Maintenance
31
Generally, the normal service period is one year. Each year the
boiler should be cleaned and checked according to the
maintenance procedure and ınstructions. If there is any doubt
whether the boiler will operate with the correct water or
combustion air quality, it is advisable that a first check is done
after half a year to determine future service period.
6
MAINTENANCE
6.1
GENERAL
WARNING: Damage to the installation due to
insufficient or improper cleaning and maintenance.
Inspect and clean the heating system once a year.
Carry out maintenance as required. Immediately remedy
faults. This will
avoid further damage to the system!
6.2
MAINTENANCE PROCEDURE
Inspection, maintenance and the replacement of parts should be
done by Gassero technical service. Besides doing
maintenance we advise to create a log chart belonging to each
boiler on which at least the following should be written:
- Serial number of the boiler
- Maintenance date
- Responsible personnel of maintenance.
- Parts and/or settings changed during maintenance.
- Special remarks
- Important points in the future.
During maintenance the following points should be checked
and/or parts must be inspected and maintained.
Before doing any work on the boiler:
- Switch off the power to the boiler by service switch or pull
out plug from wall socket
- Close the gas valve
Customer comments
Comments and notes from the customer should be taken
seriously and an effort should be made to find the cause of any
problems.
Service history
Faults and working history can be read from boiler interface or
with a computer in combination with the software and interface
cable of the PCB.
Water leakage
The pressure of the installation must be higher than 0,8 bar,
and maximum 6 bar. Find possible leaks in the system and have
these fixed.
Flue gas leakage
The flue gas discharge and air intake piping need to be checked
for gas leakage. Also check if the piping is properly mounted and
not damaged. Inspect the top of the boiler housing for traces of
water leakage or traces of water from the air vent, or leaking
condensate from the flue gas piping.
Gas lines/-connections
The gas lines need to be checked for gas leakage. Also check if
the piping is properly mounted and not damaged.
Un-assembling the Burner
Un-assembling the burner unit: Remove the 6 x M6 nuts and the
electrode cables, and move the burner unit forward. Remove the
plug of the fan cable from the fan when the burner has been
pulled half-way from the heat exchanger. Dismantle the air gas
mixing box on the intake side of the fan and check the blade
wheel of the fan.
Insulation
The insulation of the heat exchanger (located on the rear wall
inside in the heat exchanger) must be inspected. If this insulation
disk shows any sign of damage or impairment it should be
replaced with a new one. Also check if there are any signs of a
too high condensate level (caused by a blocked siphon) that
might have wetted the insulation several times. When these
signs can be seen, the rear wall insulation should be replaced.
Only use the burner door insulation that is supplied by the
manufacturer.
The same procedure must be applied on the insulation and
gaskets fitted on the burner door.
Burner- and burner door gaskets
When these show any signs of damage they must be replaced.
Siphon
Dis-assemble the bottom cover siphon and clean it. Check if the
siphon connection on the heat exchanger is not blocked, and clean if
necessary. Check afterwards if the siphon functions properly.
This can be done by pouring clean tap water in the furnace
(when burner door is removed) so it will exit the heat exchanger
through the siphon. Make sure the insulation is not wetted.
Heat exchanger/combustion room
Check if there is any debris/deposit in the heat exchanger. The
heat exchanger coils can be cleaned by using a non metallic
brush. Afterwards the loose particles may be removed with a
vacuum cleaner and/or flushing with water. Check flow of water
out of siphon, and clean siphon if necessary. Any cleaning of the
combustion chamber with acid or alkali products is prohibited!
Gas/air ratio
Always check the gas/air ratio by checking the combustion figure
CO on maximum and minimum input. If necessary adjust these
2
figures.
Pump
If the pump is becoming noisy (certainly when the pump has
been working for more than five years) it is recommended to
replace the pump as a precaution.
Burner
The burner can be cleaned using a soft (non metallic) brush.
The dust can be removed with a vacuum cleaner or pressurized
air. Check if the burner surface shows any signs of damage. If
the burner surface is damaged (example: cracks in the surface)
the burner must be replaced.
