IDEAL SUPER PLUS 200/S Installation And Servicing page 21

Control Thermostat Potentiometer
1. Unplug the potentiometer lead from the PCB 9B, inside the
controls box.
2. Slacken the small securing screw in the control knob and pull
it off.
3. Undo the backnut and washer securing the potentiometer to
the control box and remove it.
4. Fit the new potentiometer, ensuring that the locating lug is
correctly positioned in the hole in the controls box.
5. Refit the plug into the printed circuit board and replace the
control knob.
Spark Electrode / Flame Sensing Probe
1. Unscrew and remove the ferrule (Fig.19) from the spark
electrode and disconnect the ignition lead. Pull off the inline
connector in the flame sensing probe lead.
2. Remove the screw securing the electrode / probe to the burner
front plate and pull out the electrode / probe.
3. Carefully fit the new item and reconnect the leads. If applicable
check that the spark gap is 3.5 ± 0.5 mm (Fig.19).
Printed Circuit Boards No.8 and No.12
Pull out the overheat thermostat coil, retaining strip and split pin
from its pocket in the flow elbow.
Undo the 2 screws securing the 2 halves of the controls box and
carefully lower the front half.
Board No.9
1. Unplug from board No.9
(a) the wiring from the module multipin socket.
(b ) the wiring from the top of printed board No.12
(c) the pressure switch
(d) the fan
(e) the control thermostat potentiometer
(f) the control thermostat sensor.
2. Without exerting undue pressure, undo the 4 screws securing
PCB 9 to the controls box and remove it, feeding the overheat
thermostat capillary through the grommet in the right hand side.
3. Carefully fit the new Board, ensuring that the neons lockout
reset button and overheat thermostat reset button fit through
their respective holes without damage.
4. Unwind the overheat thermostat capillary and feed it through
the grommet in the right hand side.
5. Refit the 6 plugs into the new board. Note that each plug will
only fit its correct socket, though care must be taken to fit the
fan plug into the socket marked 'BLOWER'.
Board No.12
1 . Slacken the 8 terminal strip connections at the rh side and the
8 at the bottom of Board No.12 and those terminals at the top
marked 'A' to 'H' only. Remove both top and bottom terminal
strips from the board.
2. Remove the Board by squeezing in the retaining barbs on the
4 supports.
3. Fit the new Board by relocating the connections into the right
hand side terminal strip and pushing the board home on its 4
supports.
4. Fit the top and bottom terminal strips ensuring that the 10-way
strip is at the top and the 8-way is at the bottom. Tighten all
terminal strip connections.
Re-assembly
1. Lift up the controls box front and refasten it using the 2 screws.
2. Refit the overheat thermostat coil and retaining strip to the
pocket on the flow header and secure with its split pin.
Super Plus -
Installation and Servicing
SERVICING
Overheat Thermostat
1. Pull the overheat thermostat coil, retaining strip and split pin
from the pocket in the flow elbow.
2. Undo the 2 screws securing the 2 halves of the controls box
and carefully lower the front half.
3. Remove printed circuit board No.9B as described above.
4. Pull off the 2 push-on connections to the overheat thermostat
and undo the 2 screws, nuts and washers securing the
thermostat body to remove it.
5. Fit the new thermostat and reconnect the push-on connections.
6. Refit printed circuit Board No.9B, as described above, ensuring
that the overheat thermostat capillary is fed through the
grommet on the right hand side.
7. Lift up the controls box and refasten it using the 2 screws.
8. Refit the overheat thermostat coil into its pocket in the flow
elbow and secure it with its retaining strip and split pin.
Burner
1. Unscrew and remove the ferrule (Fig.l9) from the spark
electrode and disconnect the ignition lead. Pull off the in-line
connector in the flame sensing probe lead. Undo the pressure
switch earth lead.
2. Undo the screws fastening the electrical plugs to the 2 main
gas valves and pull out the plugs and gaskets.
3. Pull out the control thermostat sensing probe and retaining clip
from its pocket in the return elbow and the overheat thermostat
coil, retaining strip and split pin from its pocket in the flow elbow.
4. Undo the suction sensing line at the venturi casting and at the
pressure switch. Remove the line.
5. Undo the pressure sensing line union connection at the base of
the fan housing and at the pressure switch. Remove the line.
6. Pull out the 3 push-in connections from the pressure switch on
the rhside of the controls box. Unclip the pressure switch lead
and the fan motor lead from the clip on the controls chassis.
7. Take the weight of the controls box and fan assembly, undo
the front nuts securing it to the venturi casting and remove it.
Pull off the venturi casting gasket.
8. Remove the main burner complete with spark electrode and
flame sensing probe.
9. Remove the screws securing the electrode and probe and
transfer them to the new burner,
10. Note: they can only be assembled one way round. Replace
any worn or damaged gaskets.
11. Fit the new burner, ensuring that the extended gasket is in place
between the burner and module front plate.
12. Reassemble in reverse order, ensuring that a gasket is in place
between the burner and venturi casting and between the venturi
casting and fan and controls box assembly, and that the M8
nuts are not overtightened. Ensure that the gaskets are in place
before refitting the main gas valve plugs.
13. Refit the overheat thermostat coil into its pocket on the flow
header and secure with its retaining strip and split pin.
14. Refit the control thermostat sensor into the pocket in the return
header and push it fully home securing it with its retaining clip.
15. Ensure that the pressure switch connections are correctly made
to the side of the controls box. In particular NEVER connect
the black wire to the blue connection.
Gas Distribution Screen.
1. Remove the heat exchanger from the casing as described in
'MODULE - CLEANING INSTRUCTIONS'
2. Undo the screws securing the gas distribution screen and
remove the screen.
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