HAMWORTHY HEATING LTD
30
UPTON FLOOR STANDING SERIES
500001340/C
10 SERVICING
A Gas Safe Engineer 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 Upton 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)
Remove the front cover. Once removed access is
gained to the controls panel, the heat exchanger
components and the combustion system assembly.
2)
Carefully disengage the air filter from the venturi and
remove the electrical plugs from the gas valve.
3)
Disconnect the fan power supply and control leads
from the fan taking care with the latch on each connector.
4)
Disconnect the H.T and flame probe connectors from
the respective probes.
5)
Check that the gas service valve is closed, then undo
the flange on the inlet to the gas valve.
6)
Remove the 3 M8 socket head screws securing the
fan /burner duct assembly to the heat exchanger and
carefully remove the assembly.
7)
Remove and inspect H.T. electrode and flame probe,
ensure they are free from debris or deposits. – See
Figures 10.2.1 & 10.2.2
8)
Remove the burner from the burner duct, check 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)
Separate the gas valve / gas valve manifold / venturi
from the fan inlet noting it’s orientation and inspect the fan
scroll and impellor, clean and check for damage.
10)
Clean and check the venturi for contamination.
11)
Remove the fan from the burner duct and inspect the
non return valve in the duct for smooth operation.
12)
Check that the mesh inlet filter in the gas valve is
clear of debris, remove any foreign objects caught in the
filter.
13)
Check and clean air filter. Filter can be washed in
clean water.
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.
Isolate the boiler flow and return connections from the
heating system.
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. At the rear
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 front of
the heat exchanger. Disconnect the electrical supply to
the flow and return sensors, flow switch, spark generator,
pressure transducer and limit thermostat. Disconnect the
flexible gas pipe union and the insulation plates bolted to
the front of the heat exchanger.
Remove the 6 M8 screws securing the flow and return
pipes on the back of the heat exchanger.
Remove the 4 M8 screws securing the heat exchanger
assembly to the chassis back plate.
Remove the 6 M6 screws securing the flue elbow to the
sump. The heat exchanger can now be removed from
the casing. With the heat exchanger removed from the
appliance, remove the plastic sump from the heat
exchanger sealing plate and withdraw the sump away
from the sealing plate.
The heat exchanger fin matrix is now accessible and the
flue ways can be cleaned using a a high pressure water
hose.
When clean, re
-
assemble in reverse order using new
seals /gaskets where appropriate.
Open the isolating valve and test all joints broken or
disturbed for water soundness.
Re
-
fit the burner assembly.
Test all gas joints broken
or disturbed for soundness before firing
.
Refer to
Section 8 Commissioning The Boiler
.
