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54
Installation and Servicing
Section 3 - Servicing
SER
VICING
5
6
7
10
12
18
1
11
11
14
14
13
12
Refer to Section
3.2
1. Drain the boiler (CH Circuit Drain).
Refer to Section
3.3
2. Undo the two screws and remove the sump cover
retaining the lower flue manifold.
3. Lift the manifold to clear the bottom sealing gasket and
remove manifold.
4. Remove the fan / venturi assembly and place on one
side.
Refer to Section
3.6
5. Remove the burner and place on one side.
Refer to Section
3.4
6. Remove the ignition/detection electrode.
Refer to Section
3.18
7. Remove the spark generator.
Refer to Section
3.15
8. Remove the gas valve.
Refer to Section
3.16
9. Remove the expansion vessel.
Refer to Section
3.31
10. Remove the 2 M5 screws retaining the spark generator,
mounting bracket and transfer bracket to the new heat
exchanger.
11. Undo the pump union nut, remove clip and remove pipe
from expansion vessel.
12. Remove the two retaining pipe clips and remove pipes.
13. Remove the condensate rubber pipe.
Refer to Section
3.18 No.2
14. Remove the two heat exchanger fixing screws.
15. Remove the heat exchanger, slide out of location
bracket.
16. If replacement sump required: Rotate heat exchanger
assembly 180º. Place new sump onto heat exchanger,
ensuring correct orientation and seal is in place.
Then gently apply pressure to the base of the sump
at each tab fixing point and engage tabs onto the heat
exchanger.
3.30 HEAT ENGINE REPLACEMENT
17. Reassemble, ensuring the heat exchanger is located
correctly in the LHS retaining bracket. Replace any new
‘O’ rings supplied with new heat exchanger and replace
gaskets or seals if any sign of damage is evident. When
replacing the spring clips located on the return pipe
connection, check that the clip is oriented to correctly
match connecting pipe diametres.
18.
Ensure the trap is filled with water.
Refer to Section
3.18
19. Refill the boiler and check for leaks.
Refer to Section
2.16
20. Check that all gas valve connections are gas tight with a
gas soundness check up to the gas control valve.
9
CAUTION:
Protect the gas and electrical controls with
a waterproof sheet.
Refer to Section
2.1
4
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