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30
REPLACEMENT OF PARTS
Manual No. 405/0101
9. REPLACEMENT OF PARTS - PAGE 30
WARNING:
Before commencing work open the control panel cover (hinges down) and turn the boiler thermostat to O. Allow
the boiler to cool and isolate the electricity supply.
IMPORTANT:
Always test for gas soundness after completing any exchange of gas carrying components and carry out
functional checks of controls.
9. 1
GENERAL ACCESS PRIOR TO REPLACEMENT OF PARTS
Refer to Figs. 32 and 35.
Ensure that the electricity supply is off.
1.
Replacement of any component requires the removal of
the outer case front panel as follows:
a.
With the control panel cover open, remove the two
screws (one each side) securing the control panel to
the case side panels.
b.
Carefully slide out the assembly away from the boiler,
unclipping the neon from the back of the control panel
before fully withdrawing the assembly.
Note:
If a programmer is fitted, disconnect the wiring
harness from the rear of the programmer before fully
withdrawing the bottom panel assembly.
c.
Remove the outer case front panel by pulling it
forwards off its fixings.
d.
Place the case parts safely aside to avoid possible
damage.
e.
Turn off the gas supply at the gas service cock
(bottom L.H. corner).
2.
Sections 9.3 to 9.12 involve replacement of components
within the room-sealed section of the
Fig. 35
boiler. All necessitate the removal of the inner case front panel, see Fig. 32, as follows:
a.
Remove the screw securing the control box, see Fig. 25 and lower the control box.
b.
Remove the two tie rods from the retaining clips on the front of the expansion vessel frame and remove the split pins
from the ends of the rods. Remove the two screws securing the expansion vessel support frame to the inner case front
panel. Hook the plain ends of the tie rods into the brackets on the sides of the boiler. Carefully lower the expansion
vessel and frame (hinged at the bottom). Locate the other ends of the tie rods in the brackets on the expansion vessel
frame, then pass the split pins through the ends of the rods to secure them in place. See Fig. 32.
c.
Remove the four screws (two at the top and two at the bottom) securing the inner case front panel and lift off the panel.
See Fig. 32.
Note:
When the inner case front panel is removed, the four case seal housing channels are not secured to the boiler as
they are retained in position by the front panel. Ensure that they are correctly fitted over the chassis edges before the
front panel is replaced.
9.2
REASSEMBLE THE BOILER AFTER REPLACEMENT OF PARTS
Refer to Figs. 32 and 35.
1.
Ensure that the inner case seals are intact and in position in the seal housing channels and that the channels are correctly
located over the sides of the boiler chassis.
2.
Replace the inner case front panel (expansion vessel frame fixing brackets nearest the top), securing it in position with the
four screws previously removed. Tighten sufficiently to form a seal.
3.
Remove the split pins from the ends of the tie rods and unhook them from the support frame, raise the expansion vessel
assembly and secure the frame to the inner case front panel using the two screws previously removed.
4.
Unhook the tie rods from the sides of the boiler, replace the split pins into the rods and position them in the retaining clips on
the front of the expansion vessel frame.
5.
Raise the control box and secure in position with the screw previously removed.
