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5
Commissioning
5
Commissioning
WARNING
If a GCU compact is not properly commissioned, it may not
operate properly and can endanger human life and health.
▪ Only heating engineers, authorised and trained by gas
and energy supply companies, are allowed to commis-
sion the GCU compact.
CAUTION
If the GCU compact is not properly commissioned, it could
lead to material or environmental damage.
▪ Observe the information concerning water quality in ac-
cordance with
Chap.
▪ To avoid corrosion products and deposits, observe the
relevant technical regulations and locally applicable re-
quirements.
▪ Measures for desalination, softening or hardness stabil-
isation are necessary if the filling and top-up water have
a high total hardness (>3 mmol/l - total of the calcium
and magnesium concentrations, calculated as calcium
carbonate). We recommend the use of Fernox KSK
limescale and corrosion protector.
▪ During operation of the system, the water pressure must
be checked at regular intervals on the building-side
manometer (green range) or by querying the controller
(see accompanying controller manual). If necessary,
correct the pressure by topping up with water.
Incorrect commissioning makes the manufacturer's guarantee for the
device void. If you have questions, please contact our Technical
Customer Service.
5.1
Initial commissioning
Once the GCU compact has been fully installed and connected, it
can be commissioned by suitably trained staff.
5.1.1
Requirements
▪ The GCU compact is fully connected.
▪ The cover of the heat cell is closed and sealed tight.
▪ The flue gas system is installed according to local regulations and
connected to the heat source.
▪ The condensate siphon is filled.
▪ The heating and hot water system are filled and charged with the
right pressure.
▪ The storage tank is filled to the overflow point.
▪ The heating system's control valves are open.
5.1.2
Checks before commissioning
1
Check all connections for leakage.
2
Check all items of the "Checklist before commissioning" (see
Chap.
5.2).
3
Log the test results on the checklist.
Only once all points on the checklist can be answered with yes may
the GCU compact be started.
5.1.3
Commissioning
1
Open the gas stopcock.
2
Switch on the mains switch. Wait for the start phase.
▪ In the event of problems when starting, see
Installation and operating instructions
38
1.2.5.
Chap.
10.
3
Configure the heating system on the RoCon BF controller.
▪ For configuration and explanation, see the enclosed "RoCon BF
controller" operating instructions -> chapter "Initial commission-
ing".
▪ Enter modified setting values in the corresponding table in the
operating instructions for the RoCon BF controller.
4
First automatic calibration:
▪ On the controller, RoCon BF select the program [Emissions
measurement] -> [Full Load] (see Emissions measurement),
but do not confirm.
▪ Make sure that heat can dissipate into the heating network dur-
ing calibration.
▪ In the event of burner starting problems, see
▪ Automatic calibration of the GCU compact and adjustment of
the gas valve complete.
▪ Calibration and adaptation are completed 2 minutes after the
burner symbol
appears on the display.
▪ End the program [Emissions measurement].
▪ Burner blower switches off.
▪ After the burner blower has come to a stop, switch off the mains
plug on the boiler control panel.
▪ The GCU compact switches off.
▪ Wait 20 seconds before switching the mains switch back on.
Wait for the start phase.
5
Second automatic calibration and measurement of the flue
gas:
▪ On the controller, RoCon BF select the program [Emissions
measurement] -> [Full Load] (see Emissions measurement),
but do not confirm.
▪ Make sure that heat can dissipate into the heating network dur-
ing emission measurement.
▪ In the event of burner starting problems, see
▪ Automatic calibration of the GCU compact and adjustment of
the gas valve complete.
▪ Calibration and adaptation are completed 2 minutes after the
burner symbol
appears on the display.
▪ Use the flue gas analyser to check the burner settings and com-
pare them with
Tab. 5-1
to
▪ If the O
/CO
concentrations are within the permissible values:
2
2
No further measures required.
▪ If the O
/CO
concentrations are outside the permissible values:
2
2
Carry out 100 % calibration and set [Drop Io-base] so that the
setting range is reached (see
ment.
▪ Document the measured values on the "Installation certificate"
form and in the operating manual.
CAUTION
The combustion control is programmed to take ageing of
the components into account. 100 % calibration of the
combustion control can still have a negative impact on this
despite compliance with the flue gas setting values
(Tab. 5-1
to
Tab.
5-4).
▪ Only calibrate the combustion control when the flue gas
setting values are not adhered to or when a mechanical
change has been made, e.g. by replacing the compon-
ent with original spare parts.
Floor-standing gas condensing boiler with integrated heat storage
Chap.
7.3.4.
Chap.
7.3.4.
Tab.
5-4.
Chap.
7.3.4) and repeat measure-
Gas Combi Unit
008.1543899_02 – 04/2019 – EN
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