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Hamworthy F40V Installation, Commissioning And Operating Instructions

Fleet series boilers
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24
Combustion Checks
38
Figure 8.2.10 Lmu Error Codes
42
Fault Finding
Table of Contents
FLEET SERIES BOILERS
Floor Standing, Condensing ,
Fully Modulating, Pre-Mix,
Gas Fired Boilers for Heating & Domestic
Hot Water Installations
Installation, Commissioning
and Operating Instructions
Models: F40V, F50V, F60V, F70V, F85V,F100V
F125V & F150V
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 F40V

  • Page 1 Fully Modulating, Pre-Mix, Gas Fired Boilers for Heating & Domestic Hot Water Installations Installation, Commissioning and Operating Instructions Models: F40V, F50V, F60V, F70V, F85V,F100V F125V & F150V NATURAL GAS I IMPORTANT NOTE THESE INSTRUCTIONS MUST BE READ AND UNDERSTOOD BEFORE INSTALLING,...
  • Page 3 Gas Fired Boilers for Heating & Domestic Hot Water Installations Installation, Commissioning and Operating Instructions Models: F40V, F50V, F60V, F70V, F85V, F100V, F125V & F150V NATURAL GAS I NOTE: THESE INSTRUCTIONS MUST BE READ AND UNDERSTOOD BEFORE INSTALLING, COMMISSIONING, OPERATING OR SERVICING EQUIPMENT.

  • Page 4: Table Of Contents

    Initial Lighting Combustion Checks User Instructions BOILER CONTROLS ........................18 Controls Operation Functions FAULT FINDING ..........................34 10.0 SERVICING ............................36 11.0 REPLACEMENT OF FAILED COMPONENTS ................38 12.0 RECOMMENDED SPARES ......................39 Page HAMWORTHY HEATING LTD FLEET V Series 500001213/G...
  • Page 5 Water flow switch ........................36 Figure 9.3.1 Wiring Schematic ........................37 Figure 10.2 Combustion chamber ......................39 Figure 10.2.1 Spark electrode position ......................39 Figure 10.2.2 Flame sensing probe position ....................39 Page HAMWORTHY HEATING LTD FLEET V Series 500001213/G...
  • Page 6 Figure E1.4 Cold Feed & Vent Sizes ......................53 Figure E1.7 Pump performance curves ..................... 54 Figure E2 Typical pipe kit system connections ..................55 Figure F1 Hydraulic diagram 80 ......................56 Page HAMWORTHY HEATING LTD FLEET V Series 500001213/G...

  • Page 7: Introduction

    Failure to comply with the given in Appendix ’E’. Consult Hamworthy Heating above may lead to prosecution. Technical Department for help or assistance if in doubt.

  • Page 8: Supply And Delivery

    The flue manifold connecting the vertical modules is supplied separately to the boiler - refer to Appendix C. Warranty Full warranty assistance will be covered when the appliance is commissioned by Hamworthy Heating Ltd, see Terms & Conditions for full details.
  • Page 9 Where pipe work kits are supplied, these are packaged separately from the boilers. All ancillary items such as isolation valves and boiler make-up connectors are factory fitted and tested The whole is shrink wrapped for security and basic protection. Refer to Kit instructions 500005134 for specific information. HAMWORTHY HEATING LTD FLEET V series 500001213/G...

  • Page 10: Size And Space Requirements

    Electric Rear view Side view Fle e t V S e rie s - 3 high Fle e t V S e rie s - 2 high Figure 3.1.1 - Dimensions and clearances HAMWORTHY HEATING LTD FLEET V series 500001213/G...

  • Page 11: Figure 3.1.2 Table Dimensions And Clearances

    BOILER MODEL Dimension F40V –F100V F125V—F150V Two high Three high Two high Three high C - a 150Ø flue manifold is provided to connect the modules C* - for models F125V-375 & F150-450, the flue termination is 200Ø Figure 3.1.2 - Table Dimensions and clearances 1/2”...
  • Page 12 1/2” BSP Socket for pressure gauge RETURN FLOW DN125 DN125 R2” Figure 3.2.2 – F125/150V - water pipe work kit (3 high boiler installation shown) HAMWORTHY HEATING LTD FLEET V series 500001213/G...

  • Page 13: 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 V series 500001213/G...

  • Page 14: Flue System

    150Pa positive. In the event that the flue system when hot does generate a suction, the max. suction is 100Pa. For type B23 installations the Hamworthy supplied air inlet filter must be used at all  times. Refer to appendix C.

  • Page 15: Water Supply

     Maximum working water pressure is 5.3bar.  For minimum water pressure 0.5 bar - refer to Appendix E Flow water connection Return water connection Safety Valve Figure 4.4 - Water Connection Points HAMWORTHY HEATING LTD FLEET V series 500001213/G...
  • Page 16 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 17 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 V series 500001213/G...

  • Page 18: 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 19: 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 V series 500001213/G...

  • Page 20: Boiler Assembly

    5.3 Flue Connection 5.3.1 The Hamworthy Fleet V series boiler is designed for use with open flue systems type B23 - Intake from ventilated plant room and discharge via horizontal/vertical flue. For all B23 installations the Hamworthy supplied air inlet filter (Pt. No. 532812 008) MUST be used 1.

  • Page 21: Electrical Connections

    Ensure that;  System flushing and suitable water treatment has been implemented  Pipe work and valve arrangement is installed to Hamworthy Heating recommendations.  Circulating system is full of water, vented and pressurised appropriately.  Circulation pump is operational.

  • Page 22: Checks Prior To Lighting

    Where using Hamworthy Heating Ltd pipe work kits, assembly of these is detailed in Installation manual 500005134 supplied with kit.

  • Page 23: 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 V series 500001213/G...

  • Page 24: 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 V series 500001213/G...

  • Page 25: Figure 7.6.1 Adjusting Gas Valve Throttle

    4. If combustion is outside of the ranges defined below the factory sealed valves may be adjusted using the following procedure . Models - F40V/ F50V F60V & F70V High Fire Target Nat Gas - 9.0% ±0.25% CO If combustion level is outside of this range use the Cross Head Throttle Screw to adjust the mixture.

  • Page 26: Controls Operation

    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 27: Figure 8.2.1.2 Overview Of Fascia Panel

    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. Figure 8.2.1.1 - Fascia Label Legend Display Screen Keypad Figure 8.2.1.2 -Overview of Fascia Panel HAMWORTHY HEATING LTD FLEET V series 500001213/G...

  • Page 28: Figure 8.1.6 General Overview Of Boiler Controls

    Flue Gas Temperature Sensor - in flue elbow 230v Mains Display Return On/Off switch Pump Gas Valve Low Gas Supply Screen Temperature Pressure Switch Sensor Figure 8.1.6 - General Overview of Boiler Controls HAMWORTHY HEATING LTD FLEET V series 500001213/G...
  • Page 29 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 V series 500001213/G...

  • Page 30: Figure 8.2.1.2 Info Display Parameters

    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 V series 500001213/G...

  • Page 31: Figure 8.2.1.3 Operation And Display Philosophy

    Figure 8.2.1.3 - Operation and display philosophy HAMWORTHY HEATING LTD FLEET V series 500001213/G...

  • Page 32: Figure 8.2.2 Screen Legend

    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 V series 500001213/G...

  • Page 33: Figure 8.2.3.1 Default Display

    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 V series 500001213/G...

  • Page 34: Figure 8.2.5 Heating Circuit Setpoint

    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 V series 500001213/G...

  • Page 35: Figure 8.2.6 Overview Of End User Parameters

    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 V series 500001213/G...
  • Page 36 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 V series 500001213/G...

  • Page 37: 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 V series 500001213/G...

  • Page 38: Figure 8.2.10 Lmu Error Codes

    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 V series 500001213/G...
  • Page 39 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 40: Figure 8.3.11 Operating Phases

    Figure 8.3.11 - Operating phases HAMWORTHY HEATING LTD FLEET V series 500001213/G...

  • Page 41: Figure 8.3.12 Operating Phases

    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 V series 500001213/G...

  • Page 42: 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 43 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 V series 500001213/G...

  • Page 44: Servicing

    10.1 Regular servicing is recommended, preferably cavity) and replace with a new pad ensuring the edges by a Hamworthy appointed person, and at least are ‘tucked in’ to the gap past the last section annually, to ensure trouble free operation.

  • Page 45: Figure 10.2 Combustion Chamber

    Figure 10.2 - Combustion Chamber Figure 10.2.1 - Spark Electrode position Figure 10.2.2 - Flame Probe position HAMWORTHY HEATING LTD FLEET V series 500001213/G...

  • Page 46: Replacement Of Failed Components

    Disconnect the gas supply from the inlet to the gas valve. soundness before firing the boiler. Loosen the worm drive securing the air inlet duct to the 11.3 Flue Gas sensor - Part no. 533901549 venturi. HAMWORTHY HEATING LTD FLEET V series 500001213/G...

  • Page 47: Recommended Spares

    Control panel on the rating label. These numbers MUST be quoted when ordering spare parts. SPARES ITEM PART No. ELECTRICAL ITEMS LMU control - F40V Nat Gas ............................533901623 LMU control - F50V Nat Gas ............................533901624 LMU control - F60V Nat Gas ............................533901625 LMU control - F70V Nat Gas ............................533901626 LMU control - F85V NatGas ............................
  • Page 48 Burner Fabrication - F125V ............................533301033 Burner Fabrication - F150V ............................533301034 Gas Control Valve - F40V/F70V ..........................533903040 Gas Control Valve ‘O’ ring - F40V/F70V .........................531299051 Gas Control Valve - F85V/F150V ..........................533903044 Gas Control Valve ‘O’ ring - F85V/F150V ........................742111245 Combustion Fan - F40H/F70H ...........................533901376...

  • Page 49: Appendix A Gas Data

    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 V series 500001213/G...

  • Page 50: Appendix B Electrical Connections And Controls

    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 V series 500001213/G...
  • Page 51 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 V series...

  • Page 52: Figure B1.3 Sensor Resistance Values

    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 V series 500001213/G...

  • Page 53: Appendix C Flue Data

    HHL supply plastic flue components and suitable terminals to discharge the flue gases safely. The Fleet flue systems supplied by Hamworthy are non UV stabilised polypropylene and are therefore suitable for internal use only. For external flue runs and termination, either use the dedicated kits supplied by Hamworthy or refer to a chimney specialist .
  • Page 54 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 55: Figure C6.1 Flue Equivalent Lengths

    R ear view Side view In the instance that a B53 flue (ducted air inlet) is connected to a cascade (B23 outlet), the air inlet filters need not be fitted and therefore can be discarded. HAMWORTHY HEATING LTD FLEET V series 500001213/G...

  • Page 56: Appendix D Ventilation

    15% of the boiler room height from the ceiling. High and low level grilles shall communicate with the same room or space where compartment ventilation is used. Where grilles communicate directly with outside air, they shall be positioned on the same wall. HAMWORTHY HEATING LTD FLEET V series 500001213/G...

  • Page 57: Appendix E Water Data

    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 58 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 59: Figure E1.1 Typical Piping Layouts

    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 60 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 V series 500001213/G...

  • Page 61: Figure E2 Typical Pipe Kit System Connections

    Return Non HHL supplied single circuit low loss header Boiler Boiler Boiler Flow Plate Heat Exchanger Return Non HHL supplied plate heat exchanger separated system Figure E2 - Typical Pipe Kit system connections HAMWORTHY HEATING LTD FLEET V series 500001213/G...
  • Page 62 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. F1 HAMWORTHY HEATING LTD FLEET V series 500001213/G...
  • Page 63 NOTES : HAMWORTHY HEATING LTD FLEET V series 500001213/G...
  • Page 64 USEFUL USER INFORMATION INSTALLER SITE ADDRESS BOILER TYPE BOILER SIZE(S) UNIT NO(S). SERIAL NO(S). FLUE HAMWORTHY HEATING LTD FLEET V series 500001213/G...
  • Page 68 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.

This manual is also suitable for:

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