19
Super Plus -
Installation and Servicing
IMPORTANT: In order to ensure the safe and reliable operation
of
SUPER PLUS
boilers it is essential that regular maintenance
is carried out by competent staff who have received instruction in
maintenance, fault finding and commissioning procedures for this
boiler series. Inadvertent substitution or replacement of similar
components particularly those with plug-in bases could cause a
hazard.
SERVICING INSTRUCTIONS
ANNUAL servicing is recommended.
BEFORE CARRYING OUT ANY SERVICING PROCEDURE:
1
. ISOLATE THE BOILER ELECTRICAL SUPPLY.
2.
TURN OFF THE GAS SERVICE TAP ON THE MODULE
BEING SERVICED.
The following procedure should be carried out annually.
PREPARATION FOR SERVICING
(See Figs 2, 3 & 4)
Undo the retaining screw from the front of the module upper cover
and remove the cover by pulling forwards and lifting it slightly at
the back to clear the shoulder nuts. Pull out the multi-pin electrical
plug from the side of the module.
Undo the screw at the base of the controls chassis and remove
the lower cover by lifting it to clear the shoulder nuts and pulling
it forwards.
Unscrew & remove ferrule (Fig.18) from spark electrode &
disconnect ignition lead. Pull off in-line connector in the flame
sensing probe lead.
Undo the screws fastening the electrical plugs to the 2 main gas
valves Pull out the plugs.
Unclip the fan motor lead and pressure switch lead from the clips
on the controls chassis.
Pull out the split pin, retaining clip and overheat thermostat in the
flow elbow, release the clip from the pocket in the return elbow
and pull out the main thermostat sensor. Undo the suction sensing
line connection at the venturi casting and at the pressure switch.
Remove the line.
Undo the pressure sensing line connection at the base of the fan
housing and at the pressure switch and remove the line. Pull out
the 3 push-on connections and unscrew the earth connection from
the pressure switch on the RHS of the controls box.
Take the weight of the fan and controls box assembly, undo the
4 nuts and washers securing it to the venturi casting and remove
the assembly.
Fig. 18 Spark Electrode Setting
SERVICING & FAULT FINDING
Pull off the venturi casting and gasket.
Remove the main burner-complete with the spark electrode and
flame sensing probe.
Brush the inside and outside of the burner, making sure to clear
any blockages in the burner.
Check the pilot wedge holes and make sure that they are clear,
If the burner shows any sign of deterioration it should be replaced.
Inspect the spark electrode and the flame sensing probe. If there
is any sign of damage or erosion the part should be replaced.
Check the spark gap - it should be 3.5 ± 0.5 mm (Fig.18).
HEAT EXCHANGER
Inspect the dry side of the heat exchanger finned tubes via the
burner opening, using a torch, and by removing the inspection
panels on the sides of the boiler.
The inside of the heat exchanger can be brushed free of deposits,
using a suitable brush.
Should the inspection indicate that a more thorough cleaning is
required, necessitating the removal of the module from the boiler,
then refer to 'MODULE CLEANING'. The burner opening in the top
cover plate should be brushed free of any deposits.
CLEANING THE FAN
Undo the 4 screws retaining the fan housing to the controls box
assembly and remove the housing. The fan impeller blades can
now be cleaned using a soft brush.
CLEANING THE MODULE COVER FILTER
The module lower cover is fitted with a polyurethane foam filter
which forms the bottom panel of the cover.
To remove the filter pull it from the module cover. Wash the filter
in warm soapy water. It should then be thoroughly rinsed and left
to dry.
RE-ASSEMBLY
Push the module filter back into its retaining slots on the underside
of the module lower cover. Ensure that it is correctly positioned,
i.e. with the stiffening framework to the bottom and the central U
cutout in the framework to the rear. Refit the fan housing to the
controls box assembly.
If any of the venturi cork gaskets are damaged or in any way
unsound then the gasket must be replaced.
Carefully refit the burner to the module, ensuring that the extended
gasket is between the module and burner.
Fit one of the square gaskets and then the venturi casting over
the 4 studs. Ensure that the venturi is correctly positioned, i.e. with
the suction sensing line connection on the left hand side and with
its larger face towards the front. Refit the fan and controls box
assembly ensuring that the other square gasket is fitted between
the fan housing and the venturi casting. DO NOT OVERTIGHTEN
the elongated M8 studs or damage to the casting may occur.
Both pressure and suction sensing lines should be blown through
to free them from possible obstruction.
Refit the pressure sensing line to the pressure switch rear connection
and to the fan housing connection. Refit the suction sensing line
to the venturi casting and to the pressure switch front connection.
Reconnect the 3 push-on connections from the pressure switch
on the side of the controls box carefully observing the correct
positioning. In particular NEVER connect the black wire to the blue
connection. Refer to Fig.3.
Secure the 2 main gas valves and gaskets (with the white
cables), securing them with the screws; the pressure switch earth
connection. Reconnect the spark electrode lead and screw down
the ferrule. Refit the inline connector of flame sensing lead.
SERVICING
SER
VICING
