Commissioning The Appliance - Worcester DANESMOOR 15/19 Installation And Servicing Instructions

12. Commissioning the Appliance

Ensure that no foreign matter is left in the system as this could
cause damage to the appliance.
12.1 Check that the electrical supply to the appliance is
switched off.
12.2 When commissioning the appliance after initial installation
follow the procedure from 12.3, otherwise remove the burner
first as described in Section 14.3.
12.3 Prepare the heating system
1. After initial installation and checking for leaks, as previously
described, drain down the system sufficiently to add a flushing
agent. Flush the system in accordance with BS 7593:1992.
2. Refill the system.
12.4 Check the Burner
1. Check that the nozzle and electrode settings are correct for
the relevant burner. (See Figs. 21, 22, 23 and 24).
2. Check that the nozzle lies central with the combustion head hole.
3. Check for any visible defects.
12.5 Replace the burner
1. Connect the flexible oil supply hose to the isolating valve
bulkhead fitting and tighten sufficiently to form a good seal.
Where a double pipe system is being used refer to Fig. 9, and
connect the oil return flexible hose to the return pipe fitting.
2. With the sponge O-ring gasket around the burner blast tube
insert the burner into the housing tube. Push the burner firmly
forward to compress the gasket and tighten the two locking
screws using a 5mm Allen key.
Note: It is important that a good seal is made between the
burner and the boiler to prevent re-circulation of the flue gases
from the combustion chamber to the burner inlet, or the room in
the case of a CF/LLD appliance.
3. On the RS balanced flue model, feed the electrical lead back
through the hole in the burner surround housing and fit the
grommet into the hole ensuring a seal is made.
4. Re-connect the electrical lead plug into the control box.
12.6 Check the installation
1. Check that the appliance is correctly wired as described in
Section 10.
2. Check that all baffles are correctly located and the heatshield
is correctly mounted (20/25, 26/32, 32/50 and 50/70 models)
as shown in Fig. 25.
3. Check that the baffle retainer is correctly mounted (20/25
and 26/32, 32/50 and 50/70 models) as shown in Fig. 25c. and 25d.
4. On the 32/50 and 50/70 remove and discard the transit baffle
retainer.
5. Ensure that the cap is firmly seated inposition and check the
cap retainer is correctly mounted (32/50 and 50/70 only) as
shown in Fig. 25d and 26.
6. Check that the control thermostat and auto reset high limit
thermostat phials are correctly located in the boiler thermostat
pocket positioned in the top front of the boiler.
7. Check that the manual reset limit thermostat is located in the
steel pocket above the electrical box mounting bracket on the
front face of the boiler.
8. Check that all of the air-ways to the burner are clear of any
obstruction.
12.7 Fit a pressure gauge and manifold to the burner pump at
the point indicated in Fig. 9, or the pressure gauge port shown in
Fig. 22 on the 20/25.
12.8 Turn on the electricity to the appliance.
12.9 Bleed the burner
Single pipe systems only
Release the fuel bleed port on the manifold and place a suitable
receptacle beneath. Turn on the boiler thermostat. Set the
programmer to heating and hot water and allow the burner to
run through to lockout. Wait two minutes and reset the burner
control box. Repeat the procedure at least three times or until a
steady stream of oil, without air, is exhausted from the bleed
port. Re-lock the bleed port.
Two Pipe System
A two pipe system will automatically vent the air back to the oil
tank. Turn on the boiler thermostat and allow the burner to run
through to lockout. Wait two minutes and reset the burner con-
trol box. Repeat the procedure untill the burner fires and runs in
a steady state. This may take several attempts depending on the
oil pipe length and height.
12.10 Adjust the air shutter and pump pressure to the settings
recommended in Tables 2 to 9. After a pre-ignition period of
approximately 15 seconds the burner should ignite. Flame
sensing is carried out by means of a photocell mounted in the
burner body. Should the boiler fail to establish a normal firing
pattern (or should flame failure occur during running), the
absence of a flame is sensed and the control box is monitored to
a safe lockout condition and the boiler is shut down. The lockout
indicator light in the boiler control panel will illuminate
indicating that the burner has gone to lockout. In this instance
wait two minutes and press the red lockout reset button
mounted in the burner control box. Another start sequence is
then initiated. Repeat the procedure until a flame is established.
Note: Persistent lockout when running indicates a fault and a
Service Engineer should be consulted.
12.11 Run the boiler for approximately 3 minutes and switch
off checking that there is no after-spurting from the nozzle. This
can be detected by oil saturation on the blast tube. If after-
spurting occurs remove the burner from the boiler, unscrew the
nozzle, and while holding the burner in a vertical position, fill the
nozzle holder with oil. Refit the burner and continue to run the
boiler for three minute periods until after-spurting stops.
Note: In order that after-spurting is reduced to a minimum
during the commissioning period it is recommended that a
pressure gauge only is fitted on the external pressure gauge port
on the Electro Oil B11 (See Fig. 22). Use of a "T" piece pressure
gauge manifold will increase the oil line volume and hence
increase the degree of after-spurting.
12.12 Run the boiler for a further 15 minute period and then
finally fine tune the air shutter setting to give the CO
specified in Tables 2 to 9 less 0.5% CO
smoke will be emitted due to the burning of the organic binder
in the base insulation board. Smoke readings will therefore be
inaccurate at this point.
Note: A flue gas sampling point is located on the boiler top plate.
12.13 Check that the smoke reading is in the range 0-1. If this
cannot be achieved then check that the burner head is set
correctly and the nozzle is in good condition.
12.14 Check that the flue temperature does not exceed the
value specified in Tables 2 to 9. If this is the case then check that
the baffles are correctly located. If the baffles are correctly
located then reduce the pump pressure since nozzle variations
of up to + or – 15% may occur.
12.15 Remove the oil pressure gauge and manifold and check
all oil system joints for any signs of leakage.
12.16 On the RS balanced flue model fit the burner cover box
supplied in the flue terminal kit by lining up the four ball studs
and the polarising pin in the top flange of the box and firmly
pushing forward. Check that the cover is properly seated by
pressing forwards on the front top and then bottom face of the
box to ensure a room seal is achieved.
On the CF/LLD model fit the cabinet front panel.
12.17 Allow the burner to run for a further five minutes and
then recheck the CO level and adjust the air setting if required.
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With the burner cover/panel fitted as 12.16, repeat the previous
test procedure and check that the smoke number is in the range
0-1. Repeat the fine tuning procedure if found necessary.
12.18 Refit the cabinet top and front panels in the reverse order
to that described in Section 5.
12.19 When the heating circuit has reached full operating
temperature check the whole system for any leaks.
20
level
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. During this period some
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