Glow-worm EnergySaver 80 - Manual (Page 22)

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10 Commissioning
Diagram 10.1
0163 M
GREEN LIGHT FOR
HIGH FLAME
HIGH/LOW
CONTROL KNOB
CONTROL
THERMOSTAT KNOB
GREEN LIGHT
FOR LOW FLAME ORANGE
DEMAND LIGHT
Please ensure the “Benchmark” logbook is completed and left
with the user.
10.1 Preliminaries - All Systems
Commissioning should be carried out by a competent person in
accordance with current issue of BS6798.
Make sure that the system has been thoroughly flushed out with
cold water without the pump in place.
Refit the pump, fill the system with water, making sure that all
the air is properly vented from the system and pump.
Before operating the boiler check that all external controls are
calling for heat.
10.2 Sealed Systems
Fill the system until the pressure gauge registers 2.7bar (40lbf/
in
2 ). Clear any air locks and check for leakage.
Check the operation of the safety valve, preferably by allowing
the water pressure to rise until the valve lifts. This should be
within +/-0.3bar (+/-4.3lbf/in
2 ), of the preset pressure. Where
this is not possible a manual check should be carried out.
Release the cold water to initial design pressure.
10.3 Initial Lighting, Testing and Adjustment
WARNING: The multifunctional control, fan and control box
operate on MAINS voltage, terminals will become live.
Check that the mains electrical supply to the boiler is switched
off and that the control thermostat is turned to “O”, see diagram
10.1.
For future reference stick the self adhesive arrow indicator, from
the loose items pack, to the data label against the rating that the
boiler is going to be set to.
Turn on the supply at the gas service cock.
Loosen the burner pressure test point screw and fit a suitable
pressure gauge, see diagram 8.1.
Turn the electrical supply on to the boiler and check that all
remote controls are calling for heat.
The orange demand light will come on, see diagram 10.1.
Turn the left hand switch to “High” flame.
Turn the control thermostat knob, at the right, clockwise to any
position between “MIN” and “MAX”, see diagram 10.1. The
maximum setting is about 82
o C (180 o F).
The boiler will not light between “O” and “MIN”.
The boiler lighting operation is now automatic.
The fan operates, followed by an ignition spark until the burner
lights on “Low” flame after a short period it will go to “High” flame
the green light is on.
The burner will remain alight until switched off by the control
thermostat or other remote control.
The automatic lighting sequence will operate again when heat
is required.
10.4 Testing - Gas
With the boiler on carry on as follows:
Test for gas soundness around the boiler gas components
using a suitable leak detection fluid, in accordance with the
current issue of BS6891.
Check the burner pressure at least 10 minutes after the burner
has lit, refer to Data label.
If the main burner pressure requires adjustment, see diagram
10.2.
The brass nut, controls the main (high) burner pressure.
The centre, plastic posidrive screw controls the “Low” burner
pressure.
The centre, plastic posidrive screw must be held in position
whilst adjusting the main (high) burner pressure, brass nut.
After adjustment the low pressure must be checked, by turning
the “high/low” to “low” setting.
Should any doubt exist about the gas rate, check it using the gas
meter test dial and a stop watch, at least 10 minutes after the
burner has lit, make sure that all other gas burning appliances
are off.
The rates are as shown in Table 2.
Turn the control thermostat knob to “Off”.
Remove the pressure gauge from the test point and refit the
screw, making sure that a gas tight seal is made.
When the control thermostat is turned to “Off”, by hand, wait at
least 30 seconds before turning “On” again.
There may be an initial smell given off from the boiler when new,
this is quite normal and it will disappear after a short period of
time.
Refit the electrical controls box.
Diagram 10.2
HIGH SETTING
ADJUSTMENT
(BRASS NUT)
LOWER SETTING
ADJUSTMENT (INNER
SCREW)
9023