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approved output range of the boiler. After having
opened the fuel on-off cocks and checked that
there are no leaks in the supply line, place all
the switches on the ON position. The burner will
thus be ready for first ignition and for the adjust-
ments to be made by the authorised technician.
On first ignition, check that the door, the burner
flange and the connections to the chimney are
9. MAINTENANCE
9.1 General instructions
Periodical maintenance is essential for the
safety, efficiency and long life of the appliance.
All the operations must be carried out by qualified
personnel. All cleaning and maintenance opera-
tions must be performed after having closed the
fuel supply and disconnected the power supply.
For the correct operation and maximum efficiency
of the boiler, the combustion chamber, fire tubes
and smokebox must be cleaned regularly.
9.2 Routine maintenance
The interval between cleaning operations must
be established by the user based on the expe-
rience acquired on each individual system, con-
sequently the maintenance intervals cannot be
established in advance.
In any case, the following minimum intervals are
recommended, according to the fuel used:
- Gas: once a year
- Oil: twice a year
- Fuel oil: every 300 hours of operation
In any case, any local maintenance standards in
force should be observed. During the routine
maintenance operations, after having removed
the turbulators, brush the tube bundle and the
furnace. Remove the deposits accumulated in
the smokebox by opening the inspection doors.
For more intense cleaning, remove the rear
smokebox and, if deteriorated, replace the flue
gas seal. Check that the condensate drain is not
blocked. Ensure that the control and measure-
ment devices serving the boiler are working cor-
rectly. Measure the amount of top-up water
added, and after having analysed the water, add
descaler. The calcium and magnesium salts dis-
solved in the water will, after repeated refills,
cause deposits in the boiler and the overheating
of the metal plate, with possible damage that is
not attributable to materials or workmanship,
and consequently not covered by the warranty.
After having completed the maintenance and
cleaning operations and started the boiler again,
check the tightness of the door and the smoke-
box, and in the event of gas leaks, replace the
corresponding gaskets.
The operations carried out must be entered
in the system logbook.
9.3 Special maintenance
Special maintenance to be performed at the end
of the season or for extended shutdowns.
All the operations described in the previous
chapter must be completed, plus the following
additional operations:
- Check the condition of the turbulators for wear.
- After cleaning the flue gas circuit, wipe with a
rag dipped in a diluted solution of caustic soda.
After having left to dry, wipe all the surfaces
with a rag dipped in oil.
tight and that there is a slight negative pressure
at the base of the flue. The fuel rate must corre-
spond to the boiler's rated data and under no
circumstances must exceed the maximum out-
put value declared. The temperature of the flue
gas must never fall below 160°C.
- Hygroscopic substances (quicklime, silica gel
in small containers) should be placed inside
the furnace, which must then be closed her-
metically so that air cannot enter.
- Do not empty the system and the boiler.
- Protect the screws, nuts and pins on the door
with graphite grease.
The operations carried out must be entered
in the system logbook.
9.4 Cleaning the boiler (Fig. 17)
To clean the boiler, proceed as follows:
- Open the front door (1) and remove the turbu-
lators (2).
- Clean the inside surfaces of the combustion
chamber and the flue gas path using a brush
(3) or other suitable implements.
- Remove the deposits accumulated in the
smokebox by opening the inspection door (4).
For more intense cleaning, remove the smoke-
box cover (5) and replace the gasket before
reassembling.
- Periodically check that the condensate drain
(6) is not blocked.
9.5 Checking the operation of the boiler
Before staring and running the functional tests
on the boiler, make sure that:
- The turbulators are positioned against the
exchanger tubes.
- The cocks in the water circuit and on the fuel
lines are open.
- Fuel is available.
- The expansion vessel is suitably filled.
- The pressure of the water circuit, when cold, is
more than 1 bar and less than the maximum
limit allowed for the boiler.
- The water circuits have been vented.
- The electrical connections to the mains power
and the components (burner, pump, control
panel, thermostats etc.) have been completed.
- The phase-neutral connection must be obser-
ved, and the earth must be connected.
After having performed the operations described
above, the following operations are necessary to
start the boiler:
- If the system is fitted with a temperature con-
troller or timer-thermostat, check that these
are "on".
- Set the room timer-thermostat or the tempera-
ture controller to the desired temperature.
- Move the main system switch to "on"
- Set the boiler thermostat located on the
control panel
- Move the main switch on the control panel to
"on" and check that the green indicator light
comes on.
The boiler will run the ignition phase and will
remain on until the set temperature has been
reached. If problems occur during ignition or
operation, the boiler will "LOCKOUT", as signal-
led by the red light on the burner and the red
- 22 -
8.3 Shutting down the boiler
- Set the temperature controller to the minimum.
- Disconnect power from the burner and close
the fuel supply.
- Let the pumps operate until they are stopped
by the temperature controller.
- Disconnect power from the electrical panel.
indicator on the control panel. After a
"LOCKOUT", wait around 30 seconds before
restoring the ignition conditions. To restore the
ignition
conditions,
press
"button/light" and wait for the flame to ignite. If
this operation fails, it can be repeated a maxi-
mum 2-3 times, then check:
- The information provided in the burner instruc-
tion booklet.
- The chapter on "CHECKING THE OPERA-
TION OF THE BOILER".
- The electrical connections described on the
diagram supplied with the control panel.
When the boiler has started, check that it stops
and starts again:
- Adjust the setting of the boiler thermostat.
- Move the main switch on the control panel.
- Set the room thermostat, the timer or the tem-
perature controller.
- Check that the pumps are not blocked and
rotate in the correct direction.
- Check the total shutdown of the boiler using
the main system switch.
If all the conditions are correct, restart the
appliance, check the combustion (flue gas
analysis), the fuel rate and the tightness of the
gaskets on the door and the smokebox.
9.6 Checking the operation of the burner
- Refer to the burner instruction manual.
- Follow all the local legislation in force on
burner maintenance.
9.7 Troubleshooting
The following is a list with information on the
main faults or problems that may occur during
the operation of the boiler, showing the possible
causes and corresponding solutions.
the
burner
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