Safety Checks - IDEAL SUPER PLUS 200/S Installation And Servicing

CONTROL LINE GAS SOUNDNESS
Refer to Figs. 1, 4 & 19
Carry out the following tests on each module in turn.
Turn on the module gas service cock, and turn off the pilot gas cock.
Turn off the main inlet gas cock and observe the manometer
pressure as above (at PTP No. 1 ).
To test the second main gas valve, remove the screw from the
pressure test point at the outlet side of the first main gas valve
(PTP 2) and connect a manometer via a 'T' piece, to the pressure
test point at the gas header (PTP 1).
Close the main gas inlet cock and observe the manometer.
Any leakage from joints in the line or past the appropriate gas valve
seats must be investigated and curved.
PREFIRING CHECK
Refer to Figs. 3 & 4
Ensure that the electrical supply to the boiler is off.
EXTREME CARE SHOULD BE TAKEN WHEN THE MODULE IS
RUN WITHOUT A COVER.
Modules not being checked should have their multipin plug
removed.
Each individual module should be checked as follows:
1. Turn the module gas service cock to OFF.
2. Plug in the module multipin electrical plug.
3. Switch ON the electricity supply to the boiler:
The following sequence of events will occur:-
(a) The module mains ON light will illuminate.
(b) The fan will start and run for approximately 70 seconds.
(part of the 5-volume air change safety feature). Then either
the fan will continue to run for approximately 35 seconds
or the fan will stop for up to 35 seconds depending on the
module's position in the switching sequence then restart
and run for approximately 35 seconds.
(c) The ignition spark commences, continues for 4 seconds then
ceases. (The spark can be seen through the sightglass in
the module front).
(d) At the end of the 4-second ignition period, the lockout light
will be illuminated. The mains on light will remain illuminated
and the fan will continue to run.
4. Turn off the electrical supply to the boiler. The lights will
extinguish and the fan will stop.
FAN PERFORMANCE CHECKS
Connect a manometer to measure the pressure difference between
the fan housing and the venturi casting.
The pressure tapping should be connected to the rear pressure
test point on the pressure switch and the suction tapping to the
front pressure test point on the pressure switch, (See Figs 2 & 4).
If, when the fan is operated as above, the manometer reading is
less than 5.5 mb then the commissioning cannot proceed.
If the pressure is low, check that the fan impeller blades are clean
and free to rotate and that the venturi casting and burner are free
from obstructions. (Refer to 'Servicing' for details of dismantling).
Check also to see if the flue is unobstructed. Do NOT attempt to
adjust the pressure switch, which is factory set.
FIRING CHECKS
Refer to Figs. 1, 3 & 4
Note: (i) The minimum gas pressure in the gas header should
be as indicated in Table 1, with all modules firing. The
maximum pressure should not exceed 25 mbar (10
in.w.g.).
Super Plus -
Installation and Servicing
INSTALLATION
(ii) The draught stabiliser should be set to control between
neutral and 0.2 mbar (0.08 in.w.g.) draught in the
casing, with one or all modules firing. A test point is
provided in the boiler casing adjacent to the flue outlet
socket.
Carry out the following firing checks on each individual module,
commencing with the top left module and finishing with the bottom
right. Ensure that the boiler is full of water and that the main and
any shunt pumps are running. Modules not being checked should
have their multipin plugs removed.
Switch on the electrical supply to the boiler. Wait for 15 seconds
and then press in and release the lockout reset button.
The mains on light will be illuminated.
The fan will start and run for approximately 70 seconds ( part of
the 5-volume air change safety feature). Then depending on the
modules position in the switching sequence, either the fan will
continue to run for approximately a further 35 seconds or the fan will
stop for up to 35 seconds and then restart and run for approximately
a further 35 seconds.
Switch on the electricity supply to the boiler. The ignition cycle
will recommence. After the pilot gas flame has been lit, the main
gas valves will open and the main burner will ignite. The pressure
should be 2.7 mbar; should adjustment be necessary then remove
the screw cap on the main gas governor and screw the adjustment
screw clockwise to increase, and anticlockwise to decrease the
pressure. Switch the electricity supply to off and then on again to
check the pressure settings.
On completion of adjustment replace all pressure tapping screws
and the governor screw caps. Carry out the prefiring checks on
all other modules.
SAFETY CHECKS TO BE CARRIED OUT ON
ALL MODULES
Note: Pull out the multipin electrical plug from all modules not
being tested.
1. Ensuring Lockout
With the module running, turn off the module gas service
cock.
The burner will stop firing and the BURNER ON light will be
extinguished with the LOCKOUT light being illuminated.
2. Combustion
Fire each module on its own, blanking off the fan air inlets
of ALL the NON-FIRING modules, using the sheets of self-
adhesive paper supplied with these Instructions.
Measure the CO and CO
sampling point is provided in the top of the boiler casing,
adjacent to the flue outlet socket (Fig.1).
For DRAEGER Tests note the following:
(a) The sampling line, however short, should ALWAYS be
purged.
(b) C0
2
ONLY is required (CO
indicating parts per million (P.P.M)).
(c) The ratio CO/CO
convenient reference Table 3 shows maximum p.p.m.
CO levels in p.p.m (read direct from tube) related to
various C0
the dilutions due to casing and flue volume on the larger
boilers.
Remove the fan inlet blanking material from all modules and
fire all modules together.
Measure the gas pressure at the gas header test point (PTP
No.1, Fig.17) and ensure that it is not less than that indicated
in Table 1.
content for each module - a
2
tubes are marked in percent divisions and one pump
tubes are also marked in divisions
2
should not exceed 0.001. For
2
levels. Low CO levels are included to cover
2
17