Commissioning; Pre-Commissioning Checks; Filling The System; Water Treatment - Worcester GREENSTAR 24 Installation, Commissioning And Servicing Instructions

Commissioning

6 COMMISSIONING
6.1

PRE-COMMISSIONING CHECKS

CAUTION: Isolate the mains electricity supply before
starting any work and observe all relevant safety
precautions.
Check that the service and water pipes are connected to the correct
positions 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, refer to Fig.
26.
1. CH flow (22mm)
2. DHW (15mm)
3. Gas inlet - bonded washer (22mm)
4. Domestic Cold Water in (15mm)
5. CH return (22mm)
▶ Check the gas type specified on the data label, on the right hand side
of the combustion chamber, matches that of the gas supply.
▶ Turn on the main gas supply, carry out a tightness test on the gas pipe
work with the boiler gas isolating pipe valve open, and connections.
Rectify any leaks.
▶ Check that the condensate pipe has been connected and correctly
fitted to the condensate trap.
▶ Check pressure relief drain pipe is correctly fitted and securely
tightened.
NOTICE: If the boiler 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 bar then close
the filling loop valve(s).
▶ The Automatic Air Vent will release any air trapped in the boiler.
▶ Manually vent all radiators, tighten when completed and check the
system and correct any leaks.
▶ The boiler integral expansion vessel is pre-charged to 0.75 bar
(equal to a static head of 7.5m (22ft)). 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.
28
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 3.1 OF THESE INSTRUCTIONS.
FLUSHING (Central Heating)
▶ Ensure the boiler is switched off.
▶ Open all drain cocks and drain the system while the boiler 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 boiler/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 guarantee 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 on the
guarantee card and Benchmark checklist.
NOTICE:
▶ The concentration of inhibitor in the system should
be checked every 12 months or sooner if system
content is lost.
WATER TREATMENT
Suitable water treatment products can be obtained from the following
manufacturers:
FERNOX 01799 550811
www.fernox.com
SENTINEL 0800 389 4670
www.sentinel-solutions.net
Table 18
6 720 811 922 (2014/07)