Sime Planet Super 4 F.S., Installation & Servicing Instructions Manual

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6.1 Heat Exchanger
Isolate flow and return valves
Turn off power supply
Drain boiler using manual drain vents
Remove fan as described in 6.2
Remove AP switch assembly as described in 6.6
Remove smoke chamber
Disconnect limit stat
Remove 2 spring clips securing connection
to heat exchanger
Lift out heat exchanger
Transfer limit stat to new heat exchanger
Refit in reverse order
Refill system and recommission
6.2 Fan Assy
Turn off power supply
Remove sealed chamber front cover
Disconnect APS sensing tube from smoke
chamber
Disconnect fan wiring
Remove fan plate fixing screws
Remove fan assy from sealed chamber
Remove fan from fan mounting plate
Refit in reverse order
6.3 Main Burner
Turn off power supply
Isolate gas supply
Remove sealed chamber cover
Remove combustion chamber cover
Remove combustion chamber front panel
Remove pipe connection main burner to gas valve
Remove main burner securing nut
Remove burner support screw
Disconnect ignition electrode from ignition
transformer
Disconnect Ionisation electrode at joint
close to control panel
Manoeuvre main burner forward of sealed
chamber whilst feeding ignition and ionisa-
tion leads into sealed chamber
Refit in reverse and recommission as
described
6.4 Ignition & Ionisation Electrodes
Remove main burner as described in 6.3
Remove electrode securing screw
Replace electrode ensuring correct gap
(4mm +/- 0.5mm)
Refit in reverse order
6.5 Gas Valve
Isolate gas supply
Turn off power supply
Disconnect modulator coil
Disconnect gas valve wiring (note plug
orientation)
Disconnect and remove gas valve
Refit using new washers
Reassemble in reverse order
Recommission boiler resetting gas pressures
Check for soundness
Set gas valve as described in 5.2.1 – 5.2.2
6.6 Air Pressure Switch
Isolate power supply
Remove sealed chamber cover
Disconnect sensing tube from APS, noting
position
Disconnect APS wiring, noting connections
Remove APS assembly
Remove APS from bracket
Refit in reverse order, ensuring correct con-
nection of sensing tube and wiring
6.7 Overheat Stat
(The overheat stat is situated to the RHS of
the sealed chamber)
Isolate power supply
Disconnect the two wires
Undo fixing screws
Refit in reverse order having spread heat
sink paste to base of new thermostat (pola-
rity is immaterial)
6.8 Thermistor
(Situated to RHS of sealed chamber)
Isolate power supply
Isolate CH flow and return
Drain boiler using drain plug
Disconnect thermistor wiring
Unscrew thermistor
Replace the thermistor and reassemble in
reverse order
Table shows resistance values obtained at
the sensor as the temperature varies
Temp °C Resistance
20 12,090
30 8,313
40 5,828
50 4,161
60 3,021
70 2,229
80 1,669
6.9 Printed Circuit Board
Re hang control panel as described in 5.6.1
Remove control panel cover
Pull of the potentiometer knobs
Remove all connections to PCB and remove
6 PCB screws
Ensure links and switches on new PCB are
set correctly
Transfer potentiometer spindles and trim-
mer spindles
Refit in reverse order
Recommission, ensuring CH output is set
correctly (see section 5.3)
6.10 Pumps
Isolate power supply
Isolate flow and return valves
Drain boiler using drain vent
Disconnect pump wiring plug
Remove pump complete with non return valve
Inspect non return valve for correct operation
Transfer to new pump using new washers
Transfer auto air vent if required
Refit pump in reverse order
Recommission
6.11 Central Heating Expansion Vessel
Isolate power supply
Isolate CH flow and return
Drain boiler using drain vent
Remove expansion vessel connection pipe
Remove expansion vessel fixing bracket
Remove expansion vessel
Ensure new vessel has correct pressure (1
bar)
Refit in reverse order using new washers
Recommission boiler
6.12 DHW Expansion Vessel
Isolate power supply
Isolate DW supply
Drain cylinder using drain cock
Remove expansion vessel
Ensure new vessel has correct pressure (3 bar)
Refit in reverse order using new washers
Recommission boiler
6.13 Safety Valves
3 Bar Safety Valve (System)
Isolate power supply
Isolate CH flow and return valves
Drain boiler using drain vent
Disconnect 3 bar valve from pipe work
Transfer drain vent to new 3 bar valve
Refit in reverse order using new washers
Recommission boiler
7Bar Safety Valve (Cylinder)
Isolate power supply
Isolate Domestic water supply
Drain some water from the cylinder
Remove 7 bar valve
Refit in reverse order using new washers
Recommission boiler
6.14 Auto Air Vents
Isolate power supply
Isolate CH flow and return valves
Drain boiler using drain vents
Remove auto air vent from pump
Refit in reverse order
6.15 Timer (if fitted)
Turn off power supply
Remove PCB cover as described in 6.9
Unplug timer from PCB
Remove timer fixing screws
Remove timer
Transfer wiring to new timer ensuring cor-
rect connection
Refit in reverse
Recommission boiler
6.16 Magnesium Anode Inspection
Isolate power supply
Turn off domestic water supply
Drain some water from cylinder using drain
cock
Remove anode
Replace if required
Refit in reverse
Recommission boiler
6.17 Gas Conversion
Remove burner as described in 6.3
Remove burner bar
Replace the main nozzles with ones supplied
in kit (5185403 Nat Gas or 5144708 LPG)
Remove control board cover as described in 6.9
Refit link 7 (fig 17) if converting to LPG
Remove link 7 (fig 17) if converting to Nat Gas
Reset gas valve pressures as per table 6
Check for gas soundness
Affix correct sticker to data plate showing
gas used
20
6 REPLACEMENT OF PARTS