HAMWORTHY HEATING LTD
WESSEX-HE 200 BOILER
500001008/K
11
11.0 COMMISSIONING AND TESTING
11.1 Electrical Installation
For design see Section 9.
A suitably competent person must check wiring.
Normal supply required is 230V 50Hz single phase.
An isolator correctly fused at 5 Amperes should be
sited close to the boiler.
Any other interlocks i.e. pressurisation unit, BEM
system should be wired in series with the remote
stop/start loop (C5 & C6).
A schematic of the circuit is shown in Figure No. 5.
11.2 Gas Installation
For design see Section 5.
The whole of the gas installation including the meter,
must be inspected and tested for soundness and
purged, in accordance with the recommendations of
BS 6891, UP/1
or
UP/1A
as appropriate.
11.3 Water Circulation System
For design see Section 8.
NOTE!
If a boiler is to be fitted into an old or existing
pipework system it is advisable that this is chemically
cleaned and thoroughly flushed prior to installation.
The whole of the system should be thoroughly
flushed out with cold water without the pump in
position. Ensure that all valves are open.
With the pump fitted, the system should be filled and
air locks cleared. Vent the heat emitters and check
for leaks.
11.4 Lighting the Boiler (Initial Commissioning)
Prior to delivery, all Wessex boilers are subject to a
full sequence check and the differential pressure
switch is adjusted to design settings (See Section
2.2). The intent therefore of the following initial
commissioning procedure, is to check the correct
functioning of the sequence system up to and
including the establishment of the pilot flame, with the
gas supply to the main burner isolated.
WARNING:
Before attempting to light the boiler
ensure that any personnel involved are aware of what
action is about to be taken and begin by making the
following checks: -
i) Flueway passages and chimney are clear of
obstructions.
ii) Adequate ventilation exists in the boiler house,
reference Section 7.
iii) The system is fully charged with water, ready to
receive heat, all necessary valves are open and the
pump is running and circulating the water.
iv) The pipework and valve arrangement is installed
to Hamworthy recommendations in such a way that
adequate water flow rates will be present in
accordance with Figure No. 3.
v) The gas supply pipework is clear of any loose
matter, tested for soundness and purged.
Turn off the electrical supply to the boiler at the mains
external isolator.
a) Remove the boiler front cover.
Disconnect the main gas valve wiring assembly plug,
thus isolating the gas valves from the main burner
controller.
Remove wire link on terminals C1 & C2 and insert a
Multi-Meter set to read DC µA.
Ensure main gas supply is turned
ON
at the boiler
manual shut-off valve (Reference Figure No. 6.).
Remove the blank plug from the temperature limit
reset panel on the fascia and push in the exposed
reset button. Replace plug.
Set the control thermostat to the minimum setting
(65
o
C) and switch on the electrical supply to the boiler
at the external isolator, ensuring that all external
controls are calling for heat (e.g. time clocks etc.).
b) Switch the boiler ON/OFF switch to ‘ON’. Re-set
the controller if at lockout, the cam timer will run to its
normal start position. The fan will then start and the
boiler will pre-purge for approximately 40 seconds.
c) Following this pre-purge period, an ignition spark
will be generated and the pilot gas solenoid valve will
energise to supply gas to the pilot burner.
d) After a few seconds, the spark will cease and the
pilot flame-monitoring period will start. The pilot
flame-proving signal should be 2.5 - 5.0 µA.
e) On completion of the pilot proving period, the
green ’normal firing’ lamp will illuminate however, as
the main gas solenoid valves have been
disconnected, the controller will lockout after a
maximum of 5 seconds. The amber ‘lock-out’ lamp
on the controller will be lit and the green ‘normal
firing’ lamp will be extinguished.
f) When the commissioning engineer is satisfied that
the boiler has a stable pilot flame, switch off the boiler
and re-connect the gas valve wiring plug assembly.
