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16. Check the condition of the copper tubes to ensure each tube has not warped or annealed. If there are
any signs of damage to the heat exchanger it should be replaced.
17. If it is necessary to replace the heat exchanger, undo the self-tapping screws on the outer casing
adjacent to the header to open up the withdrawal opening. Remove the 8mm self-tapping screws from
the cast header. Take out the thermostat phials from pockets, noting their locations and move aside.
The heat exchanger can now be pulled forward (keeping it straight and parallel) to remove it from the
heater body.
18. Fit a replacement heat exchanger into the channels inside heater and push back until the cast headers
hit the stops. Fit a new sealing gasket to the water connection header and secure using the appropriate
self-tapping screws.
To reassemble the heater, sections 1-13 of the above procedure should be carried out in reverse.
To access the ignition module, terminal strip and fault relay PCB the self-tapping screws must be undone on
the large Left hand cover at the header end.
To access the thermostat dials and reset buttons, the thumb screw under the smaller right hand cover at
header end should be aligned with the slot in the cover and the cover be pulled forward and down.
Tools required:
No 2 Pozi-Drive screwdriver
Battery drill and socket driver
5/16" or 8mm spanner or socket
¼" or 6mm spanner or socket
7/16" or 11mm spanner
Leak detection spray
Gas approved jointing paste
Cable/wire cutters
Stiff bristle brush
14.6
REFILLING THE SYSTEM
1.
Close the drain valve.
2.
Open any installed vent point to allow air to escape.
3.
Open the cold water inlet valve and allow the system to fill.
4.
Follow the lighting instructions as detailed in
LIGHTING.
5.
Check for water leakage.
Section 12.4.3:
PROCEDURE FOR INITIAL
31
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