Removal/Replacement Of Boiler Components; Main Burner And Injector; Pilot Burner And Injector; Ignition Electrode - Potterton Flamingo RS40 Installation And Service Manual

NOTE: On first lighting, establishment of the pilot flame may be slightly delayed due to the presence of air
in the pipework and several operations of the Piezo igniter button may be necessary. If the pilot fails to
light or goes out at any time, immediately press in the 'off' button or turn the control button clockwise as far
as possible. Wait three minutes before repeating the lighting procedure during which time control valve
should not be touched.
k. When correctly set, the pilot flame must be sufficient to heat the thermocouple so that the pilot safety
device is 'held in' but must not cause the thermocouple to glow bright red. The correct adjustment is
achieved when the length of the pilot flame completely envelops the tip of the thermocouple, but, the tip
itself is still visible - see
the gas valve (Fig. 14) clockwise to reduce or anti clockwise to increase the flame. When the pilot is set to
the above instructions, the E.M.F. generated by the thermocouple should be of the order of 18 - 3Omv
open circuit, 10 - 15 closed circuit. Drop out should occur between 2 - 4mv closed circuit.
I. Turn on the boiler thermostat and the main burner will light. Check that the burner pressure is in
accordance with Table
If burner pressure adjustment is necessary, remove the screwed cap from the control valve
and turn the screw beneath clockwise to increase pressure or anti-clockwise to decrease. Refit the
screwed cap when the pressure is correct. Shut down the boiler, remove the pressure gauge and tighten
the screw in the pressure test nipple. With the burner set to its correct pressure, the heat input given in
Table 1 should also be obtained and this should be checked by meter reading over a period of at least five
minutes once the boiler is hot.

7. REMOVAL/REPLACEMENT OF BOILER COMPONENTS

a. Main Burner and Injector
1. Turn off the boiler main gas cock.
2. Switch off the main electricity supply to the boiler.
3. Carry out operations A to C under
4. Unscrew the wingnut securing the main burner to the right-hand side mounting bracket inside the
combustion chamber. On the Flamingo RS5OS boiler, undo the screws securing the pilot plate to the
burner. Lift out the burner as described in taking care not to damage the pilot assembly or insulation.
Remove all deposits from the burner.
5. Unscrew the main burner injector from the left-hand side panel of the combustion chamber. Take care
not to lose the washer behind the injector.
6. Replacement is the reverse of removal.
7. Test the boiler as described in
b. Pilot Burner and Injector
1. Turn off the boiler main gas cock.
2. Switch off the main electricity supply to the boiler.
3. Carry out operations A to C under
4. Pull the tag, on the end of the igniter lead, off the connector on the electrode.
5. Disconnect the pilot supply pipe at the base of the pilot. The pilot injector will drop out.
6. Disconnect the thermocouple from the pilot assembly, then withdraw the thermocouple from the
combustion chamber. Ensure that the thermocouple is clean and undamaged.
7. Remove the screws securing the pilot assembly to its mounting bracket, then withdraw the assembly
from the combustion chamber. Note: On Flamingo RS4O the pilot shield is separate and is retained by one
of the pilot bracket retaining screws.
8. Unscrew the backnut and remove the ignition electrode from the old pilot assembly and fit it to the new
one.
9. Replacement is the reverse of removal.
10. Test the boiler as described in
c. Ignition Electrode
1. Carry out operations (1) to (8) under 'B'. Pilot Burner and Injector, fitting the new electrode to the
existing pilot burner assembly.
2. Ensure that the new electrode is correctly fitted and not bent. Check that the distance between the
electrode and the hood of the pilot is between 2 and 4 mm.
3. Replacement is the reverse of removal.
4. Test the boiler as described in
d. Thermocouple
1. Carry out operations (1) to (3) and (6) under 'B' Pilot Burner and Injector.
Figure 13. If the pilot needs adjustment rotate the exposed pilot restrictor screw on
1.
1 'Preparing the
6, 'Final Adjustment'.
1. 'Preparing the
6, 'Final Adjustment'.
6, 'Final Adjustment'.
Boiler'.
Boiler'.
(Figure 14)