Hamworthy FLEET Series Installation, Commissioning And Operating Instructions
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Hamworthy FLEET Series Installation, Commissioning And Operating Instructions

Wall hung, condensing , room sealed, fully modulating, pre-mix, gas fired boilers for heating & domestic hot water installations
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FLEET SERIES BOILERS
Wall Hung, Condensing , Room Sealed,
Fully Modulating, Pre-Mix,
Gas Fired Boilers for Heating & Domestic
Hot Water Installations
Installation, Commissioning
and Operating Instructions
Models: F40W, F50W, F60W, F70W, F85W, F100W,
F125W & F150W
NATURAL GAS I
2H
IMPORTANT NOTE
THESE INSTRUCTIONS MUST BE READ
AND UNDERSTOOD BEFORE INSTALLING,
COMMISSIONING, OPERATING OR
SERVICING EQUIPMENT

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Summary of Contents for Hamworthy FLEET Series

  • Page 1 FLEET SERIES BOILERS Wall Hung, Condensing , Room Sealed, Fully Modulating, Pre-Mix, Gas Fired Boilers for Heating & Domestic Hot Water Installations Installation, Commissioning and Operating Instructions Models: F40W, F50W, F60W, F70W, F85W, F100W, F125W & F150W NATURAL GAS I...
  • Page 3 FLEET SERIES BOILERS Wall Hung, Condensing , Room Sealed, Fully Modulating, Pre-Mix, Gas Fired Boilers for Heating & Domestic Hot Water Installations Installation, Commissioning and Operating Instructions Models: F40W, F50W, F60W, F70W, F85W, F100W, F125W & F150W NATURAL GAS I NOTE: THESE INSTRUCTIONS MUST BE READ AND UNDERSTOOD BEFORE INSTALLING, COMMISSIONING, OPERATING OR SERVICING EQUIPMENT.

  • Page 4: Table Of Contents

    Combustion Checks User Instructions BOILER CONTROLS ........................26 Controls Operation Functions FAULT FINDING ..........................42 10.0 SERVICING ............................44 11.0 REPLACEMENT OF FAILED COMPONENTS ................46 12.0 RECOMMENDED SPARES ......................47 Page HAMWORTHY HEATING LTD FLEET WALL HUNG SERIES 500001211/F...
  • Page 5 Water flow switch ........................42 Figure 9.3.1 Wiring Schematic ........................43 Figure 10.2 Combustion chamber ......................45 Figure 10.2.1 Spark electrode position ......................45 Figure 10.2.2 Flame sensing probe position ....................45 Page HAMWORTHY HEATING LTD FLEET WALL HUNG SERIES 500001211/F...
  • Page 6 Pump performance curves ..................... 68 Figure E2 Typical pipe kit system connections ..................69 Figure F1 Hydraulic diagram 02 ......................70 Figure F2 Hydraulic diagram 80 ......................70 Figure F3 Hydraulic diagram 50 ......................71 Page HAMWORTHY HEATING LTD FLEET WALL HUNG SERIES 500001211/F...

  • Page 7: Introduction

    1.3 The ‘Fleet’ is a gas fired, fully modulating, pre-mix, given in Appendix ’E’. Consult Hamworthy Heating condensing, room sealed central heating / hot water Technical Department for help or assistance if in doubt.

  • Page 8: Supply And Delivery

    Appendix C Warranty Full warranty assistance will be covered when the appliance is commissioned by Hamworthy Heating Ltd, see Terms & Conditions for full details. Hamworthy Heating Ltd will not accept any liability resulting from damage due to tampering, improper use, handling, installation errors, operation and maintenance.
  • Page 9 Refer to Kit instructions for specific information. Open flue with air drawn from plant room Figure 2.3 - Single boiler arrangement showing frame, flue header, water pipework & low loss header HAMWORTHY HEATING LTD FLEET W series 500001211/F...
  • Page 10 Figure 2.4 - Two boiler arrangement showing frame, flue header, water pipework and low loss header Open flue with air drawn from plant room Figure 2.5 - Two boiler arrangement showing frame, flue header, water pipework and 6 port (multi secondary circuit) low loss header. HAMWORTHY HEATING LTD FLEET W series 500001211/F...

  • Page 11: Size And Space Requirements

    Plan View View on underside Side View Front View Side View Rear Flue Exit Side Flue Exit Side Flue Exit Figure 3.1.1 - Dimensions for individual flues - refer to table Figure 3.1.3 HAMWORTHY HEATING LTD FLEET W series 500001211/F...
  • Page 12 Boilers can be individually flued or use the cascade flue kit as illustrated Boiler Model F150W F60/70W F85/100W F125W F40/50W Dim. 200Ø 2 boilers or less - 150Ø 200Ø more than 2 boilers - 200Ø Figure 3.1.5 - Dimensions for cascade installation HAMWORTHY HEATING LTD FLEET W series 500001211/F...
  • Page 13 Figure 3.1.6 - Wall mounting template 3.2 The Hamworthy Heating Ltd frame set and pipe work kit is designed to provide a compact solution for connecting the boilers to the gas supply and flow and return water connections. Refer to kit instructions for specific information 1/2”...
  • Page 14 Figure 3.2.2 – Two boiler installation - Refer to table 3.2.5 Sensor Pocket ½” BSP Flow Return Instrument Spool Single secondary circuit Three secondary circuits Figure 3.2.3 – Optional Low Loss Headers - Refer to table 3.2.5 HAMWORTHY HEATING LTD FLEET W series 500001211/F...
  • Page 15 Figure 3.2.4 – Three boilers - 1680 Refer to table 3.2.5 Figure 3.2.5 – Four boilers - Refer to table 2650 Boiler Dimension F40-100W F125-150W A (mm) DN50 - PN16 DN65 - PN16 R 1½” R2” 2240 HAMWORTHY HEATING LTD FLEET W series 500001211/F...

  • Page 16: Site Location And Preparation

    17.5mbar) dynamic - refer to Appendix A  Boiler house gas isolation valve must be clearly identified and installed close to the entrance / exit. Gas connection Figure 4.2 - Gas Connection Point HAMWORTHY HEATING LTD FLEET W series 500001211/F...
  • Page 17 For external flue runs and termination, either use the dedicated kits supplied by Hamworthy or refer to a chimney specialist . Flue termination, routing and construction must comply with the requirements of the ...
  • Page 18 Vertically from a terminal on the same wall 1500 Horizontally from a terminal on the same wall From the wall on which the terminal is mounted From a vertical structure on the roof Above intersection with roof HAMWORTHY HEATING LTD FLEET W series 500001211/F...
  • Page 19 Maximum working water pressure is 5.3bar.  For minimum water pressure 0.5 bar - refer to Appendix E Safety Valve 22mm Return water connection Flow water connection Figure 4.4 - Water Connection Points HAMWORTHY HEATING LTD FLEET W series 500001211/F...
  • Page 20 Compliance with the manufacturer’s recommendations as detailed in the operating and maintenance manual, ensuring that the commissioning is carried out by either Hamworthy Heating Limited or a competent engineer. To ensure that the settings and checks noted on the commissioning sheet (included in the maintenance manual) are recorded and detailed within the boiler log book.
  • Page 21 Boiler gas configuration or type which is not appropriate to the type of gas approved for the appliance.  Damage caused by use of spare parts not compatible with the product.  Operation of the product at system pressures above that for which it was designed and manufactured. HAMWORTHY HEATING LTD FLEET W series 500001211/F...

  • Page 22: Condensate Connections

    Condense is mildly acidic, typically pH3 - pH5.  Condense pipe work must be non-corrosive and not copper. Hamworthy  recommend plastic waste pipe. Condense may be discharged to a standard drain subject to National or Local ...
  • Page 23 Single pipe inline drain & trap Concentric inline drain & trap Tundish Tundish to drain to drain Vertical Concentric Flue System Conventional Chimney Flue System Figure 4.5.2 - Flue Condensate Connection and discharge HAMWORTHY HEATING LTD FLEET W series 500001211/F...

  • Page 24: Electrical Supply

    NOTE: The appliance must be isolated from the electrical supply if electric arc welding is carried out on connecting pipe work. FOR TYPICAL SCHEMATIC DETAILS SEE FIGURE 4.6 FOR DETAILED WIRING INSTRUCTIONS SEE FIGURES 9.3.1 AND APPENDIX B  Figure 4.6 - Wiring Schematic HAMWORTHY HEATING LTD FLEET W series 500001211/F...

  • Page 25: Boiler Assembly

    5.3 Flue Connection 5.3.1 The Hamworthy Fleet boiler is designed for use with the following flue systems supplied by Hamworthy - see Appendix C 80/125mm concentric room sealed, balanced flue system for rear/side through the wall discharge. 100/150mm concentric, room sealed, balanced flue system for remote discharge, horizontal or vertical.

  • Page 26: Electrical Connections

    Figure 4.3.2. In the case of twin duct applications (C53), air supply inlets must be positioned at least 300 mm from flue terminals to prevent flue gas re-circulation. Hamworthy Heating recommend that flue terminals discharges are positioned higher than air inlets.

  • Page 27: Flue

    Electrical connections are correct and isolatable.  External controls are operational. WARNING: WHEN THE FRONT COVER IS REMOVED AND THE BOILER IS OPERATIONAL, CARE MUST BE TAKEN WITH ELECTRICAL COMPONENTS AND ACCESS TO PRIMARY INSULATION. HAMWORTHY HEATING LTD FLEET W series 500001211/F...

  • Page 28: Checks Prior To Lighting

    Where using Hamworthy Heating Ltd frame set and pipe work kits, assembly of these is detailed in Installation manual 500005132 supplied with kit.

  • Page 29: Checks Prior To Lighting The Boiler

    11 Check that the boiler controls wiring has not been display screen. The value is set to read dc μA. Refer to modified. Any modification could lead to boiler failure. section 8.2.1.2 - Controls Operation. HAMWORTHY HEATING LTD FLEET W series 500001211/F...

  • Page 30: Combustion Checks

    3. Insert probe horizontally into the flue elbow until depth stop is met. Figure 7.6 - Combustion Analyser Probe Setting (Note: readings taken with front cover removed and 50mm probe insertion CO = < 80 ppm). HAMWORTHY HEATING LTD FLEET W series 500001211/F...
  • Page 31 Nat Gas 9.0% ±0.25% CO If combustion readings are outside target range use Torx Bit to make adjustments To increase the CO level, turn the adjustment clockwise. Figure 7.6.4 - Adjusting gas valve offset HAMWORTHY HEATING LTD FLEET W series 500001211/F...

  • Page 32: Boiler Controls

    CONTACT HAMWORTHY HEATING TECHNICAL DEPARTMENT FOR FURTHER DETAILS 7. Shut down the boiler and isolate from the electrical supply. Remove instrumentation and replace test points and plugs.
  • Page 33 Installation and Commissioning guide, the servicing instructions manual and the user’s instructions should then be handed over and be kept in a safe place for future reference. F 50 W Figure 8.2.1.1 - Fascia Label Legend Display Screen Keypad Figure 8.2.1.2 -Overview of Fascia Panel HAMWORTHY HEATING LTD FLEET W series 500001211/F...
  • Page 34 Water Flow Switch Air Pressure Switch Fuse IEC Mains Outlet LMU Control Flue Gas Sensor Clip in Module Vfc / 0~10v On/Off switch Display Screen Figure 8.1.6 - General Overview of Boiler Controls HAMWORTHY HEATING LTD FLEET W series 500001211/F...
  • Page 35 Adjustment of dhw temperature setpoint - not used Line selection (down / up) Selection of operating parameter Adjustment of settings Adjustment of parameter settings Information Select information display screens Enable Maintenance mode Press buttons simultaneously to select HAMWORTHY HEATING LTD FLEET W series 500001211/F...
  • Page 36 Press Info button Press buttons for at least 3 seconds Press button twice Choose the relevant parameter with buttons Note after about 8 minutes, the display will automatically change to the default display. HAMWORTHY HEATING LTD FLEET W series 500001211/F...
  • Page 37 Figure 8.2.1.3 - Operation and display philosophy HAMWORTHY HEATING LTD FLEET W series 500001211/F...
  • Page 38 Operating mode is, or changes to: Automatic Continuous ‘Normal’ operation Continuous ‘Reduced’ operation Standby Operating mode of dhw. On or Off - not used Time bar Display of time program of heating circuit HAMWORTHY HEATING LTD FLEET W series 500001211/F...
  • Page 39 3 seconds. The internal error code will be displayed. Example “4975” Press the info button to return to the info display. Press to return to the default display. Figure 8.2.3.2 - Display of Status Code HAMWORTHY HEATING LTD FLEET W series 500001211/F...
  • Page 40 If no button is pressed for about 8 minutes, the screen will automatically return to the default display. Changes will be stored. 8.2.6 - Parameter settings for the Enduser The boiler is supplied with default settings. These must be modified to suit individual Enduser needs. HAMWORTHY HEATING LTD FLEET W series 500001211/F...
  • Page 41 To ensure maximum supply of heat, the chimney sweep function generates the forced signal for heat supply. During the time that the Chimney Sweep is activated, an appropriate status code is delivered. To close the function, press button HAMWORTHY HEATING LTD FLEET W series 500001211/F...
  • Page 42 Heating circuit 1 continuously on according to the adjusted operation nominal room temperature setpoint or heating circuit setpoint Continuous ‘Reduced’ Reduced room temperature set point or heating circuit frost operation protection setpoint Figure 8.2.9 HAMWORTHY HEATING LTD FLEET W series 500001211/F...

  • Page 43: Functions

    Also, the software version number of the operator module and that of the connected type of LMU... will be delivered to the display. The boiler flow sensor in combination with the return sensor, provide overheat protection as follows: HAMWORTHY HEATING LTD FLEET W series 500001211/F...
  • Page 44 Fault air pressure switch (does not close) Fault heating circuit flow switch / pressure switch Fault air pressure switch (does not open) Chimney sweep function active Controller stop function active LMU... in parameter setting mode HAMWORTHY HEATING LTD FLEET W series 500001211/F...
  • Page 45 4th past value of internal diagnostic code Engineer * When connecting to a QAA73 4th past value of ALBATROS error code Engineer * unit refer to Hamworthy OEM 5th past value of lockout code counter Engineer * manual 500001140 5th past value of lockout phase...
  • Page 46 Figure 8.3.11 - Operating phases HAMWORTHY HEATING LTD FLEET W series 500001211/F...
  • Page 47 PH_TLO PH_TNN Lockout position (display of the current PH_STOER error code) Note: -If operating phases are passed very quickly or skipped, the relevant display code will not appear. Figure 8.3.12 - Operating phases HAMWORTHY HEATING LTD FLEET W series 500001211/F...

  • Page 48: Fault Finding

    Engineer. Should a fault code appear which cannot be reset, or a fault code repeatedly occurs, contact Hamworthy Heating for assistance. Do not continue to operate or use the boiler as this may cause damage to the controls.
  • Page 49 0~10V Ground Remote On/Off Input Signal 24VDC NOT USED Neutral Normal Run Line Out Neutral Lock-Out Line Out Neutral Powered Output Supply Live Neutral Secondary Pump Output Live Neutral Mains Supply Live Earth HAMWORTHY HEATING LTD FLEET W series 500001211/F...

  • Page 50: Servicing

    9) Carefully remove the insulation pad from the heat 10.1 Regular servicing is recommended, preferably exchanger back plate (accessed through the burner by a Hamworthy appointed person, and at least cavity) and replace with a new pad ensuring the edges annually, to ensure trouble free operation.
  • Page 51 Figure 10.2 - Combustion Chamber Figure 10.2.1 - Spark Electrode position Figure 10.2.2 - Flame Probe position HAMWORTHY HEATING LTD FLEET W series 500001211/F...

  • Page 52: Replacement Of Failed Components

    Remove the screws securing the gas valve and venturi required on the threads. Check for soundness of the joint assembly to the fan inlet, noting the position of the when firing the boiler. venturi. HAMWORTHY HEATING LTD FLEET W series 500001211/F...

  • Page 53: Recommended Spares

    On/Off switch ................................. 533925009 Fascia fuse T2A ................................533922009 Clip in Module - vfc + 0~10v - AGU2.511A109 ......................533901438 Clip in Module - LPB Bus communication - OCI420A109 ................... 533901456 HAMWORTHY HEATING LTD FLEET W series 500001211/F...
  • Page 54 Top Panel rear - F125/F150W ..........................530650458 Pump Access Panel ..............................530650459 Bottom Panel - F40 / F100W .............................560650255 Bottom Panel - F125 / F150W ...........................560650256 For service or spares please contact :- Hamworthy Heating Ltd Phone Number ......01202 662500 Fleets Corner Fax Number ........01202 665111 Poole Service ..........01202 662555...
  • Page 55 Gas Pressure Switch Setting Nat Gas -mbar 12.5 Gas Flow Rate (max. per module) Nat Gas 8.25 11.7 14.6 Target CO % at High / Low fire Nat Gas ±0.25% Figure A1– Gas data HAMWORTHY HEATING LTD FLEET W series 500001211/F...
  • Page 56 DC signal that can be fed through a volt free contact for operation. Refer to BS 6644 for further information on installing the electrical supply. 7. The integral pump in Fleet boilers is managed by the LMU boiler control. NOTE: FOR BASIC TERMINATION DIAGRAM SEE FIGURE 4.6 HAMWORTHY HEATING LTD FLEET W series 500001211/F...
  • Page 57 For connection of an external alarm device, use terminals 8 & 9, which are volt free and rated at 230v - see figure For an optional programmable room thermostat, use connector X10-01 on the LMU - see figure B.1.3 HAMWORTHY HEATING LTD FLEET W series...
  • Page 58 1070 165.0 10.0 19873 90.0 170.0 15.0 15699 95.0 175.0 20.0 12488 100.0 180.0 25.0 10000 105.0 185.0 30.0 8059 110.0 190.0 35.0 6535 115.0 195.0 40.0 5330 120.0 200.0 45.0 4372 125.0 HAMWORTHY HEATING LTD FLEET W series 500001211/F...
  • Page 59 Consideration must be given to the correct calculation of the required flue size. If in any doubt consult Hamworthy Heating Ltd who can supply a full flue design and installation service. C1.2 Waste Gas Volume and Temperature.
  • Page 60 A drain with an integral trap is fitted to each module suitable for connection to a 20mm plastic waste pipe (not Hamworthy Heating Ltd supply), which must be connected to a tundish (not Hamworthy Heating Ltd supply). Discharge piping from a tundish should be of synthetic material due to the mild acidity of the condensate (pH3-5), with all discharge piping having a minimum fall of 50mm/m away from the boiler.
  • Page 61 1  1.5  0.75  100/150Ø 45° Elbow  532511116  125  100/150  7  1  1.5  0.75  100/150Ø * 1m   532511132  150  100/150  4  1  1.5  0.75  Figure C1.2 - Individual Flue equivalent lengths - refer to fig. C1.1 & C1.2 HAMWORTHY HEATING LTD FLEET W series 500001211/F...
  • Page 62 1100 min 30mm/m fall to boiler Concentric inline drain & trap to drain 1000 Figure C1.2 - Room sealed concentric C13 horizontal flue system Figure C2.1 - Room sealed concentric C33 vertical flue system HAMWORTHY HEATING LTD FLEET W series 500001211/F...
  • Page 63 Figure C2.1.2 - Individual Flue 125  100/150  7  1  1.5  0.75  equivalent lengths - refer to fig. C2.1 150  100/150  4  1  1.5  0.75  1100 min 1000 Figure C3.1 - Room sealed C53 twin duct flue system HAMWORTHY HEATING LTD FLEET W series 500001211/F...
  • Page 64 2  0.75  100Ø * 2m   532511131  125  130  100  3  4  0.75  Figure C3.2.1 - Individual Flue 150  130  75  3  4  0.75  equivalent lengths - refer to fig. C3.2 L* = Air + Flue HAMWORTHY HEATING LTD FLEET W series 500001211/F...
  • Page 65 Boiler connection kit 125-150kW - 563605639 For instances when a B53 flue (ducted air inlet) is connected to a cascade (B23 outlet), the air inlet filters need not be fitted and can therefore be discarded. HAMWORTHY HEATING LTD FLEET W series 500001211/F...
  • Page 66 Boiler connection kit (see note previous page)* Figure C4.2- B23 Open flue system 520 max 560 crs Note: Horizontal discharge is only suitable for outputs less than 150kW Figure C5.1 - Cascade flue system HAMWORTHY HEATING LTD FLEET W series 500001211/F...
  • Page 67 200  20  3  4                 500  250  90  4  5  600  250  25  4  5  Figure C5.1.1 - Cascade Flue equivalent lengths - refer to fig. C5.1 & C5.2 HAMWORTHY HEATING LTD FLEET W series 500001211/F...
  • Page 68 10mm longer than the outer section to allow sections to be joined correctly. Do not cut all the way through both sections at the same length. Cut the outer section first and then the inner section 10mm longer. HAMWORTHY HEATING LTD FLEET W series 500001211/F...
  • Page 69 For Mechanical ventilation systems an automatic 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. HAMWORTHY HEATING LTD FLEET W series 500001211/F...
  • Page 70 The calculated extract flow rate is the actual inlet flow rate minus the appropriate figure in the table above. HAMWORTHY HEATING LTD FLEET W series 500001211/F...
  • Page 71 4) Each boiler module has flow and return connections as detailed in the table above. Multiple boilers should be connected by flow and return headers. Hamworthy strongly recommend that boilers are connected in a primary circuit configuration utilising a low loss header arrangement to enable secondary circuits to be connected to the header.
  • Page 72 Maximum system hot working pressure, generally given in bar gauge. From the parameters given, Hamworthy Heating can size the pressurisation unit and also the expansion vessel. Care must be taken in sizing expansion vessels to ensure maximum acceptance factors are not exceeded.
  • Page 73 Feed & valve Air Vent expansion Valve tank Heating load Circulation pump (System) Module Module Module Feed pipe Hamworthy Modular Boilers Valve Drain valve VENTED SYSTEM: Single pipe header Pressure & Temperature Drain gauges Mains water Automatic Safety Automatic Air Vent...
  • Page 74 Head (m) F 70W Q m /h Model F 85W F 100W F 125W Head (m) Q m /h Model F 150W Head (m) Q m /h Figure E1.7 - Integral pump performance curves HAMWORTHY HEATING LTD FLEET W series 500001211/F...
  • Page 75 Flow Dosing Pot Plate Heat Exchanger Return Drain Drain Dirt/ Air Separator Typical layout for primary circuit with plate heat exchanger separation of secondary circuits Figure E2 - Typical Pipe Kit system connections HAMWORTHY HEATING LTD FLEET W series 500001211/F...
  • Page 76 Option 1 - for use with the Merley sequence controller To enable cascade control change the setting by using the + or – key and set value to 80. Press mode button to store change and return to home screen. Figure. F2 HAMWORTHY HEATING LTD FLEET W series 500001211/F...
  • Page 77 To enable an additional mixing circuit with use of AGU 2.500, change the setting by using the + or – key and set value to 50. Press mode button to store change and return to home screen Figure. F3 HAMWORTHY HEATING LTD FLEET W series 500001211/F...
  • Page 78 USEFUL USER INFORMATION INSTALLER SITE ADDRESS BOILER TYPE BOILER SIZE(S) UNIT NO(S). SERIAL NO(S). FLUE HAMWORTHY HEATING LTD FLEET W series 500001211/F...
  • Page 82 Customer Service Centre Hamworthy Heating Limited, Fleets Corner, Poole, Dorset BH17 0HH Telephone: 0845 450 2866 Fax: 01202 662522 Email: aftersales@hamworthy-heating.com Website: www.hamworthy-heating.com Hamworthy reserves the right to make changes and improvements which may necessitate alteration to the specification without prior notice.

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