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5 Commissioning Part I
5.1 Preliminary electrical checks
Check the electrical installation by carrying out short
circuit, earth continuity and resistance to earth tests and
a check for correct polarity.
5.2 Gas supply
The complete gas installation including the gas meter
must be inspected, tested for soundness and purged in
accordance with BS 6891. In IE the current edition of
IS 813. The gas supply to the boiler can be purged by
slackening the gas service valve beneath the boiler.
Ensure that there is adequate ventilation, extinguish all
naked flames and do not smoke whilst purging. After
purging, the gas service valve connection must be
retightened and tested for soundness. (The boiler itself
does not require purging as this will be done by the
automatic burner sequence control).
5.3 Initial system flush ("Cold")
The whole of the heating system must be flushed out at
least twice: once cold, and once hot as instructed later
on page 27. Open all radiator or heating valves and the
boiler CH service valves and drain the heating system
and boiler completely from the lowest points of the
system via 1/2" BSP drain taps (opened full bore to
remove any installation debris prior to lighting the boi-
ler). Refill the heating system. Check the operation of
the pressure relief valve by rotating the knob on the
valve. Now check the water pressure in the unit again
(and add more water if necessary). Close both filling val-
ves and disconnect the temporary connection.
5.4 Filling the heating system
The boiler and the heating system should be filled using
a filling method as described on page 11.
• Ensure that the boiler CH service valves are open.
• Partially open the filling valve and allow water to enter
the system. Starting with the lowest radiator, open the
radiator air release until water (clear of bubbles) is
emitted.
• Repeat this at all radiators until the complete system
is full, all air locks have been cleared and the boiler
pressure gauge reads 1.5 bar. Release any air from the
pump by slackening the centre screw.
• The boiler is equipped with an automatic air release
valve. To allow this to vent the boiler, the cap on the
top must be slackened by 1 – 2 turns. (This cap must
be left slackened during boiler operation to ensure any
residual air or system gases are released).
• Check the heating system and boiler connections are
sound.
5.5 Initial system flush ("Cold")
The whole of the heating system must be flushed out at
least twice: once cold, and once hot as instructed later
on page 27.
Instructions for installation and servicing ecoMAX
Commissioning Part I 5
• Open all radiator or heating valves and the boiler CH
service valves and drain the heating system and boiler
completely from the lowest points of the system via
1/2" BSP drain taps (opened full bore to remove any
installation debris prior to lighting the boiler).
• Refill the heating system.
• Check the operation of the pressure relief valve by
rotating the knob on the valve.
5.6 Filling condensate trap
Remove the lower part of the condensate trap (by un-
screwing and fill with water to about 10 mm from the top.
Refit to boiler.
5.7 Adjusting pump speed
The ecoMAX 635 is fitted with an automatic modulating
pump which regulates according to the resistance of the
heating circuit.
Within the diagnostic system (see next page) it is possi-
ble to preset the pump to five resistance persentage
steps up to the maximum available output in 53, 60, 70,
85 and 100 %. Therefore when using this selection opti-
on the automatic modulation is switched off.
Note!
Where a mixing valve is fitted in the heating cir-
cuit (underfloor heating circuit) the pump set-
ting in the diagnostic mode (d.14) should be set
to 100%.
400
300
200
53 %
100
0
0
200
400
600
Fig. 5.1 Pump specifications
Modulating pump settings
In order to set the pump from modulating to a number
of fixed persentage output values, please follow the
instruction below.
• Open the appliance to obtain access to the diagnostic
display.
• Turn the appliance "on/off"–contol to the "I"–position
("on").
70 %
85 %
60 %
800
1000 1200
1400
1600 1800
Volumeflow [ l/h ]
100 %
1900
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