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32
REPLACEMENT OF PARTS
Manual No. 405/0101
REPLACEMENT OF PARTS - PAGE 32
9. 5
TO REPLACE THE PILOT BURNER
Refer to Fig. 34.
1.
Gain general access as described in section 9.1.
2.
Remove the screws (four on the 80 model, six on the other models) securing the combustion chamber front cover and
remove the cover.
3.
Remove the bottom case seal housing channel (lifts off the chassis).
4.
Undo the securing nut and remove the spark electrode, see Fig. 34, from the pilot assembly.
5.
Undo the tubing nuts and disconnect the pilot supply from both the pilot assembly and gas valve.
Carefully remove and retain the pilot injector, see Fig. 34.
6.
Remove the two screws (underneath the chassis) securing the small baffle infront of the burner and remove the baffle.
7.
Remove the two screws securing the right hand end of the main burner to the chassis. Slide the burner to the right, to
remove it from the main injector and withdraw the burner.
8.
Remove the two screws securing the pilot burner to the main burner and replace with a new pilot burner.
9.
Replace the main burner (ensure that it is located over the injector) then the small baffle infront of it using the screws
previously removed.
10.
Locate the pilot injector over the end of the pilot supply, as shown in Fig. 34 and carefully position it in the pilot burner.
Secure the pilot supply to the pilot assembly and gas valve.
11.
Replace the spark electrode and check that the spark gap is 5.0 mm ± 2 mm, see Fig. 34.
12.
Ensure that the pilot supply and electrode lead are in position in the cut out in the bottom of the chassis and replace
the seal housing channel over the bottom of the chassis, ensure it is pushed fully home.
13.
Replace the combustion chamber front cover and secure in position with the screws (four or six) previously removed.
14.
Refer to the Commissioning Instructions, section 4. Light the pilot, check the pilot flame and test the pilot supply for
gas soundness.
15.
Reassemble the boiler as described in section 9.2 (ignore paragraph 6).
16.
Refer to the Lighting Instructions, section 8 and light the boiler.
9.6
TO REPLACE THE MAIN BURNER
1.
Remove the burner as described in section 9.5, paragraphs 1 to 7.
2.
Remove the two screws securing the pilot burner to the main burner and transfer it to the new burner.
3.
Replace the new burner and reassemble the boiler as described in section 9.5, paragraphs 8 to 16.
9.7
TO REPLACE THE OVERHEAT CUT-OFF DEVICE
Refer to Fig. 36.
The overheat cut-off device is positioned on the side of the heat exchanger at the front - at the left hand side on the 30, 40,
50 models and at the right hand side on the 60, 80 models.
1.
Gain general access as described in section 9.1.
2.
Remove the push rod assembly from the cut-off device
(lifts off) and disconnect the two leads.
3.
Remove the two screws securing the blanking plate at
the side of the flue hood and remove the blanking plate.
4.
Remove the two screws securing the cut-off device to the
heat exchanger.
5.
Ensure that the mounting plate is clean and secure the
new cut-off device to the heat exchanger.
6.
Replace the blanking plate, connect the leads (the
polarity is not important) and connect the push rod to the
cut-off device (the rubber sleeve locates over the cut-off
device button).
7.
Reassemble the boiler as described in section 9.2.
8.
Refer to the Lighting Instructions, section 8 and light the
boiler.
Fig. 36
