Hamworthy F100W, Installation, Commissioning And Operating Instructions

HAMWORTHY HEATING LTD 

44 

FLEET W series 

500001211/F 

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 examination following 
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

2

 and gas temperatures 

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 

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

2

 and CO levels as detailed in 

Section 8.2.

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 *