Servicing - Hamworthy FLEET Series Installation, Commissioning And Operating Instructions

10 SERVICING

A competent person registered for working on non
domestic gas appliances should check and ensure that
the flue, its support and terminal, the ventilation to the
boiler house, safety valve, drain, water filter if fitted,
pressure gauge, etc.; are in a serviceable and working
condition and still comply with the relevant standards
and codes of practice - see Section 4.
10.1 Regular servicing is recommended, preferably
by a Hamworthy appointed person, and at least
annually, to ensure trouble free operation.
For Fleet boilers, Hamworthy would recommend an
additional 6 monthly
commissioning, acknowledging site conditions and
running hours.
Although cleaning of flueways may not be necessary on
a yearly basis, it is important that all controls and safety
features are checked for correct operation.
Note:- Measuring flue gas CO
will give an indication of the state of the boiler flueways
and waterways. Results should be compared with
previously measured values to establish possible loss of
efficiency.
10.2 Annual Service
Before servicing the boiler, the following procedure must
be carried out :-
WARNING: Isolate all electrical supplies and turn off
the gas service valve.
1) Open the front casing doors by turning the 1/4 turn
latch with a flat bladed screw driver. Note the latch
mechanism passes through slots in the top and bottom
panels.
Once open, remove the screwed top panel, to provide
access to the area on top of the heat exchanger and
hinge down the controls panel to provide access to the
heat exchanger components.
2) Disconnect the H.T and flame probe connectors from
the respective probes.
3) Disconnect the fan power supply and control leads
from the fan taking care with the latch on each
connector.
4) Check that the gas service valve is closed, then undo
the compression union on the inlet to the gas valve.
5) Carefully disengage the flexible air inlet duct from the
venturi and remove the electrical plug from the gas
valve.
6) Remove the 3 M6 socket head screws securing the
fan /burner duct assembly to the heat exchanger and
carefully remove the assembly and the sealing gasket.
Carefully remove the burner from the heat exchanger,.
7) Remove and inspect H.T. electrode and flame probe,
ensure they are free from debris or deposits. – See
Figures 10.2. 10.2.1 & 10.2.2
8) Check the burner and clean using a soft brush if
HAMWORTHY HEATING LTD
examination following
and gas temperatures
2
FLEET W series
required (if possible use a vacuum cleaner to remove
the dust from inside the burner tube). After cleaning the
inside, the burner tube can be washed using a soapy
water solution. Tap the burner flange firmly downwards
on a block of wood to dislodge any residual debris from
inside the burner tube. A damaged or cracked burner
should be replaced.
Note:- Do not use a wire brush to clean the burner.
9) Carefully remove the insulation pad from the heat
exchanger back plate (accessed through the burner
cavity) and replace with a new pad ensuring the edges
are 'tucked in' to the gap past the last section
10) Separate the gas valve / venturi from the fan inlet
noting it's orientation and inspect the fan scroll and
impellor, clean and check for damage.
11) Clean and check the venturi for contamination.
12) Remove the fan/burner duct cover plate and inspect
the non return valve in the duct for smooth operation.
13) Separate the inlet flange /elbow fitting from the gas
control valve by removing the 4 M5 socket cap head
screws. Check that the mesh inlet filter in the gas valve
is clear of debris, remove any foreign objects caught in
the filter.
Re-assemble in reverse order taking care to inspect and
if necessary, replace any o-rings, gaskets or seals.
Refer to Section 8, Commissioning and Testing, and
test all gas joints broken or disturbed for soundness
before firing.
Carry out a combustion check by testing the flue gas
CO and CO levels as detailed in Section 8.2.
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10.3 Four Year Service
Repeat the annual service as previously described but
do not refit any components to the heat exchanger.
10.3.1 To clean the heat exchanger, the use of a high
pressure water hose (40-80 psi) is recommended for
the primary flue gas path. However provision must be
made for the drainage of water used in this process.
Remove the base plate to provide access to the pump.
At the front of the boiler remove the condensate drain
trap assembly from the flue elbow. Connect a hose
(32mm id.) To the flue elbow and take to a suitable drain
or receptacle. The cleaning water and any debris will
exit the sump through this opening.
To clean the condensing flue gas path, isolate the boiler
from the heating system and drain the boiler heat
exchanger using the drain valve provided in the return
pipe. Disconnect the electrical supply to the pump,
return sensor and the flow switch. Carefully support the
pump, disconnect the unions and remove the pump.
Remove the 2 M6 screws securing the return elbow /
pipe assembly to the heat exchanger and carefully
remove the assembly.
Remove the screws securing the plastic sump to the
heat exchanger sealing plate and withdraw the sump
down, disengaging the flue pipe from the flue elbow.
The heat exchanger fin matrix is now accessible and
the flue ways can be cleaned using a 25mm wide *
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