Heat Engine Renewal - Zanussi ULTRA+ COMBI 30 Installation And Servicing

3.31 HEAT ENGINE REPLACEMENT
Refer also to Section 2.1 - 'Boiler Exploded View'
IMPORTANT
Before starting the removal procedure, protect the gas and electrical controls with a waterproof sheet or plastic bag.
1. Refer to Section 3.8.
2. Drain the boiler. Refer to Section 3.21.
3. Remove the fan / venturi assembly and place on one
side. Refer to Section 3.3.
4. Remove the burner and place on one side. Refer to Section
3.4.
5. Remove the ignition and detection electrodes. Refer to
Section 3.13 & 3.14.
6. Remove the spark generator. Refer to Section 3.15.
7. Remove the gas valve. Refer to Section 3.16.
8. Remove the expansion vessel. Refer to Section 3.32.
9. Remove the return and flow thermistors. Refer to
Sections 3.12 & 3.30.
10. Remove the 2 M5 screws retaining the gas valve
mounting bracket and transfer bracket to the new heat
exchanger.
11. Undo the pump union nut and remove pipe.
12. Remove the two retaining pipe clips and remove pipes.
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Installation and Servicing
SECTION 3 - SERVICING
13. Remove the condensate rubber pipe. Refer to Section 3.18,
no. 2.
14. Remove the two heat exchanger fixing screws.
15. Remove the Heat exchanger, slide out of location bracket.
16. If replacement sump required: Rotate heat exchanger
assembly 180º. Place new sump onto heat exchanger,
ensuring correct orientation and seal is in place. Then gently
apply pressure to the base of the sump at each tab fixing
point and engage tabs onto the heat exchanger.
17. Reassemble in reverse order, ensuring the heat exchanger
is located correctly in the LHS retaining bracket. Replace
any new 'o' rings supplied with new heat exchanger and
replace gaskets or seals if any sign of damage is evident.
When replacing the spring clips located on the return
pipe connection, ensure clip is oriented to correctly match
connecting pipe diameters.
18. Ensure the trap/siphon is filled with water. Refer to Section 3.18.
19. Refill the boiler and check for leaks. Refer to Section 2.17.
20. Check that the boiler operates in both DHW & CH modes.
Shown as 180º position
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