Boiler maintenance11
11 Boiler maintenance
11.1 Why is regular maintenance important?
Heating systems should be regularly maintained for the
following reasons:
– to achieve a high level of efficiency and to operate
the system economically (low fuel consumption),
– to achieve a high level of operational reliability,
– to maintain the cleanest possible combustion.
Offer an annual inspection and maintenance contract
(depending on requirements) to your customer. You can
check in the inspection and maintenance reports
(Î Chapter 11.6, page 54) what should be included in
such contracts.
NOTICE
You may order spare parts from your local
distributor.
11.2 Preparing the boiler for cleaning
z Shut down the heating system (Î Chapter 10.1,
page 49).
DANGER TO LIFE
from electric shock.
WARNING!
z Remove the burner door panel or the burner hood
from the boiler.
z Disconnect electrical supply to burner.
WARNING!
z Before you open the control: shut off
electrical supply and secure against
accidental activation.
DANGER TO LIFE
through the explosion of volatile gases.
z Work on gas components must be
carried out by qualified and authorized
personnel only.
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Installation and maintenance instructions Logano G215 US oil/gas-fired boilers • Issue 2014/10
Boiler maintenance 11
11.3 Boiler cleaning
The boiler can be cleaned with brushes and/or by a wet
method. Cleaning equipment is available as accessory.
DANGER OF BURNS
by touching hot boiler parts.
CAUTION!
z Open burner door by removing the two hexagon bolts
on the sides.
11.3.1 Cleaning the boiler with cleaning brushes
z Note the position of the flue gas baffle plates to
enable their correct re-installation later.
z Remove the flue gas baffle plates from the flue gas
flues.
z Clean the flue gas baffle plates with one of the two
cleaning brushes.
z Wear appropriate protective gloves or
use pliers.
3
2
1
z Clean the flue passages by turning the round
cleaning brush.
Fig. 67 Open the burner door
1 Combustion chamber
2 1. flue gas pass
3 2. flue gas pass
Fig. 68 Brushing out the flue gas passages
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Installation and maintenance instructions Logano G215 US oil/gas-fired boilers • Issue 2014/10
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Boiler maintenance11
z Clean the combustion chamber with a flat brush.
Remove the debris from the combustion chamber,
the flue passages and the flue connection.
z Install the flue baffle plates in their original position.
z Check sealing rope on burner door. Replace
damaged or hardened sealing rope.
NOTICE
You can obtain suitable sealing rope from
your local Buderus distributor.
z Close burner door with the two hexagon bolts
(approx. 90 lbs/inch) Tighten the hexagon bolts
evenly to properly seal the burner door.
11.3.2 Wet cleaning (chemical cleaning)
When using a wet cleaning method use a suitable
cleaning agent (soot or accumulation of debris).
Proceed with the wet cleaning in the same order as
described for cleaning with brushes (Î Chapter 11.3.1,
page 51).
NOTICE
Observe the instructions for use of the
cleaning agent. You may need to proceed
differently from the method described here
in some circumstances.
z Cover the control panel with plastic to prevent spray
from entering the control panel.
z Spray cleaning agent evenly into the flue gas passes.
z Close burner door and start up the heating system.
z Heat the boiler to a temperature of at least 160 °F.
z Shut down the heating system.
z Brush out the hot gas flues.
Fig. 69 Brushing out the combustion chamber
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Installation and maintenance instructions Logano G215 US oil/gas-fired boilers • Issue 2014/10
Boiler maintenance 11
11.4 Checking the heating system
operating pressure
The system pressure for closed systems must be
12 – 30 psi (1 – 2.1 bar).
z Check system pressure
z If the pressure gauge shows less than 12 psi, the
pressure is too low. Top up with water.
SYSTEM DAMAGE
due to frequent topping up.
CAUTION!
CAUTION!
If you need to add water frequently, the
heating system may be damaged by
corrosion and lime accumulation.
z Ensure that your heating system is bled
properly.
z Check the heating system for leaks and
proper operation of the expansion tank.
SYSTEM DAMAGE
due to material stress as a result of
temperature differentials.
z Only fill the system when cold (the flow
temperature should be no more
than 100 °F).
Fig. 70 Pressure/temperature gauge for showing operating
pressure and feed temperature
z Add water through the feed valve.
z Vent heating system
z Check the pressure again.
11.5 Testing relief valve
The functioning of the pressure relief valve must be
checked at regular intervals (1-3 years as specified by
local codes).
z Make sure that no persons are in the discharge area
of the pressure relief valve.
z Raise the lever on the pressure relief valve.
The pressure relief valve must open and release
pressure. If the pressure relief valve does not discharge,
it must be replaced, because system components may
be damaged by excessive pressure.
We reserve the right to make any changes due to technical modifications.
Installation and maintenance instructions Logano G215 US oil/gas-fired boilers • Issue 2014/10
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Boiler maintenance11
11.6 Inspection and maintenance protocols
z Sign all service work as completed and enter the
relevant date.
Service work Page Date: ______ Date: ______ Date: ______
1. Check the general condition of the heating system
2. Visual and function check of the heating system
3. Check all fuel and water components of the system for:
– leaks during operation
– leak test
– visible signs of corrosion
– signs of ageing
4. Check the combustion chamber and the heating surface for
contamination; shut down the system for this step
5. Check the burner (Î burner manual)
6. Check the combustion air supply and flue gas routing for function
and safety
7. Check the operating pressure, relief valve and expansion tank inlet
pressure
The service and maintenance protocols can also be
used as templates.
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8. Check the DHW tank and corrosion anode for function (Î DHW
tank documentation)
9. Check the control settings (Î control manual)
10. Record the final checks of the inspection work, incl. measurements
and test results
Confirm service work
Company
stamp/signature
Company
stamp/signature
Company
stamp/signature
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Installation and maintenance instructions Logano G215 US oil/gas-fired boilers • Issue 2014/10
Boiler maintenance 11
Date: ______ Date: ______ Date: ______ Date: ______ Date: ______ Date: ______ Date: ______
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Company
stamp/signature
Company
stamp/signature
Company
stamp/signature
NOTICE
During the inspection if you identify any
required maintenance steps, do it as soon
as possible.
Company
stamp/signature
Company
stamp/signature
Company
stamp/signature
Company
stamp/signature
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Installation and maintenance instructions Logano G215 US oil/gas-fired boilers • Issue 2014/10
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Boiler maintenance11
On-demand maintenance procedures Page Date: ______ Date: ______ Date: ______
1. Shut down the heating system 49
2. Remove and clean the flue baffles 51
3. Clean the (heating surfaces) and combustion chamber, then reinstall the flue baffle plates in their original position.
4. Check and, if required, replace gaskets/sealing rope on the burner
door and burner
5. Start up the heating system 45
6. Carry out final check of the maintenance work
7. Check the function and safety in operation
Confirm professional maintenance
Date: ______ Date: ______ Date: ______ Date: ______ Date: ______ Date: ______ Date: ______
1.
2.
3.
51
52
Company
stamp/signature
Company
stamp/signature
Company
stamp/signature
4.
5.
6.
7.
Company
stamp/signature
Company
stamp/signature
Company
stamp/signature
Company
stamp/signature
Company
stamp/signature
Company
stamp/signature
Company
stamp/signature
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Installation and maintenance instructions Logano G215 US oil/gas-fired boilers • Issue 2014/10
Troubleshooting 12
12 Troubleshooting
Two different types of faults are defined
– Burner faults and
– control and heating system faults.
If there is a burner fault the alarm light on the burner
comes on (Î burner manual). Such faults can generally
be reset by pressing the reset button on the burner only
once.
Control and heating system faults are indicated on the
control display if it is fitted with a display. For further
information see Î control manual.
Correcting burner faults
z Remove the burner hood if the boiler is equipped with
an integral burner.
z Press reset button on burner only once.
1
CAUTION!
SYSTEM DAMAGE
due to freezing temperatures.
The heating system can freeze up in cold
weather if it has been switched off by a fault
shutdown.
z Immediately remedy the fault and
restart the heating system.
z If this is not possible, protect your
heating system against freezing by
draining the heating system and hot
water pipes at the lowest possible point.
Fig. 71 Resetting the burner
1 Burner
We reserve the right to make any changes due to technical modifications.
Installation and maintenance instructions Logano G215 US oil/gas-fired boilers • Issue 2014/10
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