maintenance Important
maintenance Important Maintenance is an essential part of the safe and efficient operation of the boiler and ensures its durability. It should be performed according to the instructions given in current legislation. Perform combustion analysis regularly in order to check the operating efficiency of the boiler and to make sure any polluting substances relased are within the boudaries set by current legislation. Before beginning maintenance work: - Disconnect the appliance from the electricity supply by turning the external bipolar switch to the “OFF” position; - Close the gas valve and the central heating and domestic hot water system valve. After the work has been completed the initial settings will be restored. General comments It is recommended that the following inspections be carried out on the boiler at least once a year: 1. Check the seals in the water part and, if necessary, replace the gaskets and restore the seal to perfect working order. 2. Check the seals in the gas part and, if necessary, replace the gaskets and restore the seal to perfect working order. 3. Visually check the overall condition of the boiler. 4. Visually check the combustion and, if necessary, disassemble and clean the burner. 5. Following the inspection detailed in point “3”, disassemble and clean the combustion chamber, if necessary. 6. Following the inspection detailed in point “4”, disassemble and clean the burner and injector, if necessary. 7. Cleaning the primary heat exchanger 8. Make sure the following heating safety devices are operating correctly: - temperature limit safety device. 9. Make sure that the following gas part safety devices are operating correctly: - absence of gas or flame safety device (ionisation). 10. Check the efficiency of the domestic hot water production process (test the flow rate and temperature). 11. Perform a general inspection of the boiler operation. 12. Remove oxide from the detection electrode using an emery cloth. Operational test After having carried out the maintenance operations, fill the heating circuit at a pressure of approximately 1.0 bar and release the air from the system. Fill the domestic hot water system at the same time. - Begin operating the boiler. - If necessary, release the air from the heating system again. - Check the settings and make sure all the command, adjustment and monitoring parts are working correctly. - Check the seal and that the system for the expulsion of fumes/ suction of comburent air is operating correctly. Draining procedures The heating system must be drained using the following procedure: - Switch off the boiler, make sure the external bipolar switch is in the OFF position and shut off the gas valve; - Loosen the automatic air relief valve; - Open the system discharge valve and collect the escaping water in a container; - Empty the water from the lowest points of the system (where applicable). If the system is to be left inactive in areas where the room temperature may fall below 0°C during winter, we recommend that anti-freeze liquid is added to the water in the heating system in order to avoid the need for repeated draining; when this liquid is used make sure it is compatible with the stainless steel used for the bodywork of the boiler. We recommend the use of anti-freeze products which contain PROPYLENE GLYCOLS as these inhibit corrosion and that they are used in conjunction with the anti-scaling and anti-corrosion function, in the quantities suggested by the manufacturer, at the mimimum temperature. Regularly check the pH level of the water/anti-freeze mix in the boiler circuit and replace it when the value measured is lower than the limit prescribed by the manufacturer. DO NOT MIX DIFFERENT TYPES OF ANTI-FREEZE. The manufacturer will not be held liable for any damage caused by the appliance or the system due to the use of inappropriate anti-freeze substances or additives. Draining the domestic hot water system and indirect cylinder Every time there is a danger of freezing, the domestic hot water system must be drained as follows: - Shut off the water mains inlet valve; - Open all the hot and cold water taps; - Empty the water from the lowest points of the system (where applicable). WARNING Before handling, empty all components which may contain hot water, performing bleeding where necessary. Descale the components in accordance with the instructions provided on the safety data leaflet supplied with the product used, make sure the room is well ventilated, wear protective clothing, avoid mixing different products, and protect the appliance and surrounding objects. Seal all openings used to take a gas pressure reading or to make any gas adjustments. Make sure that the nozzle is compatible with the supplied gas. If a smell of burning is detected or smoke is seen leaking from the appliance, or there is a smell of gas, disconnect it from the electricity supply, shut off the gas valve, open the windows and call for technical assistance. 42
maintenance Draining the System Draining the Heating System The heating system must be drained as follows: - Turn off the boiler; - Attach a hose pipe and open the drain valve; - Drain the system at the lowest points (where present). When the heating system is unused for an extended period of time, it is recommended that you add antifreeze with an ethylene glycol base to the water in the heating pipe work and radiators if the ambient temperature drops below 0°C during the winter. This makes repeated draining of the entire system unnecessary. Draining the Domestic Hot Water System Whenever there is the danger of the temperature dropping below the freezing point, the domestic hot water system must be drained as follows: - Turn off the general water valve for the household plumbing system; - Turn on all the hot water taps; - Empty the remaining water from the lowest points in the system (where present). Instructing The End User 1. Hand over the copy of the End User Instructions supplied with the appliance, together with these instructions, and explain how to use the timeclock and room thermostat if fitted. 2. Show the End User how to switch the appliance off quickly, and indicate the position of the electric supply isolator. 3. Inform the End User of the location of all drains, isolating valves and air vents. 4. Explain how to turn the appliance off for both short and long periods and advise on the precautions necessary to prevent damage in the event that the appliance is inoperative when freezing conditions occur. 5. Finally advise the End User that, for continued safe and efficient operation, the appliance must be serviced by a competent person at least once a year. Completion For the Republic of Ireland it is necessary to complete a “Declaration of Conformity” to indicate compliance to I.S. 813. An example of this is given in the current edtion of I.S. 813. In addition it is necessary to complete the Benchmark Log Book. Operational Checks 1. The flue system must be visibly checked for soundness. 2. On Central Heating allow the system to warm up and manipulate the Central Heating temperature control knob, check the burner modulates up and down between the high and low settings. 3. Range rate the thermal power for Central Heating, as detailed on page 30. 4. Run the Domestic Hot Water, manipulate the Domestic Hot Water temperature control knob to check the burner modulates up and down between the high and low settings (COMBI only). 5. Balance the Central Heating system until all return temperatures are correct and equal. 6. Switch ON/OFF button OFF, disconnect the pressure Gauge, retighten screw and relight boiler. 7. Re-examine Central Heating, Domestic Hot Water and Cold Water supplies for soundness. 8. Check the appearance of the gas flame to assess the adequacy of the combustion air supply. 9. If external controls have been disconnected, reconnect and test. 10. Refit boiler casing. 11. Complete the Benchmark Commisssioning Checklist on page 46 and any other necessary documentation. It is recommended that the following inspections be carried out on the boiler at least once a year: 1 - Check the seals for the water connections; replace any faulty seals. 2 - Check the gas seals; replace any faulty gas seals. 3 - Visual check of the entire unit. 4 - Visual check of the combustion process or analysis of combustion by-products (see Section 3.4) and cleaning of the burner if needed. 5 - If necessary, dismantling and cleaning of the combustion chamber. 6 - If necessary, dismantling and cleaning of the burner jets. 7 - Visual check of the primary heat exchanger: - check for overheating in the blade assembly; - clean the exhaust fan if needed. 8 - Adjustment of the gas pressure, gas rate and soft-light, partial load and full load. 9 - Check of the heating safety systems: - safety device for maximum temperature (overheat thermostat); - safety device for maximum pressure (safety valve). 10- Check of the gas safety systems: - safety device for lack of gas or flame ionisation (detection electrode). 11- Check of the electrical connection (ensure it complies with the instructions in the manual). 12- Check of Domestic Hot Water production efficiency (flow rate and temperature) 13- General check of the combustion by-products of the discharge/ventilation system. 14- Check of the general performance of the unit. 43
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