GAH Electrastream - 5 COMMISSIONING; Commissioning Procedure and Stages

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CONTENTSCONTENTS

CONTENTS

1 INTRODUCTION1 INTRODUCTION

1 INTRODUCTION

2 OPERA2 OPERA

2 OPERA

TOR CONTROLSTOR CONTROLS

TOR CONTROLS

3 TECHNICAL INFORMA3 TECHNICAL INFORMA

3 TECHNICAL INFORMA

TIONTION

TION

5 COMMISSIONING5 COMMISSIONING

5 COMMISSIONING

7 F7 F

7 F

AULAUL

AUL

T FINDINGT FINDING

T FINDING

CONTENTSCONTENTS

CONTENTS

ImporImpor

Impor

tant Informationtant Information

tant Information

----------------------------------------------------------------------------------

----------------------------------------- 4

Section 1 IntrSection 1 Intr

Section 1 Intr

oductionoduction

oduction

1-1 Introduction ---------------------------------------------- 5

1-2 System Layout ------------------------------------------- 8

1-3 Parts Supplied------------------------------------------- 11

1-4 The Electrastream System ------------------------------- 12

1-5 Tri Core Heater Operation -------------------------------- 13

Section 2 Operator ContrSection 2 Operator Contr

Section 2 Operator Contr

olsols

ols

2-1 System Control ------------------------------------------ 14

2-2 Electrastream Control Unit ------------------------------- 16

2-3 Shut Off Valves ------------------------------------------ 20

2-4 Temperature & Pressure Relief Discharge ---------------- 22

2-5 Thermostatic Mixing Valve ------------------------------ 22

2-6 Servicing ------------------------------------------------ 22

Section 3 TSection 3 T

Section 3 T

echnical Informationechnical Information

echnical Information

3-1 Specifications ------------------------------------------- 23

3-2 Dimensions --------------------------------------------- 25

3-3 Wiring --------------------------------------------------- 29

Section 4 InstallationSection 4 Installation

Section 4 Installation

4-1 Building Control ----------------------------------------- 31

4-2 Electrical ------------------------------------------------ 31

4-3 Hot Water System --------------------------------------- 33

4-4 Heating System ----------------------------------------- 37

4-5 Expansion Discharge ------------------------------------ 40

4-6 System Pressure ---------------------------------------- 43

4-7 Electrastream Connections - ---------------------------- 44

Section 5 CommissioningSection 5 Commissioning

Section 5 Commissioning

5-1 Commissioning ----------------------------------------- 47

Section 6 ServicingSection 6 Servicing

Section 6 Servicing

6-1 Routine Service ----------------------------------------- 50

Section 7 Fault FindingSection 7 Fault Finding

Section 7 Fault Finding

7-1 Fault Finding -------------------------------------------- 52

Health & SafetyHealth & Safety

Health & Safety

------------------------------------------------------------

------------------------------ Inside Front Cover

6 SERVICING6 SERVICING

6 SERVICING

4 INST4 INST

4 INST

ALLAALLA

ALLA

TIONTION

TION

IMPORTANT

BEFORE STARTING THE INSTALLATION OF THE ELECTRASTREAM CHECK ALL COMPONENTS HAVE

BEEN DELIVERED AND ARE IN SATISFACTORY CONDITION - Refer to 1-3 .

HEALHEAL

HEAL

TH & SAFETYTH & SAFETY

TH & SAFETY

COMMISSIONING 5COMMISSIONING 5

COMMISSIONING 5

5-1 Commissioning

The Commissioning Procedure should be carried out in 10 stages.

Stage 1 Electrical Check. Stage 6 Heating System Pre-fill Check

Stage 2 DHW Pre-fill Check. Stage 7 Flushing and Filling Heating System

Stage 3 Filling DHW System Stage 8 Setting and Testing Controls

Stage 4 Drain DHW System Stage 9 Accumulator Pressure

Stage 5 Cleaning DHW System Stage 10 Handing Over

Commissioning Procedure

STAGE 1 - ELECTRICAL CHECK

1.11.1

1.1

CHECK THAT ALL WIRING INCLCHECK THAT ALL WIRING INCL

CHECK THAT ALL WIRING INCL

UDING EARUDING EAR

UDING EAR

TH WIRING, HAS BEEN INSTALLEDTH WIRING, HAS BEEN INSTALLED

TH WIRING, HAS BEEN INSTALLED

CORRECTLCORRECTL

CORRECTL

, CONFORMS TO CURRENT REGULATIONS AND A SATISFACTORY, CONFORMS TO CURRENT REGULATIONS AND A SATISFACTORY

, CONFORMS TO CURRENT REGULATIONS AND A SATISFACTORY

ELECTRICAL TEST AND INSPECTION CERELECTRICAL TEST AND INSPECTION CER

ELECTRICAL TEST AND INSPECTION CER

TIFICATE HAS BEEN COMPLETED.TIFICATE HAS BEEN COMPLETED.

TIFICATE HAS BEEN COMPLETED.

1.21.2

1.2

CHECK TRI-CORE HEATER COCHECK TRI-CORE HEATER CO

CHECK TRI-CORE HEATER CO

VER, ELECTRASTREAM CONTROLLER COVER, ELECTRASTREAM CONTROLLER CO

VER, ELECTRASTREAM CONTROLLER CO

VER ANDVER AND

VER AND

ALL OTHER ELECTRICAL COALL OTHER ELECTRICAL CO

ALL OTHER ELECTRICAL CO

VERS ARE CORRECTLVERS ARE CORRECTL

VERS ARE CORRECTL

Y FITTED.Y FITTED.

Y FITTED.

1.3 Check Tundish is positioned so that any spillage or spray from the Tundish would

not contact any electrical components.

1.4 Check ALL wiring connections have been made.

Check cylinder temperature sensor is connected to temp sensor terminals 3 & 4.

Check cylinder over temperature cut-out is connected to O-T terminals 1 & 2 (see

figs. 3-3a and 3-3b).

1.5 Check the required earth continuity conductors have been fitted.

STAGE 2 - DHW PRE-FILL CHECK

2.1 Check the hot water heating discharge pipes and Tundish are correctly installed to

conform to the Building Regulations G3.

2.2 Check all pipe connections are tight and no joints have been left unsoldered.

2.3 Check ALL drain cocks are closed.

2.4 If fitted, check that the Scale Protection Device or Water Softener has been fitted

according to manufacturers instructions.

STAGE 3 - FILLING DHW SYSTEM

3.1 Open all shut off valves.

3.2 Open the incoming water isolating valve (mains stopcock) to the Electrastream and

allow the unit to fill.

3.3 Open all domestic taps in turn to purge air.

3.4 Check system for leaks including around the Tri-Core Heater.

3.5 Check no water is discharging from any TPRV or PRV.

3.6 Test the operation of the TPRV and PRV by turning the manual test cap and ensure

the water flows freely and safely to waste.

3.7 Test the operation of the Combination Valve PRV by turning the manual test cap and

ensure the water flows freely and safely to waste.

3.8 Set hot water Mixing Valve to max.

STAGE 4 - DRAIN DHW SYSTEM

4.1 Turn off incoming water isolating valve (mains stop cock).

4.2 Using hose and suitable containers, drain all water from the cylinder and pipework

using drain cocks. The cylinder will not fully drain without the use of a hose - see

page 36.

Note

DHW = Domestic Hot Water.

IMPORTANT It is the responsibility

of the installer to ensure that the

Electrastream System is properly

commissioned.

Should the commissioning not be

carried out, then the manufacturers

guarantee and any extended

warranty, will become null and

void.

The Guarantee Form MUST be

completed and returned to GAH

(HEATING PRODUCTS) in the

prepaid envelope provided.

GAH Electrastream - 5 COMMISSIONING; Commissioning Procedure and Stages

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