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39
REPLACEMENT OF PARTS
Manual No. 405/0101
REPLACEMENT OF PARTS - PAGE 39
9.23
TO REPLACE THE TEST SWITCH
Ensure that the electricity supply is off.
1.
Remove the case as described in section 7.1.
2.
Remove the four screws securing the control box front cover and carefully swing down the cover.
3.
Disconnect the push-on terminals from the switch.
4.
Note which way the switch is fitted (the end terminal should be at the right hand side, next to the 1 on the label), then
compress the clips on the switch body and push it out of the control box.
5.
Fit the new switch and connect the wires. The Orange wire must go to the end terminal (right hand side next to 1 on the
label) and the white wire to the centre terminal.
6.
Replace the control box front and secure in position with the four screws previously removed. Ensure that the boiler
thermostat capillary is located in the cut out in the side of the control box.
7.
Replace the case as described in section 7.5.
8.
Refer to the Lighting Instructions, section 8 and light the boiler.
9.24
TO REPLACE THE NEON INDICATOR
Ensure that the electricity supply is off.
1.
Remove the case as described in section 7.1.
2.
Remove the screw securing the control box, see Fig. 25 and lower the control box.
3.
Disconnect the neon wires from the terminal block on the top of the control box. Connect the new neon wires to the
same connections, see wiring diagram on page 41. The polarity of the wires is not important.
4.
Raise the control box and secure in position with the screw previously removed.
5.
Replace the case as described in section 7.5.
6.
Refer to the Lighting Instructions, section 8. Light the boiler and check the controls.
9.25
TO REPLACE THE EXPANSION VESSEL
Ensure that the system is drained.
1.
Gain general access as described in section 9.1, paragraph 1.
2.
Drain the system.
Note:
When the system is drained, filled or vented, the manual lever on the right hand side of the diverter valve, see
Fig. 27, must be moved to the 'MAN OPEN' (top) position. Return it to its original position after the system has been
filled and vented.
3.
Remove the screw securing the control box, see Fig. 25 and lower the control box.
4.
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. Lower the assembly (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. Disconnect the flexible pipe from the expansion
vessel and remove the vessel.
5.
Position the new vessel in the frame with the connection point uppermost and towards the boiler, see Fig. 26 and
connect the flexible pipe using a new washer.
6.
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. 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.
7.
Fill the system and vent the boiler as described in section 3.16, paragraphs 2 to 5. Check the expansion vessel
connection for water soundness.
8.
Reassemble the boiler as described in section 9.2, paragraphs 6 to 9.
9.
Refer to the Lighting Instructions, section 8 and light the boiler.
