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Hamworthy 105he User Manual

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

Table of Contents

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Hamworthy 105he Specifications

General IconGeneral
Flow Temperature Range30 - 85°C
Boiler TypeCondensing
Fuel TypeNatural Gas
Max. Output (kW)105 kW
Flue Diameter125 mm

Summary

INTRODUCTION

Competent Person Installation Requirements

Installation must be performed by a competent person adhering to regulations and safety standards.

Boiler Description and Features

Details the boiler's features: fully modulating, high efficiency, cast iron, LMU control system, and direct flue connection.

System Connection Considerations

Notes on un-vented systems, water treatment, reverse return layouts, and suitability for specific systems.

Optional Control Peripherals

Information on optional header kits, external sensors, LPB bus communication, and cascade control.

SUPPLY AND DELIVERY

Boiler Despatch and Handling

Boilers are delivered pre-assembled; handle with care to avoid casing damage and ensure correct positioning.

Package Contents

Details on packaging for flue components, condensate trap, and optional header kits.

SIZE AND SPACE REQUIREMENTS

Plantroom Clearances and Dimensions

Specifies minimum ceiling height, clearances from flammable materials, and necessary access space for installation.

Manifold Kit Dimensions

Provides dimensional data for 2, 3, and 4 boiler manifold installations for planning.

SITE LOCATION AND PREPARATION

Site Location Criteria

Requirements for floor/plinth, fireproofing, and adequate plantroom space for installation and access.

Gas Supply Requirements

Details gas supply pipework standards, connection size, testing, purging, and inlet pressure.

Flue System Requirements

Guidelines for flue termination, routing, construction, condensation management, slope, and pressure.

Water Supply and System Pressure

Covers tank requirements, pipe flushing, water treatment, and maximum working water pressure.

Condensate Connections and Drainage

Ensures provision for condensate removal, use of non-corrosive pipework, and proper discharge.

Electrical Supply and Wiring

Details earthing, isolation, voltage, fuses, cable size, and prohibition of time-clock switching.

BOILER ASSEMBLY

Flue Pipe Connection

Procedure for fitting the flue elbow to the boiler and securing the flue pipe.

Water Connections

Guidelines for connecting pipework, using local unions, and ensuring it is self-supporting.

Electrical Connections

Lists various electrical connections for supply, pumps, fault signals, and control inputs.

PRE-COMMISSIONING

Gas Supply Checks

Ensures gas pipework is soundness tested and purged according to relevant standards.

Ventilation Checks

Verification of correct ventilation and air supply to the plantroom.

Pipework, Valves, and Pump Checks

Checks on pipework, system fill, pump operation, isolation valves, safety valve, and condensate connections.

Flue Checks

Ensures the flue system is correctly designed, installed, clear, and traps are filled.

Electrical Checks

Verification that electrical connections are correct, isolatable, and external controls are operational.

CHECKS PRIOR TO LIGHTING

Boiler Gas System Leak Check

Procedure for performing a gas system leak check using a manometer to ensure soundness.

Checks Prior to Lighting the Boiler

Verification of electrical supply, safety limiter, control thermostat settings, and air inlet cleanliness.

Initial Lighting Procedure

Detailed steps for turning on gas/electrical supplies and initiating the ignition sequence.

Safety Checks During Operation

Performing safety checks by disconnecting flame probe and gas valve during operation.

Flame Signal Assessment

Procedure to access and view the flame ionization signal via the control panel display.

Adjusting the settings of the boiler

Steps to adjust the flow temperature setpoint using the control panel buttons.

Combustion Checks

Measuring CO2 levels at high and low fire to confirm correct combustion performance.

Setting Boiler Parameters

Refer to Controls Operation section for setting boiler parameters and timings specific to the installation.

User's Instructions

Ensuring the owner is aware of operating instructions and receives the manual for reference.

BOILER CONTROLS

Controls Overview and System Configuration

Overview of the LMU controller, HMI display, and compatibility with BMS and peripherals.

Info Button and Display Navigation

Explains how to use the Info button to access and navigate through different information levels.

Extended Info Mode Navigation

Steps to enter and navigate the extended information modes (b, c, d) for detailed data.

Button Functions and Operations

Table detailing the function and operation of each button on the control panel interface.

Info Display Parameters

Lists available parameters for display, categorized by type: temperatures, process values, and setpoints.

Operation and Display Philosophy

Diagram illustrating the operation and display logic of the control system for user interaction.

Screen Legend and Symbols

Explanation of display characters, symbols, and their meanings for heating and DHW modes.

Default Display and Error Codes

Illustrates the default display and how status and error codes are shown on the screen.

Lockout Display and Setpoint Adjustment

Shows how lockout codes are displayed and the procedure to adjust the heating circuit setpoint.

Enduser Parameter Settings

Lists default and adjustable parameters for end-users, including time of day and heating programs.

Start-up and Initialisation

Describes how setpoints are initialized on startup or after a lockout reset.

Boiler Functions and Operating Modes

Details functions like Chimney Sweep, Controller Stop, time setting, and operating modes.

LMU Error Codes

A table detailing error codes, potential causes, and recommended actions for troubleshooting.

Display of Operating Phases

Explains the meaning of display codes and their corresponding LMU internal operating phases.

FAULT FINDING

Safety Features Summary

Overview of safety features like the temperature limiter and flame probe supervision.

Fault Finding Procedures

Refers to section 8 for error messages and advises consulting Hamworthy if issues persist.

Possible Causes of Boiler Lockout

Lists common causes of boiler lockout such as igniter, gas valve, or pressure issues.

SERVICING

Regular Servicing Recommendations

Recommends annual servicing, with an additional 6-monthly check, including controls and safety features.

Boiler Servicing Procedure

Detailed procedure for servicing, including isolating power/gas and removing casing panels.

Cleaning Boiler Flueways

Steps for cleaning boiler flueways, including inspection panel removal and cleaning castings.

REPLACEMENT OF FAILED COMPONENTS

Igniter and Flame Probe Assembly Replacement

Procedure to remove, replace, and check the igniter and flame probe assembly.

Safety Temperature Limiter Replacement

Instructions for removing, replacing, and testing the safety temperature limiter.

Main Gas Valve Replacement

Procedure for replacing the gas valve, emphasizing factory settings and gas soundness tests.

Combustion Fan Replacement

Steps to remove and replace the combustion fan assembly for different boiler models.

RECOMMENDED SPARES

Electrical Spare Parts List

Lists part numbers for electrical components like controllers, sensors, igniters, and probes.

Mechanical Spare Parts List

Lists part numbers for mechanical components like burners, gas valves, fans, and switches.

Service and Spares Contact Information

Provides contact details for service, spares, and technical support from Hamworthy Heating.

APPENDIX A - GAS DATA

General Boiler Data

Provides general data including maximum input and output for different boiler models.

Gas Supply Data

Details gas inlet connection size, pressure, flow rate, and target CO2 percentages.

APPENDIX B - ELECTRICAL CONNECTIONS AND CONTROLS

Electrical Supply Specifications

Specifies normal supply voltage, maximum power consumption, and start/run current for boilers.

External Wiring and Safety Notes

Notes on external wiring, earthing, isolation, and mains supply not being switched by time-clock.

Multiple Boiler External Control Wiring

Diagrams showing external control wiring for multiple boiler installations, including control options.

Remote Monitoring Unit (RMU) Configuration

Illustrates the configuration of the Hamworthy-Trend IQ3 Remote Monitoring Unit.

APPENDIX C - FLUE DATA

General Flue System Requirements

Details flue diameter, allowable back pressure, gas temperature, and volume.

Flue System Installation Guidelines

Guidelines for flue system installation, including condensation management and slope.

Flue System Materials

Specifies requirements for flue system materials, including robustness and corrosion resistance.

Flue Discharge Location

Guidance on safe flue discharge location to prevent combustion product entry into buildings.

Flue Surface Temperatures

Specifies limits for flue surface temperatures and clearances to combustible materials.

Condensate Discharge Considerations

Advises on condensate discharge, avoiding freezing and using separate drains for modular systems.

Flue Resistance Data

Table showing equivalent lengths for flue components to calculate resistance for system design.

APPENDIX D - VENTILATION

Natural Ventilation Air Supply

Details requirements for natural air supply via permanent vents for combustion and ventilation.

Mechanical Ventilation Requirements

Guidelines for mechanical ventilation, including interlocking with boilers and airflow rates.

APPENDIX E - WATER DATA

Water Circulation System Requirements

Details water circulation requirements, including minimum flow rates and pressure loss.

Minimum System Water Pressure

Specifies minimum system water pressure requirements for single and modular boiler installations.

Pressure Relief Valve Requirements

Information on safety valve fitting and requirements, with tables for pipe sizes.

Typical Piping Layouts

Illustrates typical piping layouts for vented and unvented systems with single pipe headers.

Open Vent and Cold Feed Pipe Installation

Details requirements for open vent and cold feed pipes, including bore size and pipe routing.

Circulating Pump Considerations

Discusses circulating pump requirements, performance checks, and system flushing.

Minimum Water Flow Rate Maintenance

Emphasizes maintaining minimum water flow rates to prevent heat exchanger damage.

Water Flow Control Measures

Advises on using controls like mixing valves or flow switches to ensure minimum flow rates.

Unvented System Design Parameters

Lists parameters required for designing unvented (pressurised) hot water systems.

Single Boiler System Schematic

Schematic diagram for a single boiler system showing controls and connections.

Single Boiler, Primary Circuit Schematic

Schematic diagram for a single boiler with a primary circuit system.

Single Boiler (External 0~10V) Schematic

Schematic for a single boiler with external 0-10V control and multi-circuit system.

Multiple Boiler (Cascade) Schematic

Schematic diagram for multiple boilers in a cascade system with primary circuit.

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