Hamworthy F100H, Installation, Commissioning And Operating Instructions

Page 1: ...lers for Heating Domestic Hot Water Installations Installation Commissioning and Operating Instructions Models F40H F50H F60H F70H F85H F100H F125H F150H NATURAL GAS I2H IMPORTANT NOTE THESE INSTRUCTI...

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Page 3: ...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 EUROPEAN DIR...

Page 4: ...0 BOILER ASSEMBLY 18 5 1 General 5 2 Water Connections 5 3 Flue Connections 5 4 Electrical Connections 6 0 PRE COMMISSIONING 19 6 1 Gas Supply 6 2 Ventilation 6 3 Pipework Valves and Pump 6 4 Flue 6...

Page 5: ...e 4 6 Wiring schematic 17 Figure 7 1 Gas system leak check 20 Figure 7 2 2 Gas inlet pressure test point 21 Figure 7 2 1 On OFF Switch 22 Figure 7 6 Combustion analyser probe position 22 Figure 7 6 1...

Page 6: ...m sealed C33 concentric flue equivalent lengths 56 Figure C3 2 Room sealed twin duct vertical flue 56 Figure C3 2 1 Room sealed C33 twin duct equivalent lengths 56 Figure C4 1 Open flue B23 horizontal...

Page 7: ...ended for the heating of Commercial and Industrial premises or large residential properties It may also be used to supply hot water for these premises via an indirect cylinder 1 3 4 The Fleet has a lo...

Page 8: ...is packaged separately The boiler must be kept upright during handling The flue system is supplied separately to the boiler and must be specified at the point of order refer to Appendix C Warranty Fu...

Page 9: ...s a detailed description of the missing item Frame Set and Pipe work Header Kits Where pipe work kits are supplied these are packaged separately from the boilers All ancillary items such as isolation...

Page 10: ...hich is located above the boiler casing If this kit is not being utilised the height of the connection can be reduced 750 crs 950 min clearance 700 450 700 B A 50 8 30 1 57 0 74 crs 6 50 36 3 51 4 7 1...

Page 11: ...thy H series pipe work kit This can be reduced if the pipe work is behind the boiler Figure 3 1 3 Clearances for vertical flues Note relates to the use of the Hamworthy H series pipe work kit This can...

Page 12: ...ers to the gas supply and flow and return water connections The kit locates the pipe work above the boiler casing Refer to kit instructions 500005133 for specific information 1550 1500 120 Flow Models...

Page 13: ...ndary circuits Secondary Flow Primary Flow Pockets for temperature sensors 2 Primary Return Secondary Return 507 AAV 380 380 180 Nom 190 Nom Secondary Flows Secondary Returns 507 1430 Nom 1240 Nom 105...

Page 14: ...HAMWORTHY HEATING LTD 8 FLEET H series 500001212 F Figure 3 2 5 Four boilers Figure 3 2 4 Three boilers 2300 2250 120 3050 3000 120...

Page 15: ...tallation 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 accordance with BS 6891 or IGE UP 2 Gas supply...

Page 16: ...he vertical chimney Due to the low flue gas temperature 50 C condensation will occur in the flue flue materials must be non corrosive and utilise fully sealing joints Adequate facilities must be provi...

Page 17: ...Above an opening air brick opening window etc 300 C Horizontally to an opening air brick opening window etc 300 D Below gutters soil pipes or drain pipes 75 E Below eaves 200 F Below balconies or car...

Page 18: ...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 19: ...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 20: ...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 21: ...ly 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 r...

Page 22: ...F Figure 4 5 2 Flue Condensate Connection and discharge Concentric inline drain trap Single pipe inline drain trap Tundish to drain Horizontal Concentric Flue System Vertical Concentric Flue System C...

Page 23: ...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 24: ...or ease of visibility The Fleet is designed to operate at 20 C T across the flow and return Should the flow rate drop the boiler controls will modulate the burner to maintain 20 C T The boiler module...

Page 25: ...encer control 6 0 PRE COMMISSIONING The following pre commissioning check must be carried out before the boiler is commissioned 6 1 Gas Supply Ensure that gas installation pipe work and meter has been...

Page 26: ...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 heat e...

Page 27: ...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 28: ...e 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 from the...

Page 29: ...0W F50W F60W F70W Models F85W F100W F125W F150W 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 30: ...ntrols the flow through the boiler Using the boiler flow and return temperature sensors visi ble on the display via the LMU programme This MUST be carried out with the boiler running at maximum firing...

Page 31: ...ion active too little flow through boiler 7 8 User Instructions When the boiler is fully commissioned the owner or their representative should be made aware of the lighting up and operating instructio...

Page 32: ...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 33: ...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 34: ...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 35: ...HAMWORTHY HEATING LTD 29 FLEET H series 500001212 F Figure 8 2 1 3 Operation and display philosophy...

Page 36: ...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 37: ...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 38: ...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 39: ...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 40: ...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 41: ...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 42: ...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 43: ...ure 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 C Where...

Page 44: ...HAMWORTHY HEATING LTD 38 FLEET H series 500001212 F Figure 8 3 11 Operating phases...

Page 45: ..._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 46: ...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 9 2 Water Flo...

Page 47: ...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 48: ...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 49: ...HAMWORTHY HEATING LTD 43 FLEET H series 500001212 F Figure 10 2 Combustion Chamber A A B B Figure 10 2 1 Spark Electrode position Figure 10 2 2 Flame Probe position...

Page 50: ...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 51: ...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 52: ...ntrol Valve F40H F70H 533903040 Gas Control Valve O ring F40H F70H 531299051 Gas Control Valve F85H F150H 533903044 Gas Control Valve O ring F85H F150H 742111245 Combustion Fan F40H F70H 533901376 Com...

Page 53: ...Gas mbar 12 5 Gas Flow Rate max per module Nat Gas m3 h 3 9 4 8 5 8 6 8 Target CO2 at High Low fire Nat Gas 0 25 9 0 Figure A1 Gas data GENERAL DATA BOILER MODEL F40H F50H F60H F70H Boiler Input maxi...

Page 54: ...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 55: ...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 56: ...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 57: ...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 in the flue The drain pipe must be manufa...

Page 58: ...e given to the fitting of a flue discharge terminal or grille to stop ingress of birds etc C1 7 Surface Temperatures Combustible materials in the vicinity of the boiler and flue shall not exceed 65 C...

Page 59: ...HL Part no 562511077 Model Flue size Equivalent lengths m Max L 45 90 cond Drain 40 100 150 59 0 5 0 75 0 5 50 100 150 39 0 5 0 75 0 5 60 100 150 29 0 75 1 0 5 70 100 150 19 0 75 1 0 5 85 100 150 14 0...

Page 60: ...1 Room sealed concentric C33 vertical flue system Figure C1 2 Room sealed concentric C13 horizontal flue system 1200 min 580 min 80 125 930 min 100 150 1350 80 125 1730 100 150 30mm m fall to boiler...

Page 61: ...0 5 50 100 150 39 0 5 0 75 0 5 60 100 150 29 0 75 1 0 5 70 100 150 19 0 75 1 0 5 85 100 150 14 0 75 1 0 5 100 100 150 9 1 1 5 0 75 125 100 150 6 1 1 5 0 75 150 100 150 3 1 1 5 0 75 Figure C2 1 1 Indi...

Page 62: ...t no 562511066 Op ons 100 87 Elbow 532511115 100 45 Elbow 532511114 100 1m 532511130 100 2m 532511131 Model Flue size Equivalent lengths m Max L 45 90 cond Drain 40 100 99 0 5 0 75 0 5 50 100 49 0 5 0...

Page 63: ...85 100 19 1 1 5 0 5 100 100 14 1 5 2 0 75 125 100 9 1 5 3 0 75 150 100 5 1 5 3 0 75 Figure C4 1 1 Individual Flue equivalent lengths refer to fig C4 1 Extended Horizontal flue kit 100 twin duct HHL Pa...

Page 64: ...traight 532511131 Figure C5 1 1 Cascade Flue equivalent lengths refer to fig C5 1 C5 2 Flue Header Flue Header Equivalent lengths m Load kW Size mm Max L 45 90 80 200 100 3 4 100 200 100 3 4 150 200 1...

Page 65: ...tric Flue Cuttable extension pieces When cutting a concentric flue extension piece care must be taken to ensure that the inner sec tion is always cut 10mm longer than the outer section to allow sectio...

Page 66: ...entilation is required which must communicate direct to outside for cooling purposes Low level inlet 10cm per kW of total rated input Net High level output 5cm per kW of total rated input Net D1 2 2 A...

Page 67: ...iler house shall be as follows At floor level or 100mm above floor level 25 C At mid level 1 5m above floor level 32 C At ceiling level or 100mm below ceiling level 40 C D 1 5 General Requirements The...

Page 68: ...le secondary 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 sy...

Page 69: ...f poor or no flow 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 modul...

Page 70: ...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 Pipe Sizes further information and t...

Page 71: ...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 72: ...uits Typical layout for primary circuit with low loss header Typical layout for primary circuit with plate heat exchanger separation of secondary circuits AAV AAV AAV AAV Drain Drain Drain Drain Drain...

Page 73: ...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 a...

Page 74: ...2 F Option 2 for use with the QAA73 programmable room unit 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...

Page 75: ...HAMWORTHY HEATING LTD 69 FLEET H series 500001212 F NOTES...

Page 76: ...HAMWORTHY HEATING LTD 70 FLEET H series 500001212 F INSTALLER SITE ADDRESS BOILER TYPE BOILER SIZE S UNIT NO S SERIAL NO S FLUE USEFUL USER INFORMATION...

Page 77: ...Please complete the information on the Registration Card cut out and return to Hamworthy Heating Ltd...

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Page 80: ...1030 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 D...