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Servicing
Maintenance
Burner and boiler servicing must only
be carried out by a professionally
qualified heating engineer. The
system operator is advised to take
out a service contract to guarantee
regular servicing. Depending on the
type of installation, shorter
maintenance intervals may be
necessary.
Please note:
If maintenance is not carried out
properly in accordance with these
instructions, system malfunctions and
dangerous operating conditions could
ensue. This may result in a breakdown,
damage to property and the
environment and personal injury. A log
must be kept of all maintenance and
servicing work. All wear parts must be
replaced in accordance with the
specified cycle times (see table below).
For maintenance work, the floor
of the work area must be free of
dirt and slip-resistant.
Provision must be made for
adequate lighting. When maintaining
heavy components (e.g. the fan
motor), suitable lifting equipment
must be used.
Before carrying out any maintenance or
cleaning work on the burner, the
following steps must be followed.
1. Turn off the power supply and protect
the system from accidental start-up
2. Interrupt the supply of fuel
3. Check the system for residual power
and ensure that steps 1 and 2 have been
effective
4. Before opening the burner casing,
ensure that the fan motor has stopped
completely.
If the cooling fins of the ventilation motor
are motionless, the turbine has stopped.
Failure to observe these instructions
may result in severe or fatal injuries
and/or damage to property.
• Use original spare parts.
If original spare parts are not used, the
system may no longer be CE-compliant.
Warning:
Each time maintenance work is carried
out, it is essential to ensure that no tools,
cleaning cloths or other items are left in
the burner housing. Any items left
behind could affect the functionality of
the burner and could result in damage to
property or personal injury (risks of
serious or fatal injury).
Work recommended as part of annual
burner maintenance:
- Burner test run, input measurement in
the boiler room
- Clean the combustion components
and replace defective parts if
necessary
- Clean the fan wheel and the fan
- Clean the gas filter; replace it if
necessary
- Check the setting of the combustion
components and check the seal
between the gas head and burner
tube for leaks
- Check the ignition electrodes and
ignition sparking. Clean and readjust if
necessary
- Clean the flame sensor
- Clean the air flap and check that it
moves easily
- Check whether the fan wheel is
deformed or cracked
- Visual inspection of the burner's
electrical components; eliminate
malfunctions if necessary
- Check burner start-up (combustion
performance, emissions, burner
output)
- Leakage test
- Function tests on the burner's safety
equipment, the safety chain for the
boiler system (air pressure, gas
pressure switches, the flame monitor,
the leak detection device, the safety
valves, the safety chain components).
The maintenance and safety
specifications for the boiler system
must be complied with.
- Check/clean the pressure pipe of the
air pressure switch, in particular inside
the air box hood (opening in the
acoustic insulation.)
- Flame monitor and automatic firing
device function check
- Checking the gas circulation pressure
upstream and downstream of the gas
control system and checking the static
gas pressure
- Check the gas flow
- Check the gas train for leaks
- Check the gas valves for leaks and
cleanliness
- Clean the burner inside and out
- Correct the adjustment values if
necessary
- Draw up a measurement report*
* The following values must be recorded
at a minimum:
- Type of fuel, type of gas
- Wobbe index (heat value); calorific
value
- Volumetric gas flow,
- Lowest and highest useful combustion
efficiency; also 1 to 2 intermediate
values
- Gas and air pressures (gas
connection, gas regulator, burner
head, setting pressure, fan pressure,
furnace pressure)
- Exhaust gas emissions (NOx, O2, CO,
CO2, soot) as a percentage/ ppm
- Temperature and humidity of the
combustion air
- Flue gases temperature
- Atmospheric air pressure
General checks
- Emergency stop button function check
- Visual inspection of gas lines in the
boiler room
Warning!
Before restarting the burner following
maintenance work, make sure that any
unions unscrewed during maintenance
work are tight and firmly in place. Check
the connections of the components
03/2016 - Art. Nr. 4200 1044 8002A
located in the burner (e.g. the parts of
the combustion head) before closing the
cover. Check the cover too. Incorrectly
connected or defective components
may cause malfunctioning and
hazardous operation. This may result in
a switch to malfunction mode or damage
to the environment and to the
installation, and may even cause injury
(risks of serious or fatal injury).
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