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WD53/0/1999
4. COMMISSIONING OF THE BOILER
Important:
This condensing boiler contains components which could be damaged or blocked by grease, dirt,
solder etc., from the water system. The following commissioning procedures must be followed
precisely.
4.1
INITIAL FLUSHING
All waterways within the Keston are either copper, bronze or high alloy stainless steel. As
a result standard water treatment chemicals for conventional central heating boilers are
suitable. In any event reference must be made to BS 7593 : Treatment Of Water In Hot
Water Central Heating Systems.
a.
Disconnect the boiler from the system at the flow and return connections and
temporarily link the flow and return pipes on the system.
b.
Flush the entire system until clean water is discharged, free from dirt, flux, solder
etc. The use of a flushing chemical is recommended, e.g. Fernox Supafloc.
Sludge and scale must be removed from an existing system. Boiler failure due to
system debris or sludge shall invalidate the guarantee.
c.
Connect the system to the boiler and fill in accordance with Section 2.6 - Water
Systems. At this stage, for sealed systems, fill to a pressure of about 2.7 bar.
d.
Check the complete system for water soundness. If leaks need to be rectified
using flux and solder, the system must be flushed cold again before proceeding.
e.
Reduce the pressure to the Initial System Design Pressure for sealed systems, if
applicable. Vent the system
4.2
GAS SUPPLY
The complete gas installation up to the boiler service cock must be checked for
soundness. BS 6891.
4.3
ELECTRICAL INSTALLATION
Carry out preliminary electrical safety checks, i.e. Earth continuity, Polarity, Resistance to
Earth, Short Circuit using a suitable test meter.
4.4
INITIAL FIRING
Important
Checking the gas pressure to the pre-mix burners requires a special procedure, outlined
below, which must be carried out.
a.
Purge the gas supply in accordance with BS 6891 & IM/2.
b.
Vent the water system.
Important:
The Keston heat exchanger module consists of a single coil which can trap an air
pocket. Great care must be taken to ensure that water flow has been established
through the heat exchanger and thus ensuring no air pockets remain in the heat
exchanger and pipe work. Firing the boiler while an air pocket exists in the heat
exchanger could damage it.
c.
Turn both the integral gas service cocks to ON.
d.
Turn on the electrical supply, setting any external controls to call for heat.
e.
Set the main boiler On/Off switch to "ON" and adjust the set point temperature to
a value above actual flow temperature. (adjustment is made by holding in the
press button located below the control knob and adjusting the control knob until
the required set point temperature is displayed. Releasing the press button will
cause the control knob to be ineffective and the display to register actual flow
temperature).
Installation & Servicing Instructions
Chapter 4 : Commissioning
The Keston 260 & 340 Condensing Boilers
Page : 17
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