36
Servicing Instructions
Burner Maintenance
Furnaces should be inspected once
a year. An extract from DIN 4755
reads as follows:
„To ensure a high operational readi-
ness, functionality, safety and econo-
mic efficiency, the user should have
the boiler system inspected by an
authorized person of the manufactu-
rer or other specialist once a year.
The whole system must be checked
for proper operation and faults
detected should be rectified without
delay. It is advisable however to
make another inspection of the
system in addition to the one speci-
fied herein.“ The inspection should
comprise the following work:
1.
Inspect the boiler internals and
insulating packages and replace
by new ones if required. Check
boiler for possible accumulation of
dirt.
2.
Remove the nozzle, check it and
replace it by new one if required.
3.
Clean the ignition electrodes.
4.
Check the ignition electrode and
spark functions and readjust if
required.
5.
Clean the burner interior and exte-
rior.
6.
Clean the fan impeller.
7.
Check the fan impeller for possi-
ble deformation and cracks.
8.
Clean the flame sensor.
9.
Clean the filters and screens.
10.
Check the electrical connections.
11.
Check the flame tube and retarder
disk/swirl element (replace if
required) and check the burner
head setting after such replace-
ment
12.
Check the control equipment for
proper operation, setting and
safety period.
13.
Check the pressure switch for pro-
per setting and operation.
14.
Check the oil pump by measuring
its pressure and vacuum levels.
15.
Check the hydraulic oil system for
absence of leaks.
16.
Check the oil hoses for possible
damage and twisting.
17.
Clean the air damper and check
for smooth operation.
18.
Check the combustion process
and make exhaust gas tests:
• Fuel throughput rate adjustment
• Heating chamber temperature
(intake temperature)
• Exhaust gas temperature
• Pressure in combustion
chamber and exhaust gas pipe
• CO
2
and O
2
contents of exhaust
gases
• CO test, soot test
• UV sensor current measurement
19.
Enter measured data in test
record.
Removing the mixing unit
For replacing and setting the retarder
and ignition unit it will be necessary to
remove the nozzle rod from the burner
pipe as described below:
• Disconnect the system from its voltage
source. Set the master switch to
„OFF“.
• Close all shut-off valves upstream of
the burner.
• Remove the housing cover.
• Pull off the ignition cable.
• Remove the flame sensor .
• Loosen the Metal oil hoses on the
hydraulic block connecting to the
RDG 1250. Avoid using excessive tor-
sion on the hydraulic hoses.
• Remove left-hand or right-hand hinge
bolt depending on direction of swivel
(if swivelling unit is provided).
• Loosen locking bolts .
• Swing out burner.
• Demount the nozzle rod.
NOTE: Retarder disk / swirl element
and ignition electrodes are mounted to
nozzle rod.
Note on re-assembly:
• In the front part of the RDG 1250 is a
forward flow slide that controls oil flow
to the nozzle. To ensure a safe
functioning in this area, no fixtures are
allowed 100mm from the front edge of
the nozzle rod assembly. (such as
electrode and baffle holders)
• If you tighten the nut at the hydraulic
hoses, make sure that it is torsion-free
at the nut. A spanner will have to be
used on the opposite side.
→
Re-assembly must be done in
reverse order.
• After assembly, both function and lea-
kage test on the RDG 1250 must be
conducted. Start the burner after all
necessary components were connec-
ted and check for leakage. When
flame is establish, stop the bur-
ner.Remove the burner cover and use
a torch to check for oil leakage from
the nozzle rod assembly.Leakage
should not be more than a few drops
of oil, as they are from the remaining
oil in the nozzle head.
