Glowworm Lighting 40 manual Commissioning, Preliminaries-All Systems, Sealed Systems, Testing Gas

10 Commissioning

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/ in2). 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/in2), 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 82oC (180oF).

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 proceed 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,

GREEN LIGHT					0163M
FOR HIGH	HIGH/LOW		CONTROL
FLAME	CONTROL		THERMOSTAT
	KNOB		KNOB
			in
			m
		0
			m	p
				tem
			ax
GREEN LIGHT		ORANGE
FOR LOW FLAME		DEMAND LIGHT
				Diagram 10.1

9023

HIGH SETTING

ADJUSTMENT

(BRASS NUT)

LOWER SETTING ADJUSTMENT

(INNER SCREW)

Diagram 10.2

221834B 22