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Hamworthy F175H Installation, Commissioning And Operating Instructions

Fleet series floor standing, condensing , room sealed, fully modulating, pre-mix, gas fired boilers for heating & domestic hot water installations
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FLEET SERIES BOILERS
Floor Standing, Condensing , Room Sealed,
Fully Modulating, Pre-Mix,
Gas Fired Boilers for Heating & Domestic
Hot Water Installations
Installation, Commissioning
and Operating Instructions
Models: F175H, F200H, F250H, F300H & F350H
NATURAL GAS I
2H
IMPORTANT NOTE
THESE INSTRUCTIONS MUST BE READ
AND UNDERSTOOD BEFORE INSTALLING,
COMMISSIONING, OPERATING OR
SERVICING EQUIPMENT

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  • Page 1 Fully Modulating, Pre-Mix, Gas Fired Boilers for Heating & Domestic Hot Water Installations Installation, Commissioning and Operating Instructions Models: F175H, F200H, F250H, F300H & F350H NATURAL GAS I IMPORTANT NOTE THESE INSTRUCTIONS MUST BE READ AND UNDERSTOOD BEFORE INSTALLING, COMMISSIONING, OPERATING OR...
  • Page 3 Gas Fired Boilers for Heating & Domestic Hot Water Installations Installation, Commissioning and Operating Instructions Models: F175H, F200H, F250H, F300H, & F350H 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 ........................23 Controls Operation Functions FAULT FINDING ..........................39 10.0 SERVICING ............................41 11.0 REPLACEMENT OF FAILED COMPONENTS ................43 12.0 RECOMMENDED SPARES ......................44 Page HAMWORTHY HEATING LTD FLEET H Series 500001216/D...
  • Page 5 Water flow switch ........................39 Figure 9.3.1 Wiring Schematic ........................40 Figure 10.2 Combustion chamber ......................42 Figure 10.2.1 Spark electrode position ......................42 Figure 10.2.2 Flame sensing probe position ....................42 Page HAMWORTHY HEATING LTD FLEET H Series 500001216/D...
  • Page 6 Pump performance curves ..................... 63 Figure E2 Typical pipe kit system connections ..................64 Figure F1 Hydraulic diagram 02 ......................65 Figure F2 Hydraulic diagram 80 ......................65 Figure F3 Hydraulic diagram 50 ......................66 Page HAMWORTHY HEATING LTD FLEET H Series 500001216/D...

  • Page 7: Introduction

    Merley Boiler Sequence Controller. diverter required in the flue system. 1.8.2.3 Merley Boiler Sequencer Controller However, for B23 applications, the hamworthy air inlet Allows cascade management of up to 16 boilers, and filter MUST be used to provide the correct clean air interface with a BMS system.

  • 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 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 500005133 for specific information. HAMWORTHY HEATING LTD FLEET H series 500001216/D...

  • Page 10: Size And Space Requirements

    1446 1300 min clearance F/G - note; for room sealed applications, kits Plan view are available to adapt the flue and air ducts to 130 or 150mm Ø . Figure 3.1.1 - Dimensions HAMWORTHY HEATING LTD FLEET H series 500001216/D...
  • Page 11 700 min Figure 3.1.2 - Clearances for vertical flues Note * The dimension 1500mm can be reduced if the pipe work is behind the boiler. HAMWORTHY HEATING LTD FLEET H series 500001216/D...
  • Page 12 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. The kit locates the pipe work above the boiler casing.
  • Page 13 All flange connections DN125 Single secondary circuit All flange connections DN125 Three secondary circuits Figure 3.2.2 – Optional accessories HAMWORTHY HEATING LTD FLEET H series 500001216/D...
  • Page 14 1/2” BSP socket for pressure gauge Figure 3.2.3 – Pipe work header kit 3 boiler installation - 300- 350kW HAMWORTHY HEATING LTD FLEET H series 500001216/D...

  • Page 15: 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 H series 500001216/D...

  • Page 16: 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 air inlet filter must be used at all times. Refer to •...
  • Page 17 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 1” Figure 4.4 - Water Connection Points HAMWORTHY HEATING LTD FLEET H series 500001216/D...
  • Page 18 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 19 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 H series 500001216/D...

  • Page 20: 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 21 Figure 4.5.2 - Flue Condensate Connection and discharge Tundish to drain Conventional Chimney Cascade Flue System Single pipe inline drain & trap Tundish to drain Tundish to drain Vertical Concentric Flue System Conventional Chimney Flue System HAMWORTHY HEATING LTD FLEET H series 500001216/D...

  • Page 22: 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 H series 500001216/D...

  • Page 23: 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 130/200mm & 150/220mm concentric, room sealed, balanced flue system for remote vertical discharge. 130 & 150mm separate air and flue ducts, room sealed, balanced flue system for remote vertical discharge.

  • Page 24: Electrical Connections

    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. To comply with the requirements of the Clean Air Act 1956 installations above 150kW capacity must be terminated at high level.

  • Page 25: Checks Prior To Lighting

    20°C ∆T. As a safety precaution, a flow switch is fitted to the boiler heat exchanger to shut the system down in the event of sudden adverse flow conditions. Where using Hamworthy Heating Ltd frame set and pipe work kits, assembly of these is detailed in Installation manual 500005133 supplied with kit.

  • Page 26: Checks Prior To Lighting The Boiler

    7.3 Commissioning the Boiler Once the preliminary checks have been completed and the gas inlet pressure has been verified as HAMWORTHY HEATING LTD FLEET H series 500001216/D...

  • Page 27: Combustion Checks

    3. Insert probe horizontally into the flue collector sump 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 H series 500001216/D...
  • Page 28 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 29: User Instructions

    Remote Management O CI420 AGU2.50 0 AGU2.51xx OCI /ACS Clip-in Auxiliary mod ules Service Tool 0.. 10 V 4.. 20 mA Figure 8.2 - System configuration of boiler control (LMU) & system peripherals HAMWORTHY HEATING LTD FLEET H series 500001216/D...
  • Page 30 Display Keypad Screen Figure 8.2.1.1 - Fascia Label Legend HAMWORTHY HEATING LTD FLEET H series 500001216/D...
  • Page 31 Outlet Socket Flue Gas Temperature Sensor - in flue elbow 230v Mains Return On/Off switch Pump Gas Valve Low Gas Supply Temperature Pressure Switch Sensor Figure 8.1.6 - General Overview of Boiler Controls HAMWORTHY HEATING LTD FLEET H series 500001216/D...
  • Page 32 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 H series 500001216/D...
  • Page 33 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 H series 500001216/D...
  • Page 34 Figure 8.2.1.3 - Operation and display philosophy HAMWORTHY HEATING LTD FLEET H series 500001216/D...
  • Page 35 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 H series 500001216/D...
  • Page 36 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 H series 500001216/D...
  • Page 37 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 H series 500001216/D...
  • Page 38 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 H series 500001216/D...
  • Page 39 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 H series 500001216/D...

  • Page 40: 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 H series 500001216/D...
  • Page 41 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 H series 500001216/D...
  • Page 42 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 43 Figure 8.3.11 - Operating phases HAMWORTHY HEATING LTD FLEET H series 500001216/D...
  • Page 44 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 H series 500001216/D...

  • Page 45: 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 46 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 H series 500001216/D...

  • Page 47: Servicing

    10.1 Regular servicing is recommended, preferably are ‘tucked in’ to the gap past the last section by a Hamworthy appointed person, and at least annually, to ensure trouble free operation. 10) Separate the gas valve / venturi from the fan inlet For Fleet boilers, Hamworthy would recommend an noting it’s orientation and inspect the fan scroll and...
  • Page 48 Figure 10.2 - Combustion Chamber Figure 10.2.1 - Spark Electrode position Figure 10.2.2 - Flame Probe position HAMWORTHY HEATING LTD FLEET H series 500001216/D...

  • Page 49: Replacement Of Failed Components

    Carefully withdraw the complete assembly and place on 11.3 Flue Gas sensor - Part no. 533901549 The flue gas sensor is located in the flue elbow (175-250) a suitable working area. HAMWORTHY HEATING LTD FLEET H series 500001216/D...

  • Page 50: 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 - F175H Nat Gas ............................533901634 LMU control - F200H Nat Gas ............................533901635 LMU control - F250H Nat Gas ............................533901636 LMU control - F300H Nat Gas ............................533901637 LMU control - F350H NatGas ............................
  • Page 51 Burner Fabrication - F350H ............................533301039 Gas Control Valve - F175H - F300H ........................533903005 Gas Control Valve - F350H ............................533903045 Gas Control Valve ‘O’ ring - F175H - F350H ......................531299032 Combustion Fan - F175H - F300H..........................533704003 Combustion Fan - F350H............................533704012 Venturi - F175H ................................532418009...
  • Page 52 Gas Pressure Switch Setting Nat Gas -mbar 12.5 Gas Flow Rate (max. per module) Nat Gas 29.3 34.2 9.2 / 10.0 Target CO % at High / Low fire Nat Gas ±0.25% Figure A1– Gas data HAMWORTHY HEATING LTD FLEET H series 500001216/D...
  • Page 53 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 H series 500001216/D...
  • Page 54 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 H series...
  • Page 55 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 H series 500001216/D...
  • Page 56 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 57 A drain with an integral trap is fitted to each module suitable for connection to a 40mm o.d. 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 58 3.5  2.5  150Ø 45° Elbow ‐ pp  532511121  300  150  30  2.5  3.5  2.5  150Ø * 1m  ‐ pp  532511134  350  150  20  2.5  3.5  2.5  Table C2.1 - (C33) Individual Flue equivalent lengths - refer to fig. C2.1 - C2.2 HAMWORTHY HEATING LTD FLEET H series 500001216/D...
  • Page 59 100  4  5  4  200Ø 87° Elbow ‐ pp  532511166  350  200  75  4  5  4  200Ø 45° Elbow ‐ pp  532511167  200Ø * 1m  ‐ pp  532511136  200Ø * 2m  ‐ pp  532511170  Table C3.1 - (C53) Individual Flue equivalent lengths - refer to fig. C3.1 - C3.3 HAMWORTHY HEATING LTD FLEET H series 500001216/D...
  • Page 60 180 Ø 150 Ø Figure C3.2 - 150Ø Twin Duct C53 vertical terminal 230 Ø 200 Ø Figure C3.3 - 200Ø Twin Duct C53 vertical terminal HAMWORTHY HEATING LTD FLEET H series 500001216/D...

  • Page 61: Air Inlet

    Figure C4.1 - Individual Flue equivalent lengths - refer to figs. C4.1 - C4.3 NOTE : For all B23 flue installations, the HHL supplied air inlet filter (Pt. No. 532812008) MUST be fitted R ear view Side view HAMWORTHY HEATING LTD FLEET H series 500001216/D...
  • Page 62 180 Ø 150 Ø Figure C4.2 - B23 Open flue system 150Ø 230 Ø 200 Ø Figure C4.3 - B23 Open flue system 200Ø HAMWORTHY HEATING LTD FLEET H series 500001216/D...
  • Page 63 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 H series 500001216/D...
  • Page 64 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 H series 500001216/D...

  • Page 65: Figure D1 Mechanical Ventilation Flow Rates

    The calculated extract flow rate is the actual inlet flow rate minus the appropriate figure in the table above. HAMWORTHY HEATING LTD FLEET H series 500001216/D...
  • Page 66 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 67 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 68 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 69 10.0 (m [kW] Figure E1.7.2 Models 250 - 300H pump performance curve Head Model 250 Model 300 10 11 12 14 15 16 (m Head Figure E1.7.3 Model 350H pump performance curve Model 350 HAMWORTHY HEATING LTD FLEET H series 500001216/D...
  • Page 70 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 H series 500001216/D...
  • Page 71 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 H series 500001216/D...
  • Page 72 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 H series 500001216/D...
  • Page 73 NOTES : HAMWORTHY HEATING LTD FLEET H series 500001216/D...
  • Page 74 USEFUL USER INFORMATION INSTALLER SITE ADDRESS BOILER TYPE BOILER SIZE(S) UNIT NO(S). SERIAL NO(S). FLUE HAMWORTHY HEATING LTD FLEET H series 500001216/D...
  • Page 75 HAMWORTHY HEATING LTD FLEET H series 500001216/D...
  • Page 76 HAMWORTHY HEATING LTD FLEET H series 500001216/D...
  • Page 78 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:

F200hF350hF250hF300h

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