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8.13 ALPHA CONTROLS (if fitted) - Fig. 5.15
Note:
For replacement only use an Alpha single channel control.
Do not
fit a two channel control.
1. Gain access behind the control panel as described in Section 8.1.
2. Remove the three screws securing the terminal block cover at the rear of the panel.
3. Remove the three control retaining screws and withdraw the control from the panel.
4. Disconnect the wiring from the control.
5. Connect the wires to the new control as follows:
Blue to terminal 1, Brown to terminal 2 and Red wires to terminals 3 and 4, (or as per the instructions supplied with the
control).
6. Re-assemble in reverse order. Refer to the User's instructions and the boiler's control cover to set the control.
8.14 DHW TEMPERATURE SENSOR - Fig. 8.3
1. The DHW sensor is positioned in the hot water outlet pipe to the left of the flow switch, see Fig. 8.3. Unplug the two
connections and unclip the sensor from the pipe.
2. Re-assemble in reverse order with a new sensor.
Note:
The DHW sensor should be on the sloped part of the DHW pipe. See Fig. 8.3.
8.15 COMBUSTION CHAMBER INSULATION
Gain access to the combustion chamber as described in Section 8.1.
Front panel insulation - Fig. 7.7
1. Remove the electrodes from the combustion chamber front as described in Section 8.3.
2. Remove the four screws securing the burner.
3. Carefully remove the insulation.
Back panel insulation - Fig. 8.4
1. Remove the combustion chamber front/burner assembly.
2. Carefully remove the insulation, suction applied to the centre of the insulation will aid this.
Fit a new panel and re-assemble in reverse order.
8.16 CONDENSATE TRAP - Figs. 5.3 and 8.3
1. Gain access behind the front casing as described in Section 8.1.
2. Disconnect the top and drain connection of the condensate trap.
3.
Place a container under the boiler and unscrew the bowl at the bottom of the trap, see Fig. 5.3. Some water will spill from
the trap.
4. Remove the screw securing the trap to the bottom of the boiler casing and lift out the trap.
5. Fit the new trap in reverse order.
Note:
Fill the new trap with water once installed.
8.17 HEAT EXCHANGER THERMAL FUSE - Fig. 8.4
Note:
If the thermal fuse has failed or operated, the heat exchanger
must
be
replaced. Do not attempt to remove the thermal fuse. Disturbing the sealant
securing the thermal fuse will invalidate the warranty.
1. Gain access behind the front casing as described in Section 8.1.
2. Disconnect the wire from the thermal fuse and remove the heat exchanger
as described in Section 8.19.
3. Fit a new heat exchanger and re-assemble in reverse order.
8.18 DHW FLOW SWITCH - Fig. 8.3
1. Gain access behind the front casing as described in Section 8.1.
2. Isolate the mains water supply and open all hot taps to drain any water from the boiler.
3. Disconnect the wires from the switch.
4. Undo the union nut and remove the fixing screw from the bottom of the switch.
5. Remove the two 4 mm socket head capscrews securing the top switch and lift out the switch.
6. Fit the new switch and re-assemble in reverse order.
Alpha InTec 40GS2 - Component Replacement
Fig. 8.4
Thermal fuse
Back panel
insulation
Manual air vent
