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Commissioning
6
Commissioning
6.1
Pre-Commissioning checks
DANGER: Danger to life through electric shock!
▶ Before carrying out any work on electrical
components, isolate them from the power supply
(230 V AC) (fuse, circuit breaker) and secure against
unintentional reconnection.
Check that the service and water pipes are connected to the correct
position on the manifold.
Ensure that the washers have been fitted to the water connections and
the bonded washer to the gas connection on the manifold, ( figure 26,
page 30).
1. - CH Flow (22mm)
2. - DHW (15mm)
3. - Gas inlet (22mm)
4. - Domestic cold mains water in (15mm)
5. - CH Return (22mm)
▶ Check the gas type specified on the identification plate, on the inside
of the combustion chamber, matches that of the gas supply.
▶ Turn on the main gas supply, check the gas pipe work, connections
and rectify any leaks.
▶ Check that the discharge hose has been connected to the siphon and
condensate outlet pipe.
▶ Check pressure relief drain pipe is correctly fitted and secure.
NOTICE: If the appliance is not to be commissioned
immediately then, after successfully completing all of
the checks and any rectification work:
▶ Close the gas valve
▶ Close the water shut off valve
▶ Isolate the gas supply
▶ Isolate the electricity supply
▶ Label appropriately
6.2
Filling the system
▶ Turn on the water main and open the system valves.
▶ Open all radiator valves.
▶ Fill the system via a WRAS approved filling loop to 1 and 1.5 bar then
close the filling loop valve(s).
▶ The Automatic Air Vent will release any air trapped in the appliance.
▶ Manually vent all radiators, tighten when completed and check the
system and correct any leaks.
▶ The appliance integral expansion vessel is pre-charged to 0.75 bar
(equal to a static head of 7.5m (24.6ft)). A Schraeder type valve is
fitted to the expansion vessel to allow for pressure adjustment if
required.
▶ If an extra expansion vessel is fitted to the central heating return,
adjust this to the same pressure as the appliance internal expansion
vessel, refer to separate instructions with the extra expansion vessel.
▶ If required increase system pressure back to 1 bar.
▶ Isolate and remove filling loop connection to system.
36
6.3
Water treatment
NOTICE:
▶ Artificially softened water must not be used to fill the
central heating system.
Ensure that the system has been cleaned. Refer to section 4.1 of
these instructions.
Flushing (Central Heating)
▶ Ensure the appliance is switched off.
▶ Open all drain cocks and drain the system while the appliance is hot.
▶ Close drain cocks and add a suitable flushing agent at the correct
strength for the system condition in accordance with the
manufacturer's instructions.
▶ Run the appliance/system at normal operating temperature for the
time stated by the manufacturer of the flushing agent.
▶ Drain and thoroughly flush the system to remove the flushing agent
and debris.
Inhibitor (Central Heating)
▶ Check drain cocks are closed and all radiator valves are open before
adding a suitable inhibitor compatible with aluminium (or combined
inhibitor/anti-freeze if the system is exposed to freezing conditions)
to the heating system water in accordance with the manufacturers
instructions.
The pH value of the system water must be less than 8 or
the appliance warranty will be invalidated.
▶ Fill system via a WRAS approved filling loop to between 1 and 1.5
bar.
▶ Vent all radiators; tighten vents when complete.
▶ Re-pressurise if necessary to 1bar.
▶ Set all controls to maximum.
▶ Record the date when the inhibitor was added to the system in the
Benchmark checklist.
NOTICE:
▶ The concentration of inhibitor in the system should
be checked every 12 months or sooner if system
content is lost.
▶ The addition of sealing agents to the system water is
not recommended as this can cause problems with
deposits left in the heat exchanger.
▶ In cases where all attempts to find a micro leak have
failed, Worcester, Bosch Group supports the use of
Fernox F4 leak sealer.
Water treatment products
Suitable water treatment products can be obtain from the following
manufacturers:
FERNOX
0870 601 5000 or www.fernox.com
SENTINEL
0800 389 4670 or www.sentinel-solutions.net
Table 29
Greenstar i System
- 6 720 806 945 (2015/07)
ErP
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