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Hamworthy F40V, Installation, Commissioning And Operating Instructions


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HAMWORTHY HEATING LTD 

 

42 

FLEET V series 

 

500001213/G 

 

 

CASING ITEMS

 

Front door panel  ..........................................................................................................................................................560650267

 

LH side panel - F40 / F100V  ......................................................................................................................................530650469 
RH side panel - F40 / F100V   ....................................................................................................................................530650470 
LH side panel - F125 / F150V   ...................................................................................................................................530650471 
RH side panel - F125 / F150V   ..................................................................................................................................530650472 
Top Panel - F40 / F100V   ...........................................................................................................................................530650477 
Top Panel - F125/F150V   ...........................................................................................................................................530650478

 

 
 
 
 

For service or spares please contact :- 

 

 

Hamworthy Heating Ltd 

                                               Phone Number  ..............................01202 662500

 

Fleets Corner 

                                               Fax Number .....................................01202 665111 

Poole 

         

 

 

 

 

Service .............................................01202 662555 

Dorset BH17 0HH

 

 

 

 

 

     

Spares ..............................................01202 662525 

 

                                               Technical .........................................01202 662500

 

MECHANICAL ITEMS

 

Burner Fabrication - F40V /F50V    .............................................................................................................................533301030 
Burner Fabrication - F60V /F70V   ..............................................................................................................................533301031 
Burner Fabrication - F85V /F100V ..............................................................................................................................533301032 
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 
Combustion Fan - F85H/F100H/F125H .....................................................................................................................533704009 
Combustion Fan - F150H............... .............................................................................................................................533704010 
Venturi - F40V/F50V  ...................................................................................................................................................532418008 
Venturi - F60V/F70V  ...................................................................................................................................................532418005 
Venturi seal - F40V/F70V   .........................................................................................................................................531201067 
Venturi - F85V/F150V 

..........................................................................................................................................532418007

 

Venturi seal - F85V/F150V  .........................................................................................................................................742121238

 

Low Gas Pressure Switch  ..........................................................................................................................................533901497 
Air Pressure Switch   ....................................................................................................................................................532496004 
Flue System Non Return Valve ...................................................................................................................................530650455 
Safety Pressure Relief Valve  ......................................................................................................................................531905013 
Gasket - Burner to heat exchanger ...................................................................................................................531201162 
Gasket - Fan to burner duct   .......................................................................................................................................531201168

 

Gasket - Burner duct   ..................................................................................................................................................531299041

 

Gasket  - Ignitor   ..........................................................................................................................................................531201160 
Gasket  - Probe   ..........................................................................................................................................................531201161 
Pump F40V/F70V.........................................................................................................................................................530905059

 

Pump F85V/F125V.. . ..................................................................................................................................................530905060 
Pump F150V. ...............................................................................................................................................................530905061 
Gasket - Pump  ............................................................................................................................................................531201150 
View Port Sight Glass ..................................................................................................................................................339907043 
Air Inlet Filter............... ..................................................................................................................................................532812008 
Heat exchanger insulation pad.....................................................................................................................................533806119

 

Summary of Contents for F40V

Page 1: ...or Heating Domestic Hot Water Installations Installation Commissioning and Operating Instructions Models F40V F50V F60V F70V F85V F100V F125V F150V NATURAL GAS I2H IMPORTANT NOTE THESE INSTRUCTIONS MU...

Page 2: ......

Page 3: ...Y I2H PLEASE ENSURE RELEVANT INFORMATION REQUIRED WITHIN DOCUMENT IS FOUND BEFORE FIRING BOILER COUNTRY OF DESTINATION UNITED KINGDOM REPUBLIC OF IRELAND THIS BOILER COMPLIES WITH ALL RELEVANT EUROPEA...

Page 4: ...1 General 5 2 Water Connections 5 3 Flue Connections 5 4 Electrical Connections 6 0 PRE COMMISSIONING 13 6 1 Gas Supply 6 2 Ventilation 6 3 Pipework Valves and Pump 6 4 Flue 6 5 Electrical 7 0 CHECKS...

Page 5: ...7 6 Combustion analyser probe position 18 Figure 7 6 1 Adjusting gas valve throttle 19 Figure 7 6 2 Adjusting gas valve throttle 19 Figure 7 6 3 Adjusting gas valve offset 19 Figure 7 6 4 Adjusting ga...

Page 6: ...igure B1 3 Sensor resistance values 46 Figure C1 Flue Data 47 Figure C6 1 Flue equivalent lengths 49 Figure C6 2 Flue Accessories 49 Figure D1 Mechanical Ventilation Flow Rates 50 Figure E1 Water Data...

Page 7: ...ater for these premises via an indirect cylinder 1 3 4 The Fleet has a low water content and is fitted with an integral circulating pump to ensure that water flow rates are achieved refer to Appendix...

Page 8: ...kept upright during handling Care must be exercised to avoid toppling the boiler as this will result in damage The flue manifold connecting the vertical modules is supplied separately to the boiler r...

Page 9: ...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 Refe...

Page 10: ...icient access at sides and behind boiler for pipe work connections See Figure 3 1 Figure 3 1 1 Dimensions and clearances 750 crs 950 min clearance 700 800 F125 150V 650 F40 100V 700 A 1 43 5 2 0 40 7...

Page 11: ...N DN80 600 750 750 120 Figure 3 1 2 Table Dimensions and clearances BOILER MODEL Dimension F40V F100V A 580 580 680 680 B 320 320 320 350 C 150 150 150 200 F125V F150V Two high Three high Two high Thr...

Page 12: ...LTD 6 FLEET V series 500001213 G Figure 3 2 2 F125 150V water pipe work kit 3 high boiler installation shown 750 620 750 360 120 FLOW DN125 GAS R2 RETURN DN125 130 750 120 396 656 786 1 2 BSP Socket f...

Page 13: ...room must have sufficient space for installation of boilers pipe work pumps controls flues ventilation access and servicing and other items of plant 4 2 Gas Supply Gas supply pipes must be in accordan...

Page 14: ...to appendix C Any stabiliser fitted must be in or close to the vertical chimney Due to the low flue gas temperature 50 C condensation will occur in the flue flue materials must be non corrosive and ut...

Page 15: ...event that the system design pressure is lower than the boiler maximum operating pressure according to the requirements of BS6644 2011 The Fleet boiler has an aluminium heat exchanger It is a requirem...

Page 16: ...tenance is carried out by Hamworthy Heating Limited or a competent maintenance company the maintenance regime detail shall be provided in writing when required to prove compliance with the operating a...

Page 17: ...ntifreeze plus protection agent Fernox Restorer cleaning agent for removing rust lime and sludge Protector protection agent F1 protection agent The following applies to system design In order to avoid...

Page 18: ...ot copper Hamworthy recommend plastic waste pipe Condense may be discharged to a standard drain subject to National or Local regulations Location of condense pipe work should prevent freezing within t...

Page 19: ...modules stop start circuit 24V DC Any interlock circuit must be in series with the time control for each circuit The interlock circuit must never be used to isolate the boiler electrical supply ADDITI...

Page 20: ...quirements Each module is fitted with safety valve rated at 6bar The valve discharge pipe is routed to the rear of the boiler where it must be piped to discharge via a tundish not HHL supply suitably...

Page 21: ...ificates should be available for viewing 6 2 Ventilation Ensure that ventilation and air supply to plant room is correct 6 3 Pipe work Valves and Pump Ensure that System flushing and suitable water tr...

Page 22: ...d with a single speed circulating pump and flow is controlled through a balancing valve which must be checked and set during commissioning As a safety precaution a flow switch is fitted to the boiler...

Page 23: ...nd a dynamic reading The dynamic reading cannot be taken until the boiler has been started refer to 7 4 A maximum difference in gas pressure of 1 mbar must not be exceeded between static and dynamic c...

Page 24: ...lose the gas valve The boiler should shutdown after approximately one second and attempt a re ignition Check that the flame has been extinguished 2 Alternatively the flame probe lead can be removed fr...

Page 25: ...0V F50V F60V F70V Models F85V F100V F125V F150V 4 If combustion is outside of the ranges defined below the factory sealed valves may be adjusted using the following procedure High Fire Target Nat Gas...

Page 26: ...e relevant boiler settings specific to the installation 7 7 Setting the flow rate to achieve 20 C T Before commissioning is complete the flow rate must be checked and adjusted A ball valve is located...

Page 27: ...vision active too little flow through boiler 7 7 User Instructions When the boiler is fully commissioned the owner or their representative should be made aware of the lighting up and operating instruc...

Page 28: ...rheat Thermostat HT Spark Generator Combustion Fan Air Pressure Switch Fuse Water Flow Switch 230v Mains Supply IEC Mains Outlet Socket LMU Control Clip in Module Vfc 0 10v Display Screen On Off switc...

Page 29: ...refer to figure 8 2 1 1 A change on the information level can be made at any time by pressing the Info button Additional pushes of the Info button will deliver the following data sequence provided by...

Page 30: ...M C 4 RelModLevel Relative output C 5 Pumpe_PWM Pump setpoint PWM Not used C 6 ek0 Control differential C 7 C8 C9 Reserved Setpoints Service level d 0 Reserved d 1 Tsoll Setpoint of 2 position or modu...

Page 31: ...HAMWORTHY HEATING LTD 25 FLEET V series 500001213 G Figure 8 2 1 3 Operation and display philosophy...

Page 32: ...g of symbols Display of dhw temperature or dhw heating active not used Display of boiler or room temp set point or space heating active Display of outside temperature Operational level Normal Operatio...

Page 33: ...t display If no button is pressed for about 8 minutes the screen will automatically return to the default display Figure 8 2 3 2 Display of Status Code When a status code is displayed the display 1 sh...

Page 34: ...2 4 Display of lockout code 304 7494z35 0202 8 2 5 Adjusting the heating circuit setpoint temperature Press the flow temperature button to adjust the heating circuit setpoint Press to adjust the requi...

Page 35: ...14 Time program HC1 switch off time 2nd period 00 00 24 00 hh mm 10 min 24 00 15 Time program HC1 switch on time 3rd period 00 00 24 00 hh mm 10 min 24 00 16 Time program HC1 switch off time 3rd peri...

Page 36: ...Heating circuit operating modes The control provides 4 different heating circuit operating modes for LMU heating circuit 1 They can be directly selected depending on the requirements see figure 8 2 9...

Page 37: ...the return sensor provide overheat protection as follows If the first level temperature is exceeded a fault code is displayed If the second level temperature is exceeded an alarm code is displayed an...

Page 38: ...the boiler to cool and reset thermostat Investigate cause of overheating see section 9 3 113 Flue gas supervision equipment has cut out 117 Water pressure too high 118 Water pressure too low 119 Wate...

Page 39: ...temperature required to raise the maximum operating temperature possible from the individual boiler modules As standard the boiler modules leave the factory with a maximum operating temperature of 85...

Page 40: ...HAMWORTHY HEATING LTD 34 FLEET V series 500001213 G Figure 8 3 11 Operating phases...

Page 41: ..._TSA1_2 PH_TSA2_2 10 Heating operation PH_TI PH_MODULATION Heating mode 11 DHW operation PH_TI PH_MODULATION DHW mode 12 Parallel operation of space heating and DHW heating PH_TI PH_MODULATION Heating...

Page 42: ...r overheating The most common cause of overheating is lack of water flow rate through the boiler possibly caused by a faulty pump or blockage in the heat exchanger circuit due to system debris Figure...

Page 43: ...A DISPLAY KEYPAD MODULE FLAME IONISATION PROBE 2 1 1 3 230V 0V HT 1 2 1 3 C 1 2 HT ELECTRODE GAS VALVE SPARK GENERATOR SAFETY LIMIT THERMOSTAT 2 3 L N N L 3 2 1 1 DC FAN PUMP 2 3 3 2 1 1 BLUE BROWN BL...

Page 44: ...he 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 bur...

Page 45: ...HAMWORTHY HEATING LTD 39 FLEET V series 500001213 G Figure 10 2 Combustion Chamber A A B B Figure 10 2 1 Spark Electrode position Figure 10 2 2 Flame Probe position...

Page 46: ...nce of the sensor against Figure B 1 3 In refitting the sensor a sealant will be required on the threads Check for water soundness before firing the boiler 11 3 Flue Gas sensor Part no 533901549 The f...

Page 47: ...models reassemble in reverse order using new gaskets and check all joints for gas soundness 11 8 Main control pcb LMU refer to spares list The LMU is located on the electrical control panel which is...

Page 48: ...ntrol 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 Com...

Page 49: ...iler Output kW maximum non condensing 80 60 C kW 108 2 162 3 126 4 189 6 Boiler Output minimum 80 60 C kW 10 8 10 8 12 6 12 6 GAS DATA per boiler module F40V F50V F60V F70V Gas Inlet Connection Pipe T...

Page 50: ...only serve the boiler 4 Multiple modules It is highly recommended that each boiler is connected via its own mains isolator to facilitate servicing and maintenance of the individual boiler whilst leav...

Page 51: ...21 22 21 22 21 22 15 16 15 16 15 16 External Control Optional External Control Boiler 1 Terminal Rail Boiler 2 Terminal Rail Boiler 3 Terminal Rail 0 10V 0 10V 0 10V Control Signal 0 10V or Enable Not...

Page 52: ...4 145 0 206 10 0 55047 70 0 1753 150 0 183 5 0 42158 75 0 1481 155 0 163 0 0 32555 80 0 1256 160 0 145 5 0 25339 85 0 1070 165 0 130 10 0 19873 90 0 915 170 0 117 15 0 15699 95 0 786 175 0 105 20 0 12...

Page 53: ...al section should have a maximum slope of 3 upwards in the direction of the exhaust gas flow All joints should be such that any condensation is directed back down the slope to an open drain connection...

Page 54: ...exposed position and be so situated as to prevent the products of combustion entering any opening in a building Where the flue diameter is less than 204mm 8 diameter a terminal must be fitted Where t...

Page 55: ...ing 150 532511174 200 532511175 Pitched roof flashing 150 universal 25 45 532511178 200 23 27 532511179 200 33 47 532511180 200 48 52 532511181 Fixing brackets 150 532511033 200 532511186 Figure C6 2...

Page 56: ...on in the event of ventilation fan failure 2 Mechanical inlet and mechanical extract can be utilised providing the design extraction rate does not exceed one third of the design inlet rate 3 Mechanica...

Page 57: ...ry circuits to be connected to the header Figure E1 1 1 on the following page show typical layouts 5 Ideally individual valves should be fitted to each module to enable isolation from the system howev...

Page 58: ...w the boiler is fitted with an integral flow switch Particular attention should be paid to the restriction of external flow circuits during periods of low heat demand Each boiler module is fitted with...

Page 59: ...ble valve check Expansion Air Vent Automatic Valve Drain valve valve Drain Boiler Output Feed mm Vent mm 60 150kW 25 32 150 300 kW 32 38 300 600 kW 38 50 601 KW 50 65 Figure E1 4 Cold Feed and Vent Pi...

Page 60: ...ral pump performance curves 0 1 1 2 2 3 3 4 5 Q m h 3 Model F 40W F 50W F 60W F 70W Model F 85W F 100W F 125W Model F 150W 0 4 1 0 0 2 0 3 0 4 0 5 0 6 0 1 2 2 0 2 8 3 6 4 4 Head m Head m Head m 6 0 6...

Page 61: ...triple circuit low loss header Non HHL supplied single circuit low loss header Non HHL supplied plate heat exchanger separated system AAV Drain Dosing Pot Note secondary circuit components are not su...

Page 62: ...hold both up and down arrow keys for at least five seconds to enter advanced parameter list H90 displayed top right of HMI screen Use either up or down arrow key to scroll through the parameter list...

Page 63: ...HAMWORTHY HEATING LTD 57 FLEET V series 500001213 G NOTES...

Page 64: ...HAMWORTHY HEATING LTD 58 FLEET V series 500001213 G INSTALLER SITE ADDRESS BOILER TYPE BOILER SIZE S UNIT NO S SERIAL NO S FLUE USEFUL USER INFORMATION...

Page 65: ...Please complete the information on the Registration Card cut out and return to Hamworthy Heating Ltd...

Page 66: ......

Page 67: ......

Page 68: ...0 fax 0151 647 8101 Southern Ireland Sales Service HEVAC Limited Naas Road Dublin 12 Ireland tel 00 353 141 91919 fax 00 353 145 84806 Northern Ireland Sales Service HVAC Supplies Limited Unit A6 Darg...

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