Commissioning; Pre-Commissioning Checks; Filling The System; Water Treatment - Bosch Worcester Greenstar Utility 32/50 Installation, Commissioning And Servicing Instruction Manual

Commissioning

6 Commissioning
6.1

Pre-commissioning checks

CAUTION: Isolate the mains supplies before starting
any work and follow all relevant safety precautions.
1. Check that the service and water pipes are connected correctly.
▶ Check that all unused sockets are capped.
2. Check that the oil supply is Class C2, 28 second kerosene and that
the pipework is connected correctly to the oil pump via the supplied
flexible oil hose.
▶ Turn on the main oil supply valve at the tank, check the oil supply
pipework and connections. Rectify any leaks.
3. Check the flue is correctly fitted and the connections are secure.
4. Check the condensate pipework is correctly fitted and connected.
▶ Check the condensate trap is filled with water.
NOTICE: If the appliance is not to be commissioned
immediately then:
After successfully completing all of the checks and any
rectification work, close the water valves, shut off the oil
supply and electrically isolate the appliance.
Complete the installation part of the Guarantee
Registration Card, and complete a CD10 or equivalent to
inform the LABC of the installation.
6.2

Filling the system

▶ Open all system and radiator valves.
▶ Turn on the water main stop cock.
▶ Open vented systems only:
– Turn on the water to the system feed and expansion cistern and
allow the system to fill.
▶ Sealed systems only:
– Check and if required, adjust the expansion vessel pressure using
the Schrader type valve.
– Fill the system to between 1 and 2 bar pressure via a WRAS
approved filling link.
– Monitor the pressure gauge during venting and repressurise if
required.
▶ Vent all radiators, retighten when completed.
▶ Check the system and correct any leaks.
▶ Bleed air from the secondary heat exchanger via the air vent (a
radiator key is ideal for this).
6.3

Water treatment

NOTICE: Softened water:
▶ Salt based, softened water must not be used to fill
the central heating system.
Ensure that the system has been cleaned. Refer to section 4.1.2 of
these instructions.
Flushing (Central Heating)
▶ Ensure the appliance is switched off.
▶ Open all drain cocks and drain the system while the appliance 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 appliance/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.
28
Inhibitor (Central Heating)
▶ Check drain cocks are closed and all radiator valves are open before
adding a suitable inhibitor 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 between 6.5
and 8 or the appliance warranty will be invalidated.
▶ Fill system via a WRAS approved filling loop to between 1 to 1.5 bar.
▶ Vent all radiators; tighten vents when complete.
▶ Re-pressurise if necessary to 1bar (sealed system only).
▶ Set all controls to maximum.
▶ Record the date when the inhibitor was added to the system in the
appliance commissioning checklist and in the guarantee registration.
NOTICE:
▶ The concentration of inhibitor in the system should
be checked every 12 months or sooner if system
content is lost.
▶ In cases where all attempts to find a micro leak have
failed, Worcester, Bosch Group supports the use of
Fernox F4 leak sealer.
Water treatment products
Suitable water treatment products can be obtain from the following
manufacturers:
ADEY 01242 546717 or www.adey.com
FERNOX 0870 601 5000 or www.fernox.com
SENTINEL 0800 389 4670 or www.sentinel-solutions.net
6.4

Starting the appliance

NOTICE:
Never run the appliance when the appliance/system is
unpressurised (sealed systems) or empty.
1. Check the oil supply is correctly fitted and in good working order
before turning on the oil supply valves to the appliance.
▶ Turn on the main oil supply valve at the tank and draw off at least
2.5 litres of oil until a steady flow of clear uncontaminated oil can be
seen as follows:
– The oil supply to the appliance should be primed before the
burner is operated to avoid unnecessary pump wear.
– The use of an oil suction pump will prime and flush through any oil
supply set up simply and easily, alternatively the following
procedures can be used.
6.4.1

Priming a single pipe gravity feed systems:

▶ Disconnect the flexible oil hose and open the isolating valve to
discharge the oil into a suitable container.
Replace flexible hose at annual service to prevent
possible oil leakage.
▶ If a top entry tank has been used the pipework will need to be primed
before the oil will discharge under gravity.
▶ When completed, close the isolating valve and reconnect the flexible
oil hose.
When the oil reaches the pump, bleed the air from the pump as
follows, refer to figure 39:
▶ Open the isolating valve and the oil pump bleed port [1] to discharge
into a suitable container once the appliance is started up.
▶ Switch on the electricity supply to the appliance.
▶ Set the programmer to ON for CH and DHW.
▶ Turn on the appliance control thermostat.
Greenstar Utility ErP - 6 720 821 751 (2018/04)