Commissioning; Pre-Commissioning Checks; Filling The System - Worcester Greenstar Highflow 440CDi ERP Installation, Commissioning And Servicing Instructions

COMMISSIONING

5 COMMISSIONING
5.1

Pre-commissioning checks

CAUTION: ISOLATE THE MAINS ELECTRICITY SUPPLY
▶ Ensure that the electricity supply is safely Isolated
and secured to prevent inadvertent re-connection.
Information on safe isolation can be found in the
Health and Safety Executive guidance HSG85.
Using test equipment approved to GS38 confirm that
the electricity supply is disconnected
▶ Check that the service and water pipes [1] are connected to the
correct valve on the manifold;
A - CH flow (22mm)
B - DHW flow (22mm)
C - Gas inlet (22mm)
D - Mains water inlet (22mm)
E - CH return (22mm)
▶ Check the gas type specified on the identification plate matches that
of the gas supply.
▶ Turn on the main gas supply [2], check the gas pipe work,
connections and rectify any leaks.
▶ Check the flue [3] is correctly fitted and the connections are secure.
▶ Check the condensate pipe work [4] is correctly fitted and
connected.
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
A B C D E
1
Fig. 31 Pre-commissioning checks
26
5.2

Filling the system

▶ Pull the upper edges of the front panel towards you and lift off the
bottom lugs.
▶ Turn on the water main and open the system valves (align slot
vertically).
▶ Open all radiator valves.
▶ Unscrew the tank drain cap [1] from the Tank drain valve [7].
▶ Connect the integral filling loop from the Flow valve [5] using the
hose [4] to the Tank drain valve [7].
▶ Open the flow valve [5] and tank drain valve [7].
▶ Fill the system to a pressure up to 1.5 bar.
▶ Close the flow valve.
▶ Close the tank drain valve.
▶ Disconnect the integral filling loop.
▶ Refit tank drain cap.
▶ The Automatic Air Vent will release any air trapped in the boiler.
▶ Vent all radiators, retighten the vent when completed.
▶ Check the system and correct any leaks.
3
3
4
4
Fig. 32 Internal filling loop
The boiler integral expansion vessel is pre-charged to 0.75bar (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.
2
If an additional expansion vessel is fitted to the central heating return,
adjust this to the same pressure as the appliance internal expansion
vessel, refer to the instructions with the additional expansion vessel for
pressurising.
1.5 bar
P
2
1 bar
1 1
Min
0 bar
3
6
4
1
5
2
ErP - 6720818077 (2016/04)
Greenstar Highflow CDi
Max
3
4
5
7