Ensure that no foreign matter is left in the system as this could
cause damage to the appliance.
Benchmark Water Treatment: For optimum performance after
installation, this boiler and its associated central heating
system should be flushed in accordance with the guidelines
given in BS7593:1992 - Treatment of water in domestic hot
water systems. Full instructions are supplied with proprietary
cleansers sold for this purpose. If an inhibitor is to be used
after flushing, it should be used in accordance with the
inhibitor manufacturers instructions.
Suitable flushing agents and inhibitors are available from Betz
Dearborn Tel: 0151 4209563 and Fernox Tel: 01799 550811.
Instructions for use are supplied with these products.
IMPORTANT: Any system cleanser must be flushed from the system
before an inhibitor is added.
12.1
Check that the electrical supply to the appliance is
switched off.
12.2
When commissioning the appliance after initial installation
follow the procedure from 12.3, otherwise remove the burner
first as described in Section 14.3.
12.3 Prepare the heating system
1.
After initial installation and checking for leaks, as previously
described, drain down the system sufficiently to add a flushing
agent. Flush the system in accordance with BS 7593:1992.
2.
Refill the system.
12.4 Check the Burner
1.
Check that the nozzle and electrode settings are correct for
the relevant burner. (See Fig. 27).
2.
Check that the nozzle lies central with the combustion head hole.
3.
Check for any visible defects.
12.5 Replace the burner
1.
Connect the flexible oil supply hose and tighten sufficiently to
form a good seal. Where a double pipe system is being used con-
nect the oil return flexible hose to the return pipe fitting.
2.
Insert the burner into the burner mounting flange and tighten
the locking nut using a 13mm spanner.
Note:
It is important that a good seal is made between the
burner and the boiler to prevent the escape of the flue gases
from the combustion chamber.
12.6 Check the installation
1.
Check that the appliance is correctly wired as described in
Section 10.
2.
Check that the baffles are correctly located.
3.
Check that the combustion product high limit thermostat
phial is correctly located in the thermostat pocket positioned in
the top front of the condensing heat exchanger.
4.
Check that the water high limit thermostat is located in the
pocket on the main heat exchanger.
5.
Check that all of the air-ways to the burner are clear of any
obstruction.
12.7
Fit a pressure gauge and manifold to the burner pump at
the point indicated in Fig. 15.
12.8
Turn on the electricity to the appliance.
12.9 Bleed the burner
Single pipe systems only
Release the fuel bleed port on the manifold and place a suitable
receptacle beneath. Turn on the boiler thermostat. Set the
programmer to
heating and hot water
and allow the burner to
run through to lockout. Wait two minutes and reset the burner
control box. Repeat the procedure at least three times or until a
steady stream of oil, without air, is exhausted from the bleed
port. Re-lock the bleed port.
Two Pipe System
A two pipe system will automatically vent the air back to the oil
tank. Turn on the boiler thermostat and allow the burner to run
through to lockout. Wait two minutes and reset the burner con-
trol box. Repeat the procedure untill the burner fires and runs in
a steady state. This may take several attempts depending on the
oil pipe length and height.
12.10
Adjust the air shutter and pump pressure to the settings rec-
ommended in Table 2. After a pre-ignition period of approximately
15 seconds the burner should ignite. Flame sensing is carried out by
means of a photocell mounted in the burner body. Should the boiler
fail to establish a normal firing pattern (or should flame failure occur
during running), the absence of a flame is sensed and the control box
is monitored to a safe lockout condition and the boiler is shut down.
The lockout indicator light in the boiler control panel will illuminate
indicating that the burner has gone to lockout. In this instance wait
two minutes and press the red lockout reset button mounted in the
burner control box. Another start sequence is then initiated. Repeat
the procedure until a flame is established.
Note:
Persistent lockout when running indicates a fault and a
Service Engineer should be consulted.
12.11
Run the boiler for approximately 3 minutes and switch
off checking that there is no after-spurting from the nozzle. This
can be detected by oil saturation on the blast tube. If after-
spurting occurs remove the burner from the boiler, unscrew the
nozzle, and while holding the burner in a vertical position, fill the
nozzle holder with oil. Refit the burner and continue to run the
boiler for three minute periods until after-spurting stops.
Note:
Use of a “T” piece pressure gauge manifold will increase the
oil line volume and hence increase the degree of after-spurting.
12.12
Run the boiler for a further 15 minute period and then final-
ly fine tune the air shutter setting to give the CO
2
level specified in
Table 2. During this period some smoke will be emitted due to the
burning of the organic binder in the base insulation board. Smoke
readings will therefore be inaccurate at this point.
Note:
A combustion product sampling point is located on the
front of the condensing heat exchanger (see Fig. 26).
12.13
Check that the smoke reading is in the range 0-1. If this
cannot be achieved then check that the burner head is set
correctly and the nozzle is in good condition.
12.14
Check that the flue temperature does not exceed the
value specified in Table 2. If this is the case then check that the
baffles are correctly located. If the baffles are correctly located
then reduce the pump pressure since nozzle variations of up to
+ or – 15% may occur.
12. Commissioning the Appliance
4
1
1
4
3
2
3
19
1. Inspection/cleaning port 2. Combustion test point
3. Washer 4. Test point screw
Fig. 26. Secondary heat exchanger inspection ports
1
4
3