. accordance with Figure 2 2 p4 6 The gas supply pipework is clear of any loose matter tested for soundness and purged 11 5 Boiler Checks Prior To Lighting NOTE Refer to Figure 2 2 p4 for maximum gas inlet pressure for normal operation Information relating to propane firing can be found in Appendix A p37 NOTE All propane boilers are fitted with a low gas pressure switch set at 20mbar Should the gas supply pressure fall below this level the boiler will not operate 500001089 F Figure 11 1 Main Layout A C 2 001 0 A 008 0 C mp 029 UUUHUUUUUHUHUUU i LOW FIRE OFFSET P a 0000000000 00 anti ia MFR PCB MFR DATE OOO 9 PART 563901 SERIAL
16. and Testing NOTE Isolate electrical supply to the boiler and turn off the gas supply before removing controls cover and commencing any servicing or component exchange procedure 14 1 Igniter Assembly Reference to Figure 14 0 p31 shows position of igniter assembly To remove assembly disconnect the plug socket on the supply lead and remove the screw securing the igniter to the burner front panel Figure 14 1 p32 shows diagram of igniter assembly and relevant components part numbers Renew components as required and generally remove any loose sooty deposits and clean as required Ensure positions of components are as recommended in Figure 14 1 p32 14 2 Control Thermostat Renewal The thermostat consists of a potentiometer and remote sensor Part Nos 563901258 amp 533901350 NOTE Record existing temperature setting of thermostat for reference before removal Prise the top panel from the side panels secured by spring latches and lift boiler top panel to reveal thermostat pocket NOTE on Classic models remove the infill panel prior to lifting the top panel Carefully remove thermostat phials Drop down fascia to reveal controls section Disconnect the sensor cable plug CN23 from the PCB and remove the sensor Prise out the indicator disc from the centre of the control knob and loosen the collet nut securing the knob to the shaft Pull off the control knob and undo the securing nut on the central spindle
17. controlled steam and hot water boilers CIBSE Publications CIBSE Guide It is impractical in this document to specify all relevant information but the following extracts from the above references are emphasized since failure to comply with these requirements will almost certainly result in an unsatisfactory installation 3 2 Feed water Quality If the boiler feed water has a high degree of hardness it is recommended that the water be treated to prevent precipitation of scale or sludge in the boiler water passageways Details of additives can be obtained from any reliable manufacturer of water treatment products or the local water authority It should be noted however that even if the boiler water is of average hardness not 500001089 F requiring treatment subsequent draining of the system for repair or constant make up water due to an undetected leak will cause additional deposits and gradual build up of scale It is essential therefore that leaks are attended to promptly and draining is kept to an absolute minimum It is recommended that the system is flushed out at least twice with hot water before any treatment is added If any doubt exists regarding the internal cleanliness of an old system consideration should be given to the fitting of a coarse filter in the return pipework to the boilers 3 3 Adequate Water Flow The Hamworthy Purewell boiler is designed as a quick response low water content unit to run cont
18. draught diverter outlet all modules in a bank For optimum performance draught conditions should be between 0 05 to 0 125 mbar In the case of a single boiler installation the minimum vertical flue height is 2m above the draught diverter skirt For multiple boiler installations consult Hamworthy Heating Technical Department n some instances mechanical 500001089 F Figure 5 3 Gas Flow in Pipes Purewell Boiler Output Maximum length of gas pipe Metres ELE UAE E DE a 40kW 285 3 x 95kW 315 3 x 105kW 360 3 x 120kW 380 4 x 95kW 420 4 x 105kW 480 4 x 120kW 525 5 x 105kW 600 5 x 120kW 630 6 x 105kW 720 6 x 120kW 2 J rw WR The above table expresses pipe lengths from gas meter to appliance which will produce approx 1mbar pressure loss This table must be used in conjunction with losses of various fittings fitted in the gas line shown below For example 2 Purewell 120kW Boilers being fed by 65mm NB pipe with 6 elbows between gas meter and boiler header can have a maximum length of 72m 6 x 2m 60 metres run to achieve a 1mbar loss Note Information above is based on IM 16 8 HAMWORTHY HEATING LTD PUREWELL AUTOMATIC IGNITION 500001089 F assistance be necessary The boilers suitable for connection to a fan diluted flue system refer to Gas E publication IGE UP 10 Installation of gas appliances in industrial and comm
19. low level For an exposed boiler house air vents should be fitted preferably on four sides but at least on two sides Air vents should have negligible resistance and must not be sited in any position where they are likely to be easily blocked or flooded or in any position adjacent to an extraction system which is carrying flammable vapour Grilles or louvres must be so designed that high velocity air streams do not occur within the space housing the boiler The air supplied for boiler house ventilation shall be such that the maximum temperatures within the boiler house shall be as follows 1 At floor level or 100mm above 5 2 At mid level 1 5m above floor level 2 0 3 At ceiling level 100mm below 2 3 4 Where both low and high level openings are used the grilles shall have a total minimum free area of Low Level inlet 540cm plus 4 5cm per Kilowatt in excess of 60kW total rated input High Level outlet 270cm plus 2 25cm per Kilowatt in excess of 60 total rated input 500001089 F 7 2 Air Supply by Mechanical Ventilation Air supplied to the boiler room by Mechanical means should be as follows 1 Mechanical inlet and mechanical extract can be utilised providing design extraction rate does not exceed one third of the design inlet rate 2 Mechanical extract ventilation with natural inlet ventilation MUST NOT be used NOTE For Mechanical ventilation systems an automati
20. power supply MUST NOT be switched by a time clock especially if a single header pump kit is utilised The Purewell boiler has a remote stop start loop which can be used to operate the boiler s under a timed regime The boiler control provides a 230V signal that can be fed through a volt free contact for operation Refer to Figures 8 12 and 9 1 p14 for typical site wiring connections See BS 6644 for further information DO NOT feed mains voltage onto these terminals 9 1 Site Wiring Access to the controls is achieved by rotating the 1 4 turn latch and removing the door A 20mm dia knockout is provided in each side panel if required for electrical connections Any other routing of site cables should ensure that cables do not pass close to the boiler flue hood or that any cable trunking does not interfere with normal air circulation and supply ducts A removable bracket is supplied with every Purewell boiler having three 20mm dia holes for electrical cable anchorage A plug and socket arrangement is utilised for the site terminal connections the plug terminals being attached to the removable bracket NOTE Rigid conduit MUST NOT be connected to the bracket as this will prevent removal Care must be taken to ensure correct connections are made to the relevant terminals before applying power Refer to Figures 8 12 and 9 1 p14 for typical wiring diagram NOTE On off without flue damper boilers only The boiler control pa
21. should also be given to the maximum working pressure of the boiler as given in Section 2 TECHNICAL DATA 5 Consult Hamworthy Heating Technical Department for help or assistance if in doubt 1 5 The Purewell boiler is not suitable for direct connection to domestic hot water supplies or gravity fed heating systems 1 6 The Purewell boiler can be installed with either reverse return water flow layout optional kits available or with single pipe header layout non HHL supply See Figure 1 1 p2 for typical schematic layout 1 7 It is good practice in all heating installations to use some form of water treatment to reduce formation of lime scale and black iron oxide sludge The high efficiencies produced by the Purewell Boiler can easily be reduced by lime scale formation If a pressurised unit is used it is prudent to include an hours run meter to give an indication of pump running time and hence raw water make up Any leaks should be attended to as soon as possible to avoid calcium salt build up within the boiler s waterways 1 8 Options 1 8 1 Optional reverse return header kits comprising a pre designed arrangement of components are available for modular installations of all Purewell boiler models Please contact Hamworthy Heating for information 1 8 2 Milton boiler sequence control system for timed remote control of single and multiple on off and high low boilers with outside temperature compensation and optimum start
22. the following documents British Standards BS 7074 Application selection and installation of expansion vessels and ancillary equipment for HAMWORTHY HEATING LTD PUREWELL AUTOMATIC IGNITION sealed water systems Part 2 Code of practice for low and medium hot water systems BS 6891 Installation of low pressure gas pipework of up to 28mm in domestic premises For larger installations see IGE UP 1 IGE UP 1A and IGE UP 2 BS 6644 Installation of Gas Fired Hot Water Boilers 60kW to 2MW BS 6700 Design installation testing and maintenance of services supplying water for domestic use BS 6880 Part 1 2 amp 3 Code of practice for low temperature hot water heating systems of output greater than 45kW BS EN 60335 Part 1 Safety of Household amp Similar Electrical Appliances BS 3456 Part 201 Electrical Standards CP 342 Centralised hot water supply Part 2 Buildings other than individual dwellings 1 Gas E Publications IGE UP 1 Soundness testing and purging industrial and commercial gas installations IGE UP 1A Soundness testing and direct purging of small low pressure industrial and commercial natural gas installations IGE UP 2 Gas installation pipework boosters and compressors in industrial and commercial premises IGE UP 10 Installation of gas appliances in industrial and commercial premises Pt 1 flued appliances Health and Safety Executive Guidance note 5 Automatically
23. the safety and integrity of the plant reducing the risk of failure and improving performance and efficiency Maintenance agreements enable our customers to plan and budget more efficiently Breakdown service repair replacement 01202 662555 Hamworthy provide a rapid response breakdown repair or replacement service through head office at Poole and accred ited agents throughout the UK Spare Parts 01202 662525 A comprehensive spare parts service is operated from our factory in Poole providing replacement parts for both current and discontinued products Delivery of parts and components is normally from stock within seven days However a next day delivery service is available for breakdowns and emergencies Purewell Series Boilers Cast Iron Atmospheric Modular Boilers with Automatic Ignition for Heating and Domestic Hot Water Installations Installation Commissioning and Servicing Instructions CLASSIC MODELS 40 50 60 70 80 95 105 120 kW INTEGRA MODELS 40 70 amp 100 kW NATURAL GAS LPG PROPANE NOTE THESE INSTRUCTIONS MUST BE READ AND UNDERSTOOD BEFORE INSTALLING COMMISSIONING OPERATING OR SERVICING EQUIPMENT THE PUREWELL BOILER IS INTENDED FOR USE AS A COMMERCIAL APPLIANCE AND IS NOT CERTIFIED FOR USE IN DOMESTIC APPLICATIONS OR HABITABLE AREAS THIS BOILER IS FOR USE ON GROUP H NATURAL GAS 2 FAMILY Iz OR LPG PROPANE 3 FAMILY Isp PLEASE ENSURE RELEVANT INFORMATION REQUIRED WITHIN DOCUMENT
24. 1 Diagram of Hot Surface Igniter and Sensing Probe Assembly Hot Surface Igniter Assembly Flame Probe Electrode 563801010 533805014 Burner Bar 32 HAMWORTHY HEATING LTD PUREWELL AUTOMATIC IGNITION 500001089 F 14 3 Temperature Limiter Limit Stat Renewal Part No 339011044 or 533901179 The temperature limiter renewal procedure follows that of the control thermostat with some minor differences These are as below Remove the push on spade connections from the temperature limiter body noting position of coloured cables Remove plastic cover if fitted and unscrew holding nut to detach temperature limiter from housing Gently feed the capillary back through the controls bulkhead Re set temperature limiter to 100 C Check the operation of the device by carefully applying a heat source to the bulb Re assemble temperature limiter into controls housing ensuring correct cable notation Refer to the thermostat diagram if terminal identification differs from those given in Figure 9 1 p14 14 4 Main Gas Valve NOTE Some gas valve components can be replaced without completely removing the whole assembly from the boiler However Hamworthy Heating strongly recommend that a new gas valve assembly is fitted to ensure safe reliable operation of the boiler Please refer to Hamworthy Heating Technical Department before attempting to remove components from the gas valve NOTE Only gas valves with a
25. 1044 NOTE For any service replacement parts Especially Gas Valves the boiler Serial No on Data Plate inside boiler MUST be quoted For service or spares please contact Hamworthy Heating Limited Fleets Corner Poole Dorset BH17 0HH Phone Number 2 nihii teet 01202 662500 Fax Numiber eet eren 01202 665111 ueniet teens 01202 662555 EDI 01202 662525 Technical erre 01202 662527 662528 36 HAMWORTHY HEATING LTD PUREWELL AUTOMATIC IGNITION 500001089 F Appendix A Purewell Automatic Ignition INFORMATION RELATING TO PROPANE FIRING NOTE LPG FUELS IT IS STRONGLY RECOMMENDED THAT ON LPG INSTALLATIONS GAS DETECTION EQUIPMENT IS FITTED THIS EQUIPMENT SHOULD BE POSITIONED NEAR THE BOILER AND AT LOW LEVEL IT IS ALSO IMPORTANT THAT THE SPACE HOUSING THE BOILER IS ADEQUATELY VENTILATED AT HIGH AND LOW LEVEL REFER TO MAIN INSTALLER S GUIDE 1 0 INTRODUCTION The operation of the Purewell range of boilers on LPG Propane 3 family is similar to that Natural Gas 2 family I4 and the design and installation details described in the main body of the installers guide should be followed There are however differences in the construction and setting of the propane fired boiler which are as follows a The main gas injectors located in the gas manifold are replaced with those detailed the Figure 2 2 Performance and General Data Information GENER
26. 15 FOUND RELATING TO SPECIFIC GAS TO BE FIRED BEFORE FIRING BOILER THIS BOILER COMPLIES WITH ALL RELEVANT EUROPEAN DIRECTIVES EC TYPE CERTIFICATE Nos GAD BG EC 87 93 20 BED BE 87 97 34 PRODUCT IDENTIFICATION No 87AO20 PUBLICATION NO 500001089 ISSUE F March 2005 HAMWORTHY HEATING LTD PUREWELL AUTOMATIC IGNITION 500001089 F CONTENTS PAGE 1 0 INTRODUCTION 1 2 0 Rte bee eee ek ee t t ds 5 3 0 GENERAL REQUIREMENTS sess enne nnne 5 3 1 Related Documents 3 2 Feed Water Quality 3 3 Adequate Water Flow 3 4 Time Clock Control 3 5 Minimum System Water Pressure 4 0 LOCATION Em 6 5 0 GAS SUPPE Y s ra teet estet iate iae eee 6 5 1 Service Pipes 5 2 Meters 5 3 Gas Supply Pipes 5 4 Boosted Supplies 5 5 Boiler House Control Valve 5 6 Boiler Gas System Leak Check 6 0 FLUE SYSTEM hod RENEW 7 6 1 General Requirements 6 2 Design Waste Gas Volume and Temperature 6 3 Flue Condensation 6 4 Materials 6 5 Disconnection 6 6 Flue Discharge 6 7 Surface Temperatures 6 8 Flue System Location 7 0 Peu ug 9 7 1 Air Supply Natural Ventilation 7 2 Air Supply By Mechanical Ventilation 8 0 WATER CIRCULATION SYSTEM tet eet cetera tiec het e RR P ts ea dae RT ee 10 8 1 General 8 2 Pressure Relie
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28. AL DATA 40 50 60 70 80 95 100 Boiler Input High Fire kW Gross Performance and General Data Information table below b The nominal gas inlet pressure for propane should be 37mbar c Relevant labels are replaced to indicate the appropriate gas for which the boiler is set up to fire The following tables and paragraphs using the same numbering system as the main installer s guide highlight the different values and procedures to be used when firing propane and should be used in conjunction with the Main Installer s Guide Boiler Input High Fire kW Nett Boiler Input Low Fire kW Gross Boiler Input Low Fire kW Nett Boiler Output High Fire kW Boiler Output Low Fire kW FLUE DATA Nominal Flue Dia Classic mm Nominal Flue Dia Integra mm Approx Flue Gas Temp Approx Flue Gas Volume 9 0 CO amp 100 C m h GAS DATA Nominal Gas Inlet Pressure mbar Maximum Gas Inlet Pressure mbar Gas Manifold Pressure High Fire mbar Gas Manifold Pressure Low Fire mbar Gas Flow Rate High Fire m h kg h Injector Marking Dia mm NOTE Flue gas volumes are based on a gross flue gas temperature of 100 C at 1013mbar This is considered to be the predicted temperature of the products in the secondary flue downstream of the draught diverter HAMWORTHY HEATING LTD PUREWELL AUTOMA
29. Disconnect the potentiometer cable plug CN14 from the PCB remove the potentiometer Replace components in reverse order ensuring that the sensor is correctly located within the pocket Do not force the bulb into the pocket When replacing the potentiometer knob rotate the shaft fully anti clockwise and fit the knob with the locating pip aligned with the 60 C graduation Fit the indicator disc aligning the mark with the graduation Close fascia and re fit top panel correctly Run the boiler and turn the thermostat up and down and on and off to check for correct operation Set thermostat to previously noted setting 500001089 F Figure 14 0 General Layout Front View FLUE SOCKET CONTROLS HOUSING IGNITION SEQUENCE CONTROLLER TEMPERATURE LIMITER OVERHEAT THERMOSTAT CONTROL THERMOSTAT DROP DOWN FASCIA GAS PIPE GAS COCK GAS VALVE S BURNER MANIFOLD HAMWORTHY HEATING LTD INTEGRA CLASSIC PUREWELL AUTOMATIC IGNITION DRAUGHT DIVERTER ASSEMBLY FLUE SAMPLING POINT HIGH LOW DAMPER ASSEMBLY MAIN PCB SITE WIRING TERMINAL PLUGS GAS VALVE GLAND PLATE BOILER INSULATION FLAME PROBE VIEWING PORT HOT SURFACE IGNITER BURNER PRESSURE TEST POINT 500001089 F Figure 14
30. E NOLLO3NNOO ZHOS 2 e YSONANDAS Igel LE z er SNOILOANNOO TOYLNOOD SLOWSY YOLYNL Y S3dlAVO Sul4 HOIH YOLVNLOV S3dlAVO 333 terminals CN16 or any terminals on the fascia NOTE Volt free contacts may have separate supply Ensure all power WARNING External voltage MUST NOT be applied to remote stop start terminals CN16 or high low control loop supplies are completely isolated prior to working on the electrical circuits of this appliance NOTE Maximum rating of volt free contact s is 3 Amperes Resistive 500001089 F 14 PUREWELL AUTOMATIC IGNITION HAMWORTHY HEATING LTD 9 2 Indication Signals and Volt Free Contacts Volt free contacts are provided to enable external indicator lights or alarms to derive signals for normal run overheat and lockout Note These external circuits MUST be isolated before obtaining access to the controls for any service or maintenance procedures to be carried out 9 3 Milton Boiler Sequence Control and Sequencing Interface Module Optional Refer to the Milton boiler sequence control manuals for details of its installation The sequencing interface module is supplied as a kit for site assembly to the boiler control panel s Refer to the installation instructions supplied with the kit for assembly details The sequencing interface module incorporates a 10way plug socket screw terminal block
31. ENE LENS ES Sexta 7 RE K Lea is CERES EY use a Saat 3M asi S NEN aA CS 1 FIO OH GO FIDL Oo Q 28 059 Cong o OUO o 50 Qe 2065 S 209060980 56 a OVO OO A 65 2055 9 29 ORTOR OC 74 FRONT VIEW SIDE VIEW 3 HAMWORTHY HEATING LTD PUREWELL AUTOMATIC IGNITION 500001089 F Figure 2 2 Performance and General Data Information GENERAL DATA 40 50 60 70 80 95 100 105 120 Boiler Input High Fire kW Gross 634 74 5 884 101 0 120 0 126 0 132 0 150 0 Boiler Input High Fire kW Nett 44 4 Boiler Input Low Fire kW Gross 41 5 Boiler Input Low Fire kW Nett 37 4 Boiler Output High Fire kW 40 50 60 70 Boiler Output Low Fire kW FLUE DATA Nominal Flue Dia Classic mm Nominal Flue Dia Integra mm 206 256 Approx Flue Gas Temp d o ULM 147 3 174 6 184 1 220 0 GAS DATA Gas Inlet Connection Nominal Gas Inlet Pressure mbar Maximum Gas Inlet Pressure mbar Gas Manifold Pressure High Fire mbar Gas Manifold Pressure Low Fire mbar Gas Flow Rate High Fire m h 5 92 8 27 944 Injector Marking Dia mm 2 7
32. Hz 230V AC 50Hz f SUPPLY OUTPUT SUPPLY _ SUPPLY 1 EQUENCER SEQUENCER SEQUENCER R 1 HIGH OW BLR 2 HIGH OW BLR 3 HIGH OW CONTACT CONTACT CONTACT ISOLATOR SEQUENCER SAFETY SEQUENCER SAFETY SEQUENCER SAFETY 1 ON OFF INTERLOCK 2 ON OFF INTERLOCK BLR 3 ON OFF INTERLOCK CONTACT CONTROLS CONTROLS 9 H CONTROLS FUSED ISOLATOR FUSE iE HAMWORTHY HEATING LTD PUREWELL AUTOMATIC IGNITION 500001089 F 13M9VM8 SNOLLO3NNOO NIYIM ILIS NIYW VS OV A082 LY Galva SLOVINOD MeL NX WWE WOIWINIW SO1V TOSI SNIV V 5 208 1OVINOO 1 IVINHON LOVLINOOD 338 10A 1003201 1OVINOO 338 1710A JV3HN3AO0 55108 TIY NI NOLIVHVd3S Vc 03914 TWNOIS OV Adee NOLLO3NNOO dWNd LNNHS 3171108 006 8 Lb 9L SL GLY 99 VIOSV4 44108 HOLIMS 440 NO N INO YALAWOILNALOd 3ATVA MOTISAIN3389 GLAD oN 1109 MOYHOI 929 000000000 EXE d I 68199 2 o N elno 3ATVA SVO NIV YILIN NNY SYNOH 3418 HOIH diN31 MOV Ig A389 MOV IBr3LIHM 318 034 N3339 q34 MOTISAIN3389 MOTISAIN3389 e 5 O e 220
33. L NO OQ Do 00 I HOIIMS ANY aad VG 3tlld Go lo O00000 D HAMWORTHY HEATING LIMITED BOILER CONTROL PCB Jo HOLMS SNIAO ld ANY NVI S x OOOOOOOOOOOO 26 HAMWORTHY HEATING LTD PUREWELL AUTOMATIC IGNITION 500001089 F drops below the controllers minimum 0 7 DC the controller will induce a non volatile lockout which will require a manual re set situated on the controls fascia to re start the control sequence Classic models only Prior to the ignition sequence starting the damper mechanism has to operate and prove position With the thermostat calling for heat neon NE7 on the main PCB will be illuminated indicating power to the Low Fire damper After approximately 20 seconds neon NE10 on the main PCB will be illuminated indicating that the low fire damper is open and the ignition sequence can commence Simultaneously the green HSi LED on the control panel fascia will illuminate Once ignition has occurred the green Low Fire LED on th
34. PPLY GAS COCK OR VALVE MANOMETER 6 0 FLUE SYSTEM Detailed recommendations for flue systems are given in BS 6644 Gas E Publication IGE UP 10 Installation of gas appliances in industrial and commercial premises Pt 1 flued appliances The following notes are intended to give general guidance only 6 1 General Requirements The Hamworthy Purewell series of boilers are designed to be used with natural draught flues Flue systems should be designed in accordance with current regulations and with reference to the Gas E publication IGE UP 10 Installation of gas appliances in industrial and commercial premises Pt 1 flued appliances The following points should be noted 1 Classic boilers MUST have the correct draught diverter and primary flue damper fitted in an unmodified condition before connection to the flue system Integra boilers MUST have the flue hood incorporating the draught diverter fitted in an unmodified condition before connection to the flue system 2 The bottom of the flue header should be at least 500 mm above the draught diverter skirt bottom 3 The flue system must be self supporting in the correct position to avoid compression of the draught diverter and enable its removal for boiler cleaning 4 Boilers should be located as near the chimney as possible the nearest being not more than 2m 6ft away 5 The flue system should be designed to achieve a negative suction at all times at the
35. RREUR ARRIERE 21 Figure 11 7a Diagram of Automatic Gas 23 Figure 11 76 Diagram of Hi Flow Gas Valve Assembly Natural Gas 24 Figure 12 1 Boller Function Neoris 26 Figure 12 2 Fault Finding Procedures ieu tr oid ape Ce Dee cie e aet e ae ee du va o el e vais 28 29 Figure 14 0 General Layout Front View anie eei te Dade cea ma ee a ead 31 Figure 14 1 Diagram of Hot Surface Igniter and Sensing Probe 32 Figure 14 5a Damper Actuator Wiring Details ssssssssee nemen 34 Figure 14 5bDamper Actuator Motor 34 iv HAMWORTHY HEATING LTD PUREWELL AUTOMATIC IGNITION 500001089 F 1 0 INTRODUCTION 11 competent person holding CORGI registration or equivalent must install this boiler All installations MUST conform to the relevant Gas Safety and Building Regulations Health amp Safety requirements must also be taken into account when installing any equipment Failure to comply with the above may lead to Prosecution 1 2 These instructions are for Group H Natural Gas 2nd Family and LPG Propane 3rd Family The information relative to propane firing is to be found in Appendix A p37 Boilers MUST NOT use gas other than that for which they were designed and made 1 3 The Purewell is an atmospheric gas fi
36. TIC IGNITION 500001089 F 11 5 BOILER CHECKS PRIOR LIGHTING Ensure that the gas supply is connected but turned to the OFF position Remove the cover on the low gas pressure switch and connect a multi meter across terminals C amp NO to measure circuit continuity Connect a manometer suitable for 5 to the pressure tapping on the switch body and gradually turn ON the gas supply The switch should operate at approximately 20mbar noted on the multi meter Turn OFF the gas supply and undo the pressure test point on the gas valve inlet and allow the gas pressure to fall The switch should operate at approximately 20mbar noted on the multi meter 11 5 1 Gas Pressure Adjustment After approximately 30 minutes of normal firing connecting a manometer to test point on the manifold should check the manifold gas pressure Minor adjustments to the appliance governor may be necessary to correct for site gas pressure conditions NOTE The above is a first order check Final setting must be made using a gas meter 11 5 2 Combustion Checks A flue gas sampling point is provided in the front boiler casing see Figure 14 0 p31 To check combustion take a flue gas sample from each module test point and for reference measurements should be between 8 0 and 11 5 or 9 0 to 4 0 dependant upon model Normal CO levels should not exceed 200ppm NOTE All the above measurements refer to dry flue gas sample
37. TOMATIC IGNITION 500001089 F valve system up to high fire Check gas pressure against that shown in Figure 2 2 p4 or Appendix A p37 If necessary adjust high fire governor to suit Occasionally this high fire adjustment can influence the low fire start rate therefore remove link and check low fire pressure again Adjust if required Repeat until low and high fire pressures are as shown in Figure 2 2 p4 or Appendix A p37 The Purewell boiler has been designed to conform with the requirements of the Gas Appliance Safety Regulations 1992 For Natural Gas the gas pressure governor control system is configured for a nominal gas inlet pressure of 20mbar with a maximum inlet pressure of 25mbar Larger Purewell Automatic boilers 95 105 and 120kW are fitted with a unique flow share gas valve arrangement Refer to Figure 11 7b p24 to establish method of adjustment of the by pass throttle arrangement NOTE The by pass valve throttle MUST be used as a coarse adjuster the main control MUST always be accomplished by the high low control valve For Propane firing boilers the nominal gas inlet pressure is 37mbar with a maximum inlet pressure of 47mbar All Propane firing boilers are fitted with a low gas pressure switch set at 20mbar Should the gas supply pressure fall below this level the boiler will not operate All Propane firing boilers are fitted with a single gas valve providing high and low control Refer to Figur
38. afety features are checked for correct operation NOTE Measuring flue gas CO and gas temperatures will give an indication of the state of the boiler flueways and waterways Results should be compared with previously measured HAMWORTHY HEATING LTD PUREWELL AUTOMATIC IGNITION values to establish possible loss of efficiency 13 2 Before servicing the boiler the following procedure must be carried out WARNING Isolate the electrical supply and turn off the gas service cock to the boiler module being serviced 1 Remove the front casing door by using a screwdriver to rotate the turn latch 2 Turn off gas service cock fitted upstream of gas control valve and carefully drop down the fascia of the controls housing 3 Undo both screws on gas valve gland plate situated under controls assembly and carefully disconnect the plug from the PCB Withdraw the cable and plug assembly 4 Disconnect igniter and probe leads carefully A protective boot will require pulling back to reveal the sensing probe connector 5 Slacken union below gas service cock and release Slacken and remove nuts washers holding gas valve and manifold assembly Remove manifold assembly taking care not to damage high low gas solenoid 6 Carefully remove burner assembly by pulling burner front plate Check condition of igniter assembly and probe for damage Clean as required Check burner bars and clean using a soft brush if required if possible use
39. c control should be provided to cut off the gas supply to the boiler in the event of failure of air flow in either inlet or extract fans Figure 7 2 Mechanical Ventilation Flow Rates Flow rate per 1000kW total rated heat input Gross Atmospheric Inlet air Boilers Combustion Extract air ventilation Ventilation m s 8 0 WATER CIRCULATION SYSTEM 8 1 General The Purewell Cast Iron Boiler has a low water content and the requirements of minimum water flow are given in Section 8 8 Minimum Water Flow Rates p11 and Figure 2 2 p4 Recommendations for the water circulation system are given in BS 6644 and CP 342 The following notes are of particular importance 1 In a combined central heating and hot water system the hot water storage vessel must be of the indirect cylinder or calorifier type The hot water storage vessel should be insulated preferably with not less than 75mm 3 in thick mineral fibre or its thermal equivalent 2 Circulating pipework not forming part of the useful heating surface should be insulated to help prevent heat loss and possible freezing particularly where pipes are run through roof spaces and ventilated cavities Cisterns situated in areas which may be exposed to freezing conditions should also be insulated Insulation exposed to the weather should be rendered waterproof 3 Draining taps must be located in accessible positions which permit the draining of the whole system includi
40. compressed air to blow out the dust inside the bar Damaged or cracked burner bars should be replaced To replace an individual bar will require drilling out the rivets holding it on to the front plate replacement burner bar will be supplied with clinch nuts and screws to fix onto the front plate 13 3 The boiler flueways can now be cleaned as follows 13 3 1 Classic models 1 Check the flue above the draught diverter is self supporting before removing the two bolts on the draught diverter clamp and sliding the primary flue up inside the double cone assembly The complete assembly can be removed and stored safely Disconnect the damper electrical connections CN1 amp CN2 from the control panel PCB and carefully lift the damper assembly from the flue hood Remove the top casing panel and bezel The panel is secured by spring latches Lift off and store in a safe place to avoid damage or scratching 2 Undo the screws supporting the gas pipe clamp NOTE The boiler gas pipe may require supporting in order not to place undue stress on the main gas header pipe 3 Carefully prise away the silver insulation jacket 500001089 F Figure 12 2a Fault Finding Procedures Initiate start procedure oes ine m igniter Is the mains power on Check fuses etc Reset ignition control 2 Is ignition control reset Lockout reset button on fascia Check Operation of Low Gas Pressure Switch Classic models _ only Is neon
41. d the Milton boiler sequence control and sequencing interface module instructions for further details Alternatively the Purewell boilers can be controlled on off or high low via the remote on off and high low control loops by non HHL control system see Figure 8 12 9 0 ELECTRICAL SUPPLY WARNING THIS APPLIANCE MUST BE EARTHED Wiring external to the boiler must be installed in accordance with the IEE Regulations and any local regulations which apply Wiring must be completed in heat resistant 3 core cable Size 1 0mm csa Boilers are normally supplied suitable for 230 volts 50Hz Internal fuse rating is 6 3A T rated External fuses should be 10A for all single boiler sizes The method of connection to the mains electricity supply must facilitate complete electrical isolation of the single boiler battery with a contact separation of at least 3mm in all poles HAMWORTHY HEATING LTD PUREWELL AUTOMATIC IGNITION 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 isolator must be provided adjacent to the boiler in a readily accessible position The supply should only serve the boiler NOTE Volt free contact electrical supplies must also be isolated when fitted see note on fascia Further details regarding connection to the electricity supply are given in BS EN 60335 Part 1 or BS 3456 Part 201 The mains
42. dure is carried out correctly 500001089 F Figure 11 7b Diagram of Hi Flow Gas Valve Assembly Natural Gas Only PUREWELL 95 100 Integra 105 amp 120kW P z Automatic The Flowshare gas assembly is designed to pe kcu icu ue o DRE of 25mbar Refer to Figure 2 2 to find low fire start and high fire gas pressures for the boiler being fired Alternative position Fit a manometer suitable for 30mbar onto gas BIETEN manifold pressure tapping point I Throttle Adjuster qmm Light the boiler Remove protective from the 1 Lo pressure regulator im Turn the Hi Lo valve high fire pressure regulator outer nut clockwise until the pressure stops Le increasing Loosen Throttle locking nut if fitted and A rotate the throttle valve adjuster screw until the manifold pressure is a approx 0 5mbar greater than the required high fire gas pressure Tighten the locking nut if fitted on the throttle adjuster screw Turn the Hi Lo valve high fire rate adjuster anti clockwise to fine trim the high fire pressure Refer to Figure 11 6a for procedure on how to adjust valves for correct low fire start gas pressures NOTE Honeywell valves shown in diagram High fire rate adjuster External nut Low fire Start rate adjuster Inner screw 24 HEATING LTD PUREWELL AU
43. e 11 7a p23 Remove manometer and close pressure test point Record all readings for future reference on relevant commissioning sheet Check no flue gas spillage occurs from the diverter Ref BS 5440 Part 1 will give guidance if required Allow system to warm up sufficiently to check operation of control thermostat A combustion check must be taken when first commissioning the boiler A sampling point is provided in the flue on Classic models or inspection door on Integra models which is covered by a small push in plug which can be removed NOTE Care should be exercised if the boiler is firing as the flue can achieve temperatures which will produce injury if touched Combustion figures for Natural Gas should be as follows 8 5 9 volume in dry flue gas CO 0 50ppm however figure should not exceed 200ppm under normal operating conditions Details of flue gas composition relating to propane firing can be found in Appendix A p37 11 8 Temperature Limiter Limit Thermostat Reset and test the operation of the temperature limiter by firmly pressing the button in the controls fascia HAMWORTHY HEATING LTD PUREWELL AUTOMATIC IGNITION removing the clip and bulb from the pocket and carefully applying a heat source to the bulb The reset button should operate If satisfactory refit the bulb in the pocket and secure with the clip Check temperature limiter setting Removing plastic cover u
44. e control panel fascia will illuminate Should there be a demand for hire fire neon NE8 on the main PCB will be illuminated indicating power to the High Fire damper After approximately 20 seconds neon NE12 on the main PCB will be illuminated indicating that the High Fire damper is open Simultaneously the green High Fire LED on the control panel fascia will illuminate The boiler should now be operating at High Fire If the boiler continues to lockout then an investigation must be made to ascertain the cause See Figure 12 2 p28 29 for possible corrective scenarios All Propane firing boilers are fitted with a low gas pressure switch set at 20mbar Should the gas supply pressure fall below this level the boiler will not operate 12 2 Fault Finding Procedures General fault finding is shown in Figure 12 2 p28 29 If the boiler still cannot be operated satisfactorily after following the chart consult your local office of Hamworthy Heating for assistance 12 3 Possible Causes of Boiler Lockout 1 Ignition failure due to faulty igniter 2 Ignition failure due to faulty gas valve 3 No or low gas supply pressure 4 No ignition due to faulty controller 5 Ignition failure due to faulty damper mechanism 13 0 SERVICING 13 1 Regular annual servicing is recommended to ensure trouble free operation Although cleaning of flueways may not be necessary on a yearly basis it is important that all controls and s
45. eak Check Although the boiler receives a gas leak check and gas train component integrity check prior to leaving the factory transport and installation may cause disturbance to unions fittings and gas valve assemblies etc During commissioning a further test for soundness should be carried out on the boiler gas pipework and components A procedure guide is given below Care must be taken not to allow leak detection fluid on or near any electrical parts or connections If used See Figure 5 6 Gas valve pipework leak check test procedure Note Main gas supply pressure G20 20mbar G31 37mbar To Check Valve B 1 Turn off the electrical power and gas to the appliance 2 Connect the manometer to gas valve test point 3 With A B closed open C and monitor manometer over a 2 minute period a rise indicates a leak on valve B To Check Valve A 1 Open C 2 Open B to produce the main gas supply pressure between A and B 3 Close B 4 System may be considered sound if over a period of 2 minutes any drop in pressure is less than 0 5 mbar 0 2 wg NOTE Allow a manometer stabilisation period of approximately 1 minute before each 2 minute check period Following soundness tests close valve B and remove manometer connections and tighten test points HAMWORTHY HEATING LTD 7 PUREWELL AUTOMATIC IGNITION Figure 5 6 Gas valve pipework leak test procedure MAIN GAS APPLIANCE ISOLATING VALVE MAIN GAS SU
46. ent Affix half union and gas valve assembly to gas pipe as shown using proprietary sealing compound Ensure gas valve lever is correctly orientated Offer gas pipe to boiler as shown Bracket should be mounted as shown Brackets position will be dependent on boiler size Figure 10 3a 500001089 F Figure 10 3b shows the pipe clamp fitted to Purewell 60 70 80 and 120 kW boilers Figure 10 3b Figure No 10 3c shows the pipe clamp fitted to Purewell 40 50 95 and 105 kW boilers Figure 10 3c Tighten screws ensuring U clamp threads do not damage insulation It may be necessary to remove the bottom thread of the U clamp with the bracket in lower position as it may foul the draught hood Ensure no undue stress is placed on the gas pipe manifold and ensure pipe is vertical horizontal before clamping in position 10 4 Connection of Boilers to the Flue System Notes on the recommendation for design of the flue system are given in Section 6 FLUE SYSTEM 10 4 1 Classic models The draught diverter and primary flue damper supplied with the boiler must be fitted to the boiler in accordance with the fitting instructions NO modifications are permitted on site Prior to fitting the assembly to the boiler read the primary flue damper instructions Care should be taken to ensure the seals between primary flue damper draught diverter and boiler spigot are sound as a leak may affect the boiler
47. ents packaged fan dilution systems General enquiries 0121 360 7000 bespoke flue components bespoke flue systems design and installation Direct Email Addresses Customer Services spares hamworthy heating com service hamworthy heating com technical hamworthy heating com sales flues hamworthy heating com Hamworthy Heating Accredited Agents North West England Scotland Gillies Modular Services McDowall Modular Services 210 218 New Chester Road Birkenhead Merseyside L41 9BG 14 46 Lomond Street Glasgow Scotland G22 6JD tel 0151 666 1030 fax 0151 647 8101 tel 0141 336 8795 fax 0141 336 8954 Southern Ireland North East England HEVAC Limited Allison Heating Products Naas Road Dublin 12 Ireland 17 Beech Road South Shields Tyne amp Wear 2QH tel 00 3531 141 91919 fax 00 3531 145 84806 tel 0191 455 7898 fax 0191 455 7899 Northern Ireland HVAC Supplies Limited Unit 2 Antrim Line Business Park Sentry Lane Newtownabbey 6 8XX tel 02890 849826 fax 02890 847443 Website www hamworthy heating com Associate Companies Offices and Agents throughout the World Hamworthy reserves the right to make changes and improvements which may necessitate alteration to the specification without prior notice
48. ercial premises Pt 1 flued appliances 6 Purewell boilers are suitable for installation in a balanced compartment in accordance with the requirements of BS 6644 Consult Hamworthy Heating Technical Department for help assistance if in doubt 6 2 Design Waste Gas Volume and Temperature It is recommended that the volume and temperature of the waste gases used for design of the flue system be as shown in Figure 2 2 4 6 3 Flue Condensation Care should be taken to ensure that the flue is installed in such a way that any condensation produced on start up will drain away naturally 6 4 Materials Materials used for the flue system must be mechanically robust resistant to internal and external corrosion non combustible and durable under the conditions to which they are likely to be subjected 6 5 Disconnection On Classic models the draught diverter is designed to enable separation from the primary flue damper such that it can be lifted clear of the boiler to ease disconnection The flue must be correctly reconnected when servicing is complete ensuring locating bolts are securely fitted See Section 13 SERVICING p27 for further information 6 6 Flue Discharge The flue system must ensure safe and efficient operation of the boiler to which it is attached protect the combustion process from wind effects and disperse the products of combustion to the external air The flue must terminate in a freely exposed
49. ere this might occur Figure 8 3 Cold Feed and Vent Pipe Sizes IET IAEA 60 kW 150 kW CE ee ee 300 KW 600 KW 8 4 Altitude Gauge Water Pressure Gauge Every boiler or group of boilers should be provided with a gauge complete with isolating cock See Figure 1 1 p2 for typical position 8 5 Thermometer See Figure 1 1 p2 for typical position A thermometer complete with pocket should be fitted in the pipework to indicate water flow temperature 8 6 Drain Valves Each boiler should have a 15mm NB drain valve not H H L supply fitted to drain the boiler only The heating system in total should have drain valves as recommended by BS 6644 See Figure 1 1 p2 for recommended positions 500001089 F 8 7 Circulating Pump One or more circulating pumps will be required to circulate water around the boilers and heating system Figure 2 2 p4 shows the hydraulic resistance of the boiler The pump should be sited to facilitate servicing It is important to note that when Purewell boilers are used to replace boilers on an existing system the pumps should be checked for performance against the new boiler waterside pressure drop to ensure that the minimum flow rate can be obtained It is also important that the existing system be flushed through twice to remove any loose matter which may have accumulated If in any doubt regarding the cleanliness of the system a coarse filter should be fitted in the return pipewo
50. f Valve Safety Valve 8 3 Open Vent and Cold Feed Pipe 8 4 Altitude Gauge Water Pressure Gauge 8 5 Thermometer 8 6 Drain Valves 8 7 Circulating Pump 8 8 Minimum Water Flow Rates 8 9 Waterside Pressure Drop 8 10 Control Schemes 8 11 Unvented Pressurised Systems 8 12 Modular Boiler Control Schemes i HAMWORTHY HEATING LTD PUREWELL AUTOMATIC IGNITION 500001089 F 9 0 ELECTRICAL SUPPLY 5 retenir seth e oe c e D oe co e dott 12 9 1 Site Wiring 9 2 Indication Signals and Volt Free Contacts 9 3 Milton Boiler Sequence Control and Sequencing Interface Module Optional 10 0 BOILER ASSEMBLY AND INSTALLATION emere 15 10 1 General 10 2 Heat Exchanger Insulation Fitting Instructions 10 3 Gas Pipe Fitting Instructions 10 4 Connection of Boilers to the Flue System 10 5 Gas Connections 10 6 Water Connections 10 7 Casing and Controls Assembly 11 0 COMMISSIONING AND TESTING 20 11 1 Electrical Installation 11 2 Gas Installation 11 3 Water Circulation System 11 4 Commissioning the Boiler 11 5 Boiler Checks Prior to Lighting 11 6 Procedure for Initial Lighting 11 7 Gas Pressure Adjustment and Combustion Checks 11 8 Temperature Limiter Limit Thermostat 11 9 Safety Checks 11 10 User s Instructions 12 0 FAULT FINDING ninh puta 25 12 1 Safety Features Summary 12 2 Fault Finding Procedures 12 3 Possible Causes of Boiler Lockout 13 0 SERVICING wissen paced ede Aden eid Sv
51. hunt Pump T2A Sequencing Interface Module F4 T2A A schematic of the electrical control circuit s is shown in Figure 9 1 p14 11 2 Gas Installation For design see Section 5 GAS SUPPLY p6 The whole of the gas installation including the meter must be inspected and tested for soundness and purged in accordance with the recommendations of BS 6891 or IGE UP 1 IGE UP 1A and IGE UP 2 as appropriate 11 3 Water Circulation System For design see Section 8 WATER SYSTEM p10 The system should be thoroughly flushed out with cold water without the pump in position Ensure all the valves are open With the pump fitted the system should be filled and air locks cleared Vent the radiators and check for leaks If the system is unvented the pressurisation unit should not be utilised for the initial filling This should be carried out using a WRC approved double check valve and temporary filling loop In order to comply with local Water Authority Regulations this loop must be disconnected when HAMWORTHY HEATING LTD PUREWELL AUTOMATIC IGNITION filling is complete Water treatments should not be fed through the pressurisation unit unless permitted by the manufacturer Check the expansion vessel cushion pressure as detailed by the manufacturer s Installer s Guide 11 4 Commissioning the Boiler A competent person holding CORGI registration MUST be responsible for the commissioning of this boiler Before attem
52. igh Fire Motor 5 2 1 Remove the motor cover secured by four screws 5 2 2 Slacken the U clamp and slide the motor off the High Fire shaft NOTE The bush supporting the High Fire shaft is a light press fit onto the Low Fire shaft and may need released to remove the High Fire motor 6 Refit the replacement parts in reverse order noting the following Discard the pointer and M5 nuts supplied with the new motor and replace with the nuts and washers from the failed unit ensuring that the serrated faces of the washers interlock 6 1 High Fire Motor 6 1 1 Depress the manual operating button on the side of the motor body and rotate the clamp arrangement fully counter clockwise See Figure 14 5b p34 Rotate the High Fire damper blade into the horizontal position refit the motor and tighten the U clamp The anti vibration washers should be locked Check the position of the damper blade and that it is central in the duct Manually operate the actuator fully clockwise to check the open position of the damper blade Should adjustment be necessary in either open or closed positions reposition the end stops and secure the fixing screws 6 1 2 Set the actuator reversing switch to the L position and with the High Fire damper in the open position adjust the position switch dial as shown in Figure 14 5b p34 Check the operation of the position switch by rotating the actuator about the open position listening for the switch ope
53. iler s operation may be affected if these seals are not completely fitted 6 Before replacing the burner bar assembly lift out both halves of the radiant reflector and brush off any dust and fallen deposits accumulated on it Also clean the area under the reflector before re placing it in its correct location Re assemble the burner bar assembly ensuring correct location on the rear support bracket Refit the gas manifold taking care not to damage fragile components Check all gas connections are tightened securely before opening the gas service cock Re connect electrical connections Switch on the electricity supply and re light the boiler following the correct procedure on the inside of the door 7 Take gas pressure readings and exhaust gas readings and compare with Figure 2 2 p4 or for propane firing refer to Appendix A p37 adjust as required Ensure no gas leaks are evident from the gas connections see Figure 5 6 p7 for procedure Check thermostat settings and adjust if required 8 Re fit door and tidy floor around boiler as necessary HAMWORTHY HEATING LTD PUREWELL AUTOMATIC IGNITION 14 0 REPLACEMENT OF FAILED COMPONENTS There are a number of components listed below which can be replaced simply and quickly by following the given procedure In each case carrying out the appropriate part of the commissioning procedure must check the operation of each replaced component See Section 11 0 Commissioning
54. iler slid into position 2 Casing including all screws fasteners etc to permit site assembly Instructions are included in each box to show method of assembly Two sizes are manufactured these are Small casing for boilers up to 80kW NOTE P70 Integra utilises larger casing large casing for boilers from 95kW to 120kW NOTE When installing a multi casing set the spacing plates must be used to correctly space the boilers approx 3mm apart prior to fitting the casing See label attached to the basket fixing It is recommended that all mechanical work is carried out prior to fitting the casing assembly this will reduce possible damage to the panels The casing assembly includes a component list which is also shown in Figure 10 7 p18 19 You should check to ensure that all parts are supplied prior to assembly 3 Controls assembly including fascia bezel This assembly will be suited to the desired controls and can accommodate the fitting of any optional extras Refer to Figure 10 7 for fitting instructions Ensure all thermostat capillaries are inserted and correctly located into the top of the boiler The controls assembly also incorporates a socket which matches the gas valve wiring plug Care must be taken to ensure both plug and gland plate are correctly located and fixed in position by the screws provided 4 Classic models only Primary flue damper and draught diverter complete with flue bezel Instructions are supp
55. insulation Fit the flue bezel over the primary duct refit and secure the damper to the flue hood Secure the connectors to the PCB the gland plate to the rear of the control panel and carefully route and secure the cables 6 4 Prior to refitting the draught diverter check for correct operation of the damper by briefly firing the boiler Upon satisfactory operation refit the motor cover and draught diverter assembly Support the flue bezel and fit the top panel and infill 6 5 _ Re light the boiler using instructions on the inside of the door and check for correct operation 500001089 F 15 0 RECOMMENDED SPARES Please Note To ensure the correct spare parts are despatched by our spares department it is imperative that the complete Boiler Control Panel Serial numbers are given The Boiler Serial Number is located on the gas manifold inside the door The Control Panel Serial Number is located inside the Control panel on the maximum power rating label These numbers MUST be quoted when ordering spare parts SPARES ITEM PART NO Electrical Items 2 Amperes Control FUS ok eed ord de ed dew ue e do ue dir edd dh 747225834 Main f se E1 oni P CB T6 9A test bobo e eun o co 533901221 PGBfuses F2 E3 amp EA 2 icit E pete tete conducted ect ette ee nete 533922002 Sequencing Interface Module PCB Fuse T250MA
56. inuously with maximum reliability Care should be taken in the initial design and layout having due regard for adequate water flow through the boilers and the influence of the system controls NOTE The Standards Authority recommend a minimum return temperature of 50 in all heating systems other than condensing boilers Figure 2 2 p4 shows recommended and minimum water flows required The control system and valves where fitted should be regulated to avoid lower flows occurring The flow corresponding to 22 temperature rise across the boiler is the minimum recommended flow at any time For boiler hydraulic resistance see Figure 2 2 p4 3 4 Time Clock Control In order to avoid local overheating and progressive calcium deposition at zero flow conditions where boilers are operated from time clocks provision should be made for a 5 minute circulating pump over run after the last boiler has ceased firing NOTE Time clocks should not interrupt live neutral or earth connections see Section 9 0 ELECTRICAL SUPPLY 12 for details See Figure 9 1 p14 for wiring details 3 5 Minimum System Pressure To comply with guidance note PM5 Health and Safety Executive the minimum pressure requirements at the boiler are given below as examples 1 Single installed boiler running at 82 flow temperature Minimum head required is not less than 2 metres or 0 2 bar 2 Single installed boiler running at 95 flow tempe
57. le build up in boiler waterways Descale boiler Gas control valve faulty Check replace gas valve Boiler gas setting pressure Check adjust gas pressure at incorrect manifoid Boiler operates satisfactorily 29 HAMWORTHY HEATING LTD PUREWELL AUTOMATIC IGNITION 500001089 F from the flue hood Undo and remove the nuts holding the flue hood to the boiler Take care not to move the locking nuts which locate the hood s position Remove the gas baffle not fitted to 120kW boiler 13 3 2 Integra models 1 Check the flue above the flue pipe is self supporting Remove the top panel to gain access to the draught diverter Remove the insulation and inspection cover M6 bolts on sloping front 2 If further access is required remove M6 bolts along top of draught diverter The top section should now drop down to free the flue pipe Undo M6 bolts from baffle and swing away 3 NOTE This baffle MUST be relocated in the correct position when re assembling the draught diverter 13 3 3 All models 4 The boiler flueways are now exposed and can be brushed through diagonally in both directions to remove deposits from the cast iron finned surfaces 5 Re assemble the boiler in the reverse order to that shown above Ensure a new rope seal is fitted to the flue hood to maintain a gas tight seal see spares list Ensure primary flue damper is sealed into flue hood spigot and draught diverter is sealed to damper The bo
58. lied with the primary flue damper on how to assemble the damper and draught diverter These instructions MUST be followed correctly and fully complied with to ensure correct operation NOTE Prior to fitting the damper ensure the baffle Not fitted to 120kW boiler is positioned correctly and laying flat on the heat exchanger It is recommended that the heat exchanger insulation be fitted prior to fitting the damper 500001089 F 10 2 Heat Exchanger Insulation Fitting Instructions With reference to Figure 10 2a Unfold blanket and offer up to the boiler as shown Ensure gas pipe cutout is positioned to the left and that the petals are uppermost Sit the insulation blanket onto the basket ensuring a snug fit Figure 10 2a Reference to Figure 10 2b Insulation should be folded around boiler such that its rear edges meet in the centre Ensure flow and return connections are clear and unobstructed Apply foil tape down join Figure 10 2b HAMWORTHY HEATING LTD PUREWELL AUTOMATIC IGNITION Reference to Figure 10 2c Fold down petals as shown Use foil tape to affix edges Fold as required Ensure gas pipe bracket is clear and unobstructed Figure 10 2c Ensure combustion air passages are unobstructed when fully fitted 10 3 Gas Pipe Fitting Instructions With reference to Figure No 10 3a Remove half union and gas valve from gas train Ensure gas valve manifold bracket does not suffer undue stress movem
59. ly and check for integrity of all joints using a proprietary leak detector Ensure gas valve s operation is correct and safe before continuing Refer to Section 5 6 p7 if necessary for valve integrity check procedure 5 Re light the boiler using instructions on the inside of the door Check and adjust the low fire start gas and high fire gas pressures refer to Figure 2 2 p4 for Natural Gas or Appendix A p37 propane firing for correct settings Re set throttle valve position if replaced see Figure No 11 7b p24 for procedure If necessary refer to Section 11 4 Commissioning the Boiler p20 for correct procedures 14 5 Damper Actuator Motor 1 Remove the 2 screws securing the split top casing panel and remove the two halves of the top panel from the ballstuds Should the damper cables be routed through the top panel insert refer to 2 2 Drop down the control panel fascia and unplug the damper motor electrical connections CN1 amp CN2 from the PCB Remove the cable gland from the rear of the control panel and withdraw the damper cables unclipping them from the boiler side panels 3 Remove the clamp band and collapse the draught diverter onto the primary flue Remove the screw securing the primary flue to the boiler flue hood and carefully remove the complete assembly and flue bezel Alternatively remove the clamp band and 2 screws securing the draught diverter to the primary duct Collapse the short primar
60. n identical Type No may be used for replacement Please contact Hamworthy Heating spares Dept for further information Various types and manufacturers of gas valves are used Refer to Figure 11 7 p23 24 for particular valve s fitted 1 Ensure power and gas supplies are isolated 2 Remove the gas valve wiring plugs from the gas valve s secured by M3 screws through the plug body NOTE The position of the relevant electrical cables should be noted especially on the 95 120kW boilers Undo the union connection and 8mm nuts holding the gas valve manifold assembly to front plate this will allow the whole assembly to be removed from the boiler 3 Remove the gas valve by unscrewing cap head screws holding valve to pipework When replacing the gas valve it is advisable to renew the O ring seals sealing both ends See SECTION 15 0 Recommended Spares p36 for Part Nos Note that the O ring fitted to the 40 80kW Natural Gas and all propane models is different to that used on the 95 120kW Natural Gas models Do not over tighten cap head screws in gas valve body Ensure electrical plugs are firmly and correctly located and holding screws are tightened HAMWORTHY HEATING LTD PUREWELL AUTOMATIC IGNITION 4 Replace assembly ensuring correct orientation of the gas valve Ensure that the gas flow is in the same direction as the arrow on the bottom of the valve Refit all external components Switch on gas and power supp
61. n immediate shutdown regardless of firing mode An overheat neon on the controls fascia will indicate that this condition has occurred The door will have to be removed to permit access to the temperature limiter re set pin If after pushing the pin in the light on the fascia does not go out and the boiler does not light up it could be that the boiler is still too hot i e the control thermostat has not re set An investigation should be carried out to ascertain the reason for the overheating An obvious reason would be too low a water flow rate through the boiler The flame is under constant supervision by the burner logic controller This is accomplished by measuring the flame s ability to rectify an AC current If the flame diminishes for whatever reason and the rectified current 500001089 F Figure 12 1 Boiler Function Neons F3 F4 F2 F1 aC LOW FIRE OFFSET 000000000 MFR MFR DATE PART NO 563901 SERIA
62. nel is supplied with 1off 6way and 1off 7way link connector supplied loose inside the control panel These connectors MUST be fitted to sockets CN1 6way and CN2 7way located on the top left corner of the control panel main PCB Failure to correctly fit the link connectors will prevent operation of on off boilers The link connectors are not required for high low with flue damper boilers 500001089 F Figure 8 12 Site Wiring Diagram 1 SINGLE BOILER INSTALLATION ON OFF OR HIGH LOW CLASSIC WITH FLUE HIGH LOW FLUE DAMPER MODELS ONLY OPERATION VIA REMOTE TIME CLOCK CONTROL BOILER SITE WIRING TERMINALS BOILER PCB PLUG SOCKET TERMINALS BOILER MAIN SITE WIRING TERMINALS PLUG BRACKET 230V AC 50Hz 230V AC 50Hz VOLT FREE SIGNAL OUTPUTS 230V AC 50Hz OUTPUT SUPPLY 11118 19 201 REMOTE CONTROL LOOP ON OFF ONE EX NOTE TERMINAL 1 IS SUPPLIED WITH 230VAC MAINS VOLTAGE MUST NOT BE FED ONTO THESE TERMINALS 1 REMOTE SAFETY INTERLOCK CONTROLS CONNECTIONS FUSED AT 2A LOCKOUT VOLT FREE BOILER SHUNT PUMP OVERHEAT VOLT FREE CONTACT CONNECTIONS CONTACT CONNECTIONS NORMAL RUN VOLT FREE CONTACT CONNECTIONS 2 MULTIPLE BOILER INSTALLATION ON OFF OR HIGH LOW CLASSIC WITH FLUE HIGH LOW FLUE DAMPER MODELS ONLY OPERATION VIA HAMWORTHY HEATING LIMITED MILTON BOILER SEQUENCE CONTROL NOTE ROTARY SWITCH SW1 ON THE SEQUENCING INTERFACE MODULE POSITIONS 1 TO 9 SETS THE BOILER FIRING ORDER BOILER
63. ng port on the burner front plate As the gas service cock is closed the controls should go to lockout after approximately 3 seconds amber neon on fascia lit If the above occurs correctly open service cock and press reset button on fascia After a delay the ignition should be visible and the main gas valve should energise lighting the main burner Turn the control thermostat to the required flow temperature NOTE The multi meter should be reading at least 1 11 7 Gas Pressure Adjustment and Combustion Checks After the boiler has operated for approximately 10 minutes press the control thermostat knob to switch off the boiler Open the pressure test point screw on the burner manifold and fit a manometer suitable for 30mbar Natural Gas or 5 Propane Check low fire start rate against pressure shown in Figure 2 2 p4 or Appendix A p37 If necessary adjust low fire pressure refer to Figure 11 7a p23 for relevant gas valve fitted Having checked the low fire pressure carefully adjust the differential low fire offset R21 see Figure 11 1 p21 between high and low fire 0 to 10 C on the main PCB A recommended setting is 5 C Carefully replace high fire plug CN16 on the main PCB to energise the damper Classic only and 500001089 F Figure 11 7a Diagram of Automatic Gas Valves HONEYWELL Inlet pressure Low fire tapping point solenoid GAS INLET Hi Lo pressure
64. ng the boiler and hot water storage vessel 4 Each boiler has one Rc2 BS21 flow and one Rc2 BS21 return tapping Flow and return headers should connect boilers but sufficient length of connecting pipe should be allowed to clear the casing before connecting into the headers The HAMWORTHY HEATING LTD PUREWELL AUTOMATIC IGNITION headers should be connected to the system in a reverse return arrangement the water flow in each header is in the same direction to ensure equal flow in each module Figure 1 1 p2 shows typical layout 8 2 Pressure Relief Valve Safety Valve Each boiler or in the case of a modular installations each bank of boilers must be fitted with a pressure relief valve to BS 6759 Part 1 and sized as shown in BS 6644 BS 6644 provides comprehensive information for the selection and location of safety valves and attention is drawn to the higher capacity requirements of safety valves for pressurised hot water systems 8 3 Open Vent and Cold Feed Pipe See BS 6644 for further information Every boiler or group of boilers should have an open vent pipe and cold feed pipe installed between the boiler and the first water isolating valve The minimum bore mm of these pipes per installation is as follows The vent pipe must rise continually it must not be valved except by a design which when closed for maintenance ensures the boiler is open to atmosphere The pipe shall be protected against freezing wh
65. nscrewing can achieve this if fitted Undo holding nut and withdraw into the controls housing Adjust if required and replace in reverse order to above 11 9 Safety Checks To check for correct operation of the controller break the multi meter pA circuit remove plug connection CN21 from the main the boiler should lockout after approximately one second Check that the flame has been extinguished Remove multi meter and replace wire link to the plug CN21 If a sequencing interface module is fitted set the hand auto switch SW1 on the boiler main PCB refer to Figure 11 1 p21 to the auto position Wait at least 15 seconds before pressing re set button on fascia to re set controller After a waiting period the boiler will light and run normally 11 10 User s Instructions When the above is complete the boiler owner or their representative should be made aware of the lighting and operating instructions fitted to the inside of the boiler door A practical demonstration should be given describing each functional step This Installer s Guide and User s Instructions should then be handed over and be kept in a safe place for easy reference 12 0 FAULT FINDING 12 1 Safety Features Summary The main PCB is fitted with neons to indicate correct operation of the boiler functions refer to Figure 12 1 26 Should the control thermostat fail causing an overheat condition the temperature limiter will trip thus creating a
66. of holes and 2off in the angle bracket at the top Fix the rear support rail to the bottom support rail using 2off M6 screws and washers items 18 and 10 500001089 F Figure 10 7 Assembling the Casing Multi Casing Set y DETAIL A STANDARD BOILER CASING TOP REF DETAIL A AGA 16 1 Ga 1 18 HAMWORTHY HEATING LTD PUREWELL AUTOMATIC IGNITION 500001089 F Parts List of Figure 10 7 Assembling the Casing Multi Casing Set Quantity Quantity 1 jLeftandsidepane 2 Righthandside panel 7 11 M6 x 16mm pozi drive pan head screw 6 __7 ___ 8 9 011 Top panel 19 Bottom supportrail tT 20 Topsupportrail tT __21 Rearsupportrail tT __22 Frontsupportral tT 23 __ Doorlocationpin __________ _ 2 20 23 2 24 2 0 J 24 M4 x 20 pozi drive pan head screw internally serrated shake proof washer 26 M4 hexagon nut 27 Fascia bezel 28 Boiler top panel insert 25 4 Select the front support rail item 22 and fit the door location brackets item 5 using 4off M6 screws and spring washers items 13 and 14 Fit 2off U nuts item 15 to the top 45 return Fix the front support rail to the bottom support rail using 2off M6 screws and washers items 18 and 10 5
67. on the water system is available the thermostat may be adjusted to operate up to 120 C see Note A standard electro mechanical temperature limiter hand reset limit thermostat is also fitted to the boiler and must be set at 100 C with a maximum setting of HAMWORTHY HEATING LTD PUREWELL AUTOMATIC IGNITION Figure 8 10 1 Temperature Controls and Boiler On Off Switch Temperature Limit Thermostat Reset Switch On Off Knob Push to activate 110 C The minimum difference between control thermostat and temperature limiter MUST NOT be less than 10 C Note A high temperature control kit is available incorporating a new temperature limiter label and instructions For further information contact Hamworthy Heating for details 8 10 2 Water Flow Controls Any external mixing valves or similar controls should ALWAYS ensure that the minimum water flow rate shown in Figure 2 2 p4 is maintained 8 10 3 Frost Protection Consideration should be given to fitting a frost thermostat set at approximately 4 C 8 11 Unvented Pressurised Systems See Figure 1 1 p2 for typical layout of a pressurised Un vented Hot Water System In order to correctly size a pressurisation unit for any heating system certain parameters are required These are 1 Static height of highest component in system 2 System volume if not known a general rule of thumb of 10 litres kW installed boiler power can be used 3 Maximum fl
68. ot HHL supply Care must be taken when installing water system pipework that undue stress is avoided on the boiler flow and return connections is recommended that unions are fitted local to the boiler to permit future servicing requirements Fully closing valves must not be connected to both flow and return pipes unless the boiler is fitted with an individual correctly sized safety valve t is recommended that a 3 way L port valve is fitted in the flow connection to allow an open vent situation should the boiler need to be fully isolated from the system 10 7 Casing and Controls Assembly For assembly of casing components and controls unit see Figure 10 7 p18 19 Multi casings Note Where boilers are in Modular form i e MPC360 3 x 120kW a multi casing pack is provided for each additional boiler For example a triple boiler module will require 1 off single casing pack plus 2 off multi casing packs If the bottom support rail item 19 has not been pre assembled the following procedure must be taken 1 Loosen the nuts that clamp the basket assemblies of the 2 boilers together 1 front and 1 rear Remove the bolt spacer and nut assembly 2 Position the bottom support rail item 19 between the boiler baskets Assemble to boiler baskets using 201 M6 screws nuts and shake proof washers items 18 9 amp 10 3 Select the rear support rail item 21 and fit Goff U nuts item 15 4off in the 2 lower pairs
69. ow temperature i e most systems run at 82 500001089 F 4 Maximum system hot working pressure generally given in barg From the above information Hamworthy Heating can size the pressure unit and also the expansion vessel required Care must be taken in sizing expansion vessels to ensure maximum acceptance factors are not exceeded Normally manufacturers of vessels impose a limit of 0 5 This value must not be exceeded at any time during the operation of the boiler this includes the over pressure condition should a safety valve lift Consideration should also be given to sizing of the safety valve s in the system See BS 6759 Part 1 for information See also BS 6880 Part 1 for design considerations 8 12 Modular Boiler Control Schemes For modular installations of the Purewell automatic ignition range of boilers Hamworthy Heating can supply an optional Milton boiler sequence control system This system comprises a wall mounted Boiler Sequence Control unit and a Sequencing Interface Module unit mounted to the fascia of each boiler s control panel which provides on off or high low switching of the boiler The Boiler Sequence Control communicates with the Sequencing Interface Modules via a 2 wire data BUS PT1000 type water flow temperature optional room temperature and optional outside air temperature sensors available which are wired to the Boiler Sequence Control Refer to Figure 8 12 an
70. position and be so situated as to prevent the products of combustion entering any opening in a building Where the flue diameter is less than 200mm 8 a terminal must be fitted Where the flue is of a larger size consideration should be given to the fitting of a flue discharge terminal or grill to stop ingress of birds etc 6 7 Surface Temperatures Combustible materials in the vicinity of the boiler and flue shall not exceed 65 C during boiler HAMWORTHY HEATING LTD PUREWELL AUTOMATIC IGNITION operation The flue shall not be closer than 50mm to any combustible material except where it passes through such material with a non combustible sleeve when the air gap may not be less than 25mm 6 8 Flue System Location The flue system must not be placed or fitted where there is undue risk of accidental damage to the flue pipe or undue danger to persons in the vicinity NOTE The flue MUST be self supporting Check that the flue and chimney are clear from any obstruction 7 0 AIR SUPPLY Detailed recommendations for air supply are given in BS 6644 The following notes are intended to give general guidance In all cases there must be provision for an adequate supply of air for both combustion and general ventilation in addition to that required for any other appliance 7 1 Air Supply by Natural Ventilation The boiler room must have or be provided with permanent air vents directly to the outside air at high level and at
71. pting to commission any boiler ensure that personnel involved are aware of what action is about to be taken and begin by making the following checks 1 Flueway passages to chimney are clear 2a Classic models If necessary remove the primary flue damper and draught diverter assembly flue hood and baffle not fitted to the 120kW boiler to ensure the boiler flueways are clear Reposition the gas baffle ensuring that it is laying flat on the top section Re fit the flue hood damper and draught diverter assembly Ensure primary flue damper and draught diverter passages are clear and clean 2b Integra models The Integra draught diverter incorporates an integral inspection cover To gain access remove insulation and M6 bolts on the sloping front of the hood assembly This will reveal the inner part of the boiler if further access is required remove primary flue pipe ensure it is correctly supported and remove complete top of the draught diverter assembly After cleaning the boiler re assemble draught diverter in reverse order Ensure all joints are correctly sealed 3 Adequate ventilation as per Section 7 Air Supply exists in the boiler house 4 The system is fully charged with water ready to receive heat All necessary valves are open and the pump is circulating water 5 The pipework and valve arrangement is installed to Hamworthy Heating recommendations in such a way that water flow rates will be in
72. ration Adjust as necessary 6 2 Low Fire Motor 6 2 1 Pass the Low Fire torque sleeve over the Low Fire shaft Replace the actuator location bracket refit the motor and fix the torque sleeve to HAMWORTHY HEATING LTD 35 PUREWELL AUTOMATIC IGNITION the Low Fire shaft Depress the manual operating button on the side of the motor body and rotate the clamp arrangement fully counter clockwise See Figure 14 5b p34 Rotate the Low Fire damper blade into the horizontal position and tighten the U clamp The anti vibration washers should be locked Check the position of the damper blade and that it is central in the duct Manually operate the actuator fully clockwise to check the open position of the damper blade Should adjustment be necessary in either open or closed positions reposition the end stops and secure the fixing screws Both High and Low Fire damper blades should align in the open and closed positions 6 2 2 Set the actuator reversing switch to the L position and with the Low Fire damper in the open position adjust the position switch dial as shown in Figure 14 5b p34 Check the operation of the position switch by rotating the actuator about the open position listening for the switch operation Adjust as necessary 6 3 Reassemble the cables to the gland plate and refit the terminations to the PCB connectors push in See Figure 14 5a p34 NOTE The cables have identification numbers printed onto the
73. rature Minimum head required 5 1 metres or 0 5 bar HAMWORTHY HEATING LTD PUREWELL AUTOMATIC IGNITION 3 Modular boiler installation running at 82 C flow temperature and 11 rise across system Minimum head required 4 3 metres or 0 42 bar 4 Modular boiler installation running at 82 C flow temperature and 22 rise across system Minimum head required 10 5 metres or 1 03 bar See Section 8 11 p11 for Pressurised Water Systems 4 0 LOCATION 4 1 Refer to Figure 2 1 p3 for dimensions weights and clearances The location chosen for the boiler MUST permit the provision of a satisfactory flue system and an adequate air supply The location must also provide adequate space for servicing and air circulation around each unit This includes any electrical trunking laid along the floor Allow adequate space this should not normally be less than 460mm at the rear for flow and return connections Also allow at least 460mm on one side the other side must be no less than 150mm Allow 610mm minimum in front of the boiler for servicing The boiler must be installed on a level non combustible surface that is capable of adequately supporting its weight when filled with water and any ancillary equipment Any combustible material adjacent to the boiler and the flue system must be so placed or shielded to ensure that its temperature does not exceed 65 C Further details regarding boiler location are given in BS 6644
74. red boiler manufactured from horizontal cast iron sections nippled at alternate ends These sections are mounted on a fabricated mild steel basket assembly which houses the burner bar and igniter assemblies A unique radiant baffle is fitted beneath the burner bars protecting the floor below by reducing heat lost from the boiler The Classic version of the Purewell boiler is designed to be connected to the flue via a specifically designed draught diverter which incorporates a High Low Damper in the primary flue duct This damper MUST be fitted into the spigot on top of the heat exchanger as supplied NO modification or variance is permitted as this may change operational characteristics Flue outlets from more than one boiler may be connected together to form a header Integra versions have an in built draught diverter and can therefore be connected direct to a header assembly via a suitable flue pipe 1 4 If the boiler is to be connected to an un vented pressurised heating system care must be taken to ensure all extra safety requirements are met and that the relevant interlocks will shut down the boiler s should a high or low pressure fault occur The pressurisation unit must also incorporate a low level water switch which protects the water pumps and will directly or indirectly shut down the boiler plant should a low water condition occur HAMWORTHY HEATING LTD 1 PUREWELL AUTOMATIC IGNITION Consideration
75. regulator adjustment High fire solenoid GAS OUTLET solenoid Outlet pressure tapping point ADJUSTMENT PROCEDURE Refer to Figure 2 2 to find the low fire start and high fire gas pressures for the boiler being fired Fit a manometer suitable for 30mbar onto manifold test point Light the boiler then remove the protective cover from the Hi Lo pressure regulator To adjust the high fire gas pressure turn the outer nut on the hi lo pressure regulator To adjust low fire start gas pressure remove the link between terminals C3 and C4 CN16 nominally set the low fire start gas pressure by rotating the inner HAMWORTHY HEATING LTD 23 PUREWELL AUTOMATIC IGNITION Low fire solenoid GAS INLET Inlet pressure tapping point Outlet pressure tapping point MHU LO pressure regulator adjustment High fire solenoid GAS OUTLET Low fire sotenoid cross head screw whilst keeping the outer nut from rotating Turn the boiler off then on again and fine trim the pressure Insert or make high fire link on terminals C3 and C4 CN16 the boiler should now drive to high fire Replace protective cap on Hi Lo gas valve Note The low fire setting must always be set last of all The valves operation may be incorrect if this omitted Note It is also advisable to carry out this procedure with all the boilers firing The long term reliability of the ignition system may well be reduced unless this proce
76. rk to the boilers 8 8 Minimum Water Flow Rates Minimum water flow rates are shown in Figure 2 2 p4 These flow rates should be maintained through the boiler at all times whilst the boiler is firing If the water flow rate is allowed to fall below the minimum the boiler heat exchanger could fail due to the resultant scale formation Particular attention should be paid to the restriction of external flow circuits during periods of low heat demand 8 9 Water Pressure Drop The waterside hydraulic resistance Pressure drop is shown in Figure 2 2 p4 NOTE f boilers are run off time clock control a pump overrun not HHL supply should be fitted which must run for a minimum of 5 minutes on shut down of the last boiler 8 10 Control Schemes 8 10 1 Temperature Controls An electronic control thermostat using a 10kO NTC thermistor temperature sensor is incorporated within the boiler controls A potentiometer is used to adjust the control thermostat set point between the range 65 to 95 C The potentiometer also acts as the boiler on off switch via a push and release action An additional potentiometer fitted to the boiler main control PCB provides a temperature offset below the main control set point for high low control switching Classic models with high low flue damper only which can be adjusted up to 10 C below the main set point 5 C recommended If a higher water temperature is required and providing sufficient head
77. s HAMWORTHY HEATING LTD PUREWELL AUTOMATIC IGNITION Gas Pressure Switch Location Key I Gas Pressure Switch II Main Gas Valve Gas Pressure Switch Adjustment NYLOCK NUT M3 SCREW M4 X 6 PAN With the cover removed turn the M3 nut clockwise to increase the set point and vice versa Seal the adjuster after setting 15 0 RECOMMENDED SPARES MECHANICAL ITEMS PART No Low Gas Pressure Switch 339009477 500001089 F USEFUL USER INFORMATION INSTALLER SITE ADDRESS DATE OF COMMISSIONING BOILER TYPE BOILER SIZE S UNIT NO S SERIAL 5 39 HAMWORTHY HEATING LTD PUREWELL AUTOMATIC IGNITION 500001089 F 5 40 HEATING LTD PUREWELL AUTOMATIC IGNITION 500001089 F Notes Connect direct Direct Dial Telephone and Fax Numbers Poole Office 9 Hamworthy Hamworthy Heating Limited HEATING amp HOT WATER PRODUCTS Fleets Corner Poole Dorset BH17 OHH England Main switchboard tel 01202 662500 boilers controllers Technical enquiries 01202 662527 662528 01202 665111 water heaters Spare parts 01202 662525 01202 665111 pressurisalon sets Service department 01202 662555 01202 662522 Birmingham Office 9 Hamworthy Hamworthy Heating Limited FLUE amp CHIMNEY SYSTEMS Shady Lane Great Barr Birmingham B44 9ER Main switchboard tel 0121 360 7000 0121 325 2309 flue compon
78. s operation Note take care in routing the damper electrical cables over the boiler flue hood and into the control panel The top panel can be fitted after having made the damper electrical connections to the control panel 10 4 2 Integra models The Integra model incorporates its own draught diverter and care must taken to ensure the seal between the outlet spigot and flue pipe is sound to avoid the escape of flue gas HAMWORTHY HEATING LTD PUREWELL AUTOMATIC IGNITION 10 4 3 The top panel will require protecting to ensure no damage occurs to the plastic coating during subsequent site assembly of other components It is important for service requirements that the flue system is fully self supporting Check the flue and chimney are clear from obstruction 10 5 Gas Connection The Purewell boiler is supplied with a gas pipe which when assembled exits the casing at the rear see Figure 2 1 p3 for position The incoming mains gas supply must be capable of supplying gas to the boiler at the required pressure under all firing conditions For sizing information see Figure 5 3 p8 approved isolating valve amp union should be installed for each boiler in a convenient and safe position and be clearly marked 10 6 Water Connections See Figure 2 1 p3 for position of water connections flow and return A BS21 plug is fitted local to the return connection for the fitting of a drain cock NOTE N
79. s of commissioning 4 Check setting of both temperature limiter and control thermostat The temperature limiter is generally set at 100 C from the factory unless otherwise instructed Set thermostat to required temperature normally 82 NOTE Minimum temperature setting should not be less than 72 C to avoid condensation in the flue if a 22 system temperature rise is used NOTE It is generally recommended that the minimum return temperature to a non condensing boiler is 50 5 Drop down fascia on the controls housing to reveal access to the main PCB Figure 9 1 p14 shows the correct location of incoming wires Remove the plug connection CN21 from the main PCB and replace the link by inserting a multi meter set to read DC pA Carefully remove high low plug connection CN16 from the main PCB this will ensure burner stays at start rate low fire when fired 6 The Purewell fully automatic boiler utilises a low fire start gas rate ignited by hot surface igniter HSI see Figure 14 1 p32 To ascertain which type of gas valve is fitted and the method of low fire and high fire adjustment refer to Figure 11 7a p23 You should familiarise yourself with this procedure for use later when required 7 If a single header pipe kit is fitted ensure that the shunt pump is connected to the plug connection CN13 on the main PCB The run on timer is preset to 5 minutes Check that the fuse on the main is fitted and sound
80. to make the site wiring connections Refer to Figure 8 12 and the Milton boiler sequence control installation manual for wiring connection details Note For correct operation of the sequencing interface module a number of wire links MUST be removed from the boiler main PCB refer to Section 11 5 clause 8 p22 for details 10 0 BOILER ASSEMBLY AND INSTALLATION 10 1 General Each boiler is despatched to site as follows i Heat exchanger amp basket including burners and gas valve s etc on a pallet ii Casing complete with assembly instructions Control panel assembly iv Primary flue incl High Low Damper amp draught diverter Classic models only Further details of each individual assembly are given below 1 Factory tested heat exchanger casting assembly complete including insulation wrap gas valve assembly including pre wired plug assembly The gas connection pipe should be fitted to the boiler flue hood once the heat exchanger is in place NOTE Care must be taken to ensure no damage HAMWORTHY HEATING LTD 15 PUREWELL AUTOMATIC IGNITION occurs to either insulation wrap or gas connecting pipe THIS PIPE MUST NOT BE USED TO MANOEUVRE OR POSITION THE BOILER NOTE Consideration must be given to the weight of the boiler See Figure 2 1 p3 before lifting It is recommended that the boiler is moved complete with pallet and positioned correctly The pallet can then be dismantled and the bo
81. ve Expansion pipe Ficat Pressure amp V Temperature Gauges Feed amp expansion Valve tank Ok Valve Mains water Automatic Air Vent Circulation pump odule Module System Modular Boilers pk Heating load Circulation pump Drain V VENTED SYSTEM Single pipe header Pressure amp Temperature e prani Mains water Automatic Automatic Air Vent System Sd Module Drain Hamworthy uad A kK Lockshield l Safety 7 Air Vent valve i Valve ac un 9 Q m Heating load Expansion valve Circulation pump Primary loop Doubl Lockshield Temporary Check valve fill line valve La UNVENTED SYSTEM Single pipe header 2 HAMWORTHY HEATING LTD PUREWELL AUTOMATIC IGNITION 500001089 F Figure 2 1 Boiler Dimensions Clearances Ed ae xs 1055 0 sec eo A Boiler Height Casing mm 70 2 NOTE The 533 centres relate to boilers close coupled in modular form For stand alone applications a minimum of 150mm should be allowed between casings Space baskets 200mm apart 2 6 7 66 76 460 RECOMMENDED INTEGRA 150 MIN SIONN nian S
82. y duct into the draught diverter and remove the damper assembly and flue bezel leaving the draught diverter assembly connected to the flue system Temporarily support the draught diverter 4 Identify the motor cables and carefully remove the terminations from the PCB connector using a small terminal screw driver See Figure 14 5a p34 Remove the cables from the strain relief bushes in the gland plate NOTE The Low Fire motor MUST be removed to gain access to the High Fire motor 5 1 Low Fire Motor 5 1 1 Remove the motor cover secured by four Screws 5 1 2 Remove the two screws securing the actuator location bracket to the mounting plate Slacken the U clamp and remove the M4 button head screw securing the torque sleeve to the Low Fire damper shaft Withdraw the motor and shaft 500001089 F Figure 14 5a Damper Actuator Wiring Details TOP VIEW OF To release Cable ITEM 6 press here with a 6 WAY CONNECTOR sharp implement and then tug gently CABLES FROM LOW Supply FIRE DAMPER SUR 51 1 ACTUATOR m y TOP VIEW OF Gruner ITEM 7 7 WAY CONNECTOR CABLES FROM HIGH Supply FIRE 4 DAMPER Switch sv 1 ACTUATOR Figure 14 5b Damper Actuator Motor _ACTUATOR END STOP MANUAL OPERATION PUSH BUTTON POSITION SWITCH DIAL SHOWING SETTING POSITION ACTUATOR REVERSING SWITCH 34 HAMWORTHY HEATING LTD PUREWELL AUTOMATIC IGNITION 500001089 F 5 2 H

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