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9
Inspection and maintenance
DANGER
Risk of electric shock!
▶ Isolate electrical components from the power supply (230 V AC)
(fuse, circuit breaker) and secure against unintentional re-
connection before carrying out any work.
Information on safe isolation can be found in the Health and Safety
Executive guidance HSG85.
▶ Check for zero potential before proceeding with work, using test
equipment approved to GS38 to confirm that the electricity supply is
disconnected.
CAUTION
Mains supplies:
▶ Safely isolate both the gas and electrical supply before starting any
work on the appliance and observe all relevant safety precautions.
NOTICE
Personnel and equipment
▶ Any service work must carried out by competent registered
engineers.
▶ Service work must not be attempted if a calibrated CO/CO
and manometer are not available.
WARNING
Hot surfaces!
If the appliance has been operating components may be hot.
▶ Ensure precautions are taken when working on the appliance.
CAUTION
Annual maintenance checks:
Annual maintenance checks have to be conducted to ensure the
continued safe and reliable operation of the appliance.
▶ During each maintenance check, the gas valve, all gas joints and test
points should be checked for leakage using an analyser/sniffer.
▶ If a leak is found on the gas valve then it needs replacing as a gas valve
is a non-repairable component.
WARNING
Combustion chamber soundness!
Risk of legality and health!
After servicing or performing any maintenance on the boiler ensure that:
▶ Both flue test point plugs are in place.
▶ Front cover is correctly fitted.
▶ Front cover securing screws are fully tightened.
CAUTION
Component replacement:
▶ After replacement of a gas related component, where a gasket or seal
has been disturbed or replaced, check for gas tightness using a gas
sniffer/analyser.
▶ Also after re-assembly, carry out the following checks:
Flue gas analysis.
Greenstar 1000 – 6721835943 (2023/08)
9.1
Inspection and maintenance considerations
• To ensure continued efficient operation the appliance must be
checked at regular intervals.
• The frequency of servicing will depend upon the particular
installation conditions and usage, however, at least an annual service
is recommended.
• The extent of the service work required on the appliance is
determined by the operating condition of the appliance when tested
by qualified engineers.
• After each service, the service interval record sheet at the rear of this
manual, must be completed.
See the following instructions for detail of some of the service
requirements:
▶ Check all joints and connections in the system and remake any that
show signs of leakage. Refill and re-pressurise if applicable as
described in the commissioning section.
▶ When it is frequently necessary to add water to maintain pressure in
the installation, even though no leaks have been discovered, perform
an expansion vessel check.
▶ Check that the condensate system is not obstructed, clean and refill
the condensate trap.
▶ Inspect the primary heat exchanger and clean if necessary
( Chapter 9.7, page 54)
analyser
▶ If the appliance is in a compartment or cupboard check that the
2
specified clearances around the appliance is clear.
▶ Check that the flue system is unobstructed and undamaged, clean/
replace as necessary.
– If fitted ensure the flue terminal guard is also unobstructed and
undamaged.
▶ Operate the appliance and take note of any irregularities.
– Refer to the fault finding pages for rectification procedure.
Maximum system pressure
▶ 2.5 bar must not be exceeded when the heating system water is at
maximum temperature. If this pressure is exceeded then an
additional expansion vessel must be fitted into the system return as
close as possible to the appliance.
▶ If the system does not retain the pressure, the pressure relief valve
(PRV) and the heating system should be checked for leaks.
9.2
Service functions
An overview of the faults can be found in chapter 11 from page 86.
9.3
Component access
Removing the front casing
The front casing is secured with two screws which are critical to maintain
the case seal and to prevent unauthorised removal (electrical safety).
▶ Always secure the casing with these screws.
Removing the front cover prior to hanging the boiler is recommended in
order to protect the front from scratches and damage.
▶ Loosen the two screws [1].
▶ Pull the bottom of the casing forward.
▶ Lift off the casing.
Inspection and maintenance
53
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