ZZ 1019/1E
8
9.
SERVICING
IMPORTANT:
Ensure that the gas and electricity supplies are isolated before commencing any
maintenance or replacement of components. After completion of any maintenance, always test for gas
soundness and carry out a complete functional test of the appliance in accordance with the
Commissioning Instructions.
9.1
ROUTINE MAINTENANCE:
9.1.1
Operate the appliance and check for correct function.
9.1.2
Clean the air circulation fan and the air filter.
Note:
The air/fuel ratio is controlled automatically and therefore combustion is and will remain extremely clean. In the
unlikely event of this ratio deviating from the norm, the system will lock out. It is, therefore, not necessary to remove the
burner assembly for internal inspection during an annual service.
9.1.3
Reassemble all items in reverse order and carry out the commissioning procedure as detailed in Sect 6.
9.2
MULTIFUNCTIONAL CONTROL REMOVAL:
9.2.1
Ensure that the gas and electrical supplies are switched off.
9.2.2
Remove the single screw securing the heater front cover, and remove the front cover.
9.2.3
Remove the central securing screws and disconnect 2 x electrical plugs from Multifunctional control.
9.2.4
Disconnect the flexible silicon tube from the rear and the 8mm pipe from the top of the multifunctional control.
9.2.5
Disconnect the gas supply union from beneath the multifunctional control.
9.2.6
Remove 2 x screws securing multifunctional control mounting bracket to heater body, and withdraw the
multifunctional control.
9.2.7
Refitting or replacement is in reverse order.
Note:
If the multifunctional control is to be replaced, transfer the
pipe fittings and mounting bracket to the new unit.
9.3
BURNER ASSEMBLY REMOVAL:
9.3.1
Referring to 9.2, remove the multifunctional control.
9.3.2
Disconnect the igniter lead from the ignition/detection electrode.
9.3.3
Disconnect the gas feed pipe from the burner assembly.
9.3.4
Remove the four hexagonal burner manifold fixing screws from the manifold front flange, and slacken the three
hexagonal screws at the rear of the manifold.
9.3.5
Slide the manifold down to disengage the air connection, and then forward to disengage the rear screws. Withdraw
the burner manifold and burner face plate.
9.3.6
Refitting or replacement is in reverse order, ensuring that the metal fibre on the burner face plate is
TOWARDS
the manifold.
9.4
BURNER ASSEMBLY CLEANING:
9.4.1
Referring to 9.3, remove the burner assembly.
9.4.2
Using a soft brush, lightly brush the burner manifold inside and out, taking care to avoid damaging the injector.
9.4.3
Using a vacuum cleaner with nozzle attachment, carefully clean the burner face plate element if necessary.
DO
NOT USE
a wire brush or sharp implement, since the element is fragile and easily damaged.
9.5
AIR CIRCULATION FAN REMOVAL AND CLEANING:
9.5.1
Ensure that the electrical supply is switched off.
9.5.2
Remove the heater front cover.
9.5.3
Disconnect the air circulation fan flying lead from the electrical panel.
9.5.4
Release the 4 screws securing the electrical panel, withdraw, swing down and support the electrical panel,
ensuring that no strain is place upon or any damage is caused to any electrical wiring or connections.
9.5.5
Remove the air circulation fan securing screw, and slide the fan from its locating channel.
9.5.6
Remove all dust from both the impeller and motor, taking care to avoid disturbance of the fan balancing.
9.5.7
Refitting or replacement is in reverse order, referring to Fig. 7 for correct wiring.
ZZ 1019/1E
9
9.6
REMOVAL OF INJECTOR:
9.6.1
Referring to 9.3, remove the burner assembly.
9.6.2
Using 14mm A/F ring spanner, undo the nut and washer, and remove injector from burner manifold.
9.6.3
Refitting or replacement is in reverse order.
9.7
FUSE REPLACEMENT:
9.7.1
Ensure that the electrical supply is switched off.
9.7.2
Remove the heater front cover.
9.7.3
Replace the appliance fuse, situated on the electrical panel.
The only fuse to be fitted is 20mm, T3.15 (slow
blow)
.
9.8
FAN SPEED TRANSFORMER REMOVAL:
9.8.1
Ensure that the electrical supply is switched off.
9.8.2
Remove the heater front cover.
9.8.3
Disconnect the leads from the transformer as follows:
a.
YELLOW
lead from terminal marked ‘
T1
’,
b.
WHITE
lead from terminal marked ‘
T2
’,
c.
BROWN
lead (terminal block ‘8’) from terminal marked ‘
L
’,
d.
BROWN
lead (fan speed terminal block ‘230V) from terminal marked ‘
L2
’,
e.
BLUE
lead from terminal marked ‘
N
’.
9.8.4
Release the 4 screws securing the electrical panel, withdraw, swing down and support the electrical panel,
ensuring that no strain is place upon or any damage is caused to any electrical wiring or connections.
9.8.5
Release the 2 x securing screws, nuts and lock washers, and withdraw the transformer from the electrical panel.
9.8.6
Refitting or replacement is in reverse order, ensuring the leads are correctly reconnected to the transformer.
9.9
CONTROL MODULE TRANSFORMER REMOVAL:
9.9.1
Ensure that the electrical supply is switched off.
9.9.2
Remove the heater front cover.
9.9.3
Disconnect the transformer leads as follows:
a.
2 x
ORANGE
leads from the Control Module terminals,
b.
BROWN
lead from the terminal block terminal marked ‘
8
’,
c.
BLUE
lead from the terminal block terminal marked ‘
9
’.
9.9.4
Release the 4 screws securing the electrical panel, withdraw, swing down and support the electrical panel,
ensuring that no strain is place upon or any damage is caused to any electrical wiring or connections.
9.9.5
Release the 2 x securing screws, nuts and lock washers, and withdraw the transformer from the electrical panel.
9.9.6
Refitting or replacement is in reverse order, ensuring the leads are correctly reconnected to the transformer.
9.10
IGNITION/DETECTION ELECTRODE REMOVAL:
9.10.1 Referring to 9.3, remove the burner assembly.
9.10.2 Remove the securing nut and washer, and carefully remove the electrode from the burner.
9.10.3 Refitting or replacement is in reverse order, taking care to avoid bending the electrode since its profile is critical.
9.11
IGNITION MODULE REMOVAL:
9.11.1 Ensure the electrical supply is switched off.
9.11.2 Remove the heater front cover.
9.11.3 Disconnect the ignition lead from the ignition module.
9.11.4 Disconnect the ignition module edge connector plug.
9.11.5 Remove the 2 x securing screws and withdraw the ignition module.
9.11.6 Refitting or replacement is in reverse order.
