Gas Control Valve Replacement; Combustion Chamber Insulation Replacement - IDEAL Classic LXRS 230 Installation And Service Manual

46 GAS CONTROL VALVE REPLACEMENT

1. Refer to Frame 36.
2. Remove the burner support bracket, burner and air box
assembly. Refer to Frame 31.
3. Remove the gas control valve cover and remove the electrical
connections.
4. Disconnect the thermocouple from the gas control valve.
5. Disconnect and remove the gas union from the control valve.
6. Whilst supporting the gas control valve, remove the 2
screws retaining the manifold to the back panel.
7. Remove the gas control / manifold assembly.
8. Remove the 4 screws retaining the manifold to the gas control
valve and fit the new manifold to the gas control valve,
ensuring that it is fitted the correct way round (an arrow
engraved on the back indicates the direction of flow).
Note. Remove the thermocouple reroute and gas cock stub
and refit into the new gas control valve. Use an approved
jointing compound on the pipe stub.
9. Re-assemble in reverse order.
10. Replace the boiler casing.
11. Check the gas valve operation.

47 COMBUSTION CHAMBER INSULATION REPLACEMENT

1. Refer to Frame 36.
2. Remove the burner and air box
assembly. Refer to Frame 31.
3. Remove the 4 tie rods.
4. Remove the combustion chamber.
5. Remove the 2 side panel retaining
brackets.
6. Remove the side insulation panels.
48 HEAT EXCHANGER REPLACEMENT
Note. Refer to Frame 54 of 'Exploded Views' for illustration of the
procedure detailed below:
1. Refer to Frame 36.
2. Drain the system.
3. Remove the burner and air box assembly. Refer to Frame 31.
4. Disconnect the water flow and return connections. If
compression fittings are used, cut the pipes both above and
below the fittings in order to allow the heat exchanger
assembly to be removed.
Remove the heat exchanger drain plug and drain the residual
water into a suitable receptacle.
5. Remove the collector hood. Refer to Frame 32.
6. Remove the 4 screws retaining the flue duct and remove the duct.
7. Remove the combustion chamber by unscrewing the 4 tie rods.
24
SERVICING
Note. Refer also to Frame 54 'Exploded Views' for
7. Remove the front and rear
insulation panels.
8. Fit the new front and rear
insulation panels.
9. Fit the new side panels and
retain with the brackets and
screws previously removed.
10. Re-assemble in reverse
order.
8. Unclip the thermostat capillary and remove the phial from the
pocket. Refer to Frame 41.
9. Slacken 3 turns only the 4 screws retaining the heat exchanger /
interpanel assembly.
10. Lift the heat exchanger / inter-panel assembly upwards and
forwards to disengage the keyhole fixings. Pull the assembly
downwards to clear the water pipes from the back panel.
11. Remove the 4 rubber grommets from the top of the back panel,
to facilitate the fitting of the new heat exchanger.
12. Fit the new heat exchanger assembly, complete with its 4 pipe
connections and hang the 4 keyhole slots over the screws.
Retighten the 4 screws.
13. Replace the 4 rubber grommets in order to seal the gap between
the water pipes and the back panel.
14. Re-assemble in reverse order.
15. Remake all water connections.
16. Fully test all functions, including water and gas soundness.
illustration of the procedure detailed below.
Detail of boiler combustion chamber
Classic LX, RS -
Installation