48
Installation and Servicing
Section 3 - Servicing
SER
VICING
Refer to Section
3.2
1. Drain the boiler.
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
3.7
6. Remove the ignition/detection electrode.
Refer to Section
3.9
7. Remove the spark generator.
Refer to Section
3.14
8. Remove the gas valve.
Refer to Section
3.15
9. Remove the expansion vessel.
Refer to Section
3.24
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 and remove pipe.
12. Remove the two retaining pipe clips and remove pipes.
13. Remove the condensate rubber pipe.
Refer to Section
3.10
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.
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, ensure clip is oriented to correctly match
connecting pipe diametres.
3.25 HEAT ENGINE REPLACEMENT
18. Ensure the trap is filled with water.
Refer to Section
3.16
19. Refill the boiler and check for leaks.
Refer to Section
2.15
20. Ensure all gas valve connections are gas tight with a gas
soundness check up to the gas control valve.
21. Check that the boiler operates.
5
4
7
10
12
18
1
12
14
14
11
8
6
9
CAUTION:
Protect the gas and electrical controls with
a waterproof sheet.
13
Refer to Section
2.1
