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Alpha Pro Tec - Routine Servicing
6 ROUTINE SERVICING
To ensure efficient operation of the boiler it is recommended that it is checked and serviced as necessary at regular intervals.
The frequency of servicing will depend upon the particular installation conditions and usage, this must be at least once per
year to maintain the boiler guarantee.
It is the law that any service work must be carried out by a competent person, i.e. Gas Safe registered personnel.
Warning:
Before servicing the boiler, isolate the electrical supply and close the boiler gas service cock. Allow the boiler to cool.
The data label is positioned on the inside of the right hand side of the base plate.
Always test for gas tightness after servicing any gas carrying components.
Always carry out electrical system checks i.e. Earth Continuity, Resistance to Earth, Short Circuit and Polarity with a suitable
meter after servicing.
General
Please Note:
During routine servicing, and after any maintenance or change of part of the combustion circuit, the following
must be checked:
1. The integrity of the flue system and the flue seals.
2. The integrity of the boiler combustion circuit and relevant seals.
3. The operational (working) gas inlet pressure at maximum rate.
4. The combustion performance, as described below.
Competence to carry out the check of combustion performance
Please Note:
BS 6798:2009 Specification for installation and maintenance of gas-fired boilers of rated input not exceeding
70 kW net
advises that:
1. The person carrying out a combustion measurement should have been assessed as competent in the use of a
flue analyser and the interpretation of the results.
2. The flue gas analyser used should be one meeting the requirements of BS 7927 or BS-EN 50379-3 and be
calibrated in accordance with the analyser manufacturers' requirements.
3. Competence can be demonstrated by satisfactory completion of the CPA1ACS assessment, which covers the use
of electronic portable combustion gas analysers in accordance with BS 7967, Parts 1 to 4.
Combustion check
Connect the flue gas analyser to the flue gas sampling point as shown in Fig. 6.4 or 6.5.
Notes: 1.
Prior to servicing, it is recommended that a flue gas analyser is used to measure the performance of the boiler. If
the CO/CO
2
ratio measured is greater than 0.003
or
when other checks and comments from the customer have
indicated that there may be problems, cleaning of the heat exchanger will be necessary. Repeat the flue gas
analyser test after reassembling the boiler and check that the CO/CO
2
ratio is less than 0.003.
If the CO/CO
2
ratio reading is still above, then you must repeat the checks and cleaning until you obtain a ratio
reading of below 0.003.
If the combustion reading is greater than the acceptable value AND the integrity of the complete flue
system and combustion circuit seals have been verified and the inlet gas pressure (and gas rate) have
been verified. Please call our Technical Helpline.
2.
If the CO/CO
2
ratio measured is less than 0.003 and other checks and comments from the customer suggest
there are no problems then only Section 6.1 and Section 6.2 paragraphs 1, 2 and 3 need to be carried out to
allow a visual check of the components within the boiler casing.
6.1 IMPORTANT NOTES PRIOR TO SERVICING
1. Check the flue terminal outside and ensure it is not blocked.
2. Run the boiler and check the operation of its controls.
3. Ensure that all system connections and fittings are sound.
4. Refill, vent and re-pressurise the system as necessary. (Refer to Commissioning, Section 5.1).
If the system pressure exceeds 3.5 bar when operating at maximum temperature, the heating expansion vessel should
be checked and re-pressurised, if necessary.
Notes: 1.
Check the expansion vessel charge only when the system pressure is zero.
2.
The expansion vessel must be the correct size for the system.
5. Check that the condensate trap drain pipe is connected and all joints are sound.
6. Record details of the service in the Service Record Section at the back of this manual.