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3.
REMOVE THE BOILER INNER COVER, FLUE HOOD,
COMBUSTION CHAMBER FRONT PLATE, BURNER
AND PILOT ASSEMBLY
(a)
Remove the boiler inner casing cover
(See Fig. 23.)
Remove the six MS screws and washers holding the inner
cover
onto the boiler casing. Remove the inner
cover.
(b) Remove the flue hood
(See Fig. 14.)
Slacken the wing nuts securing the
'j'
bolts until the
'j'
sections
can be manipulated to pass upwards through their location
brackets.
Lift the flue hood clear of the heat exchanger and
remove
from
the casing. Gently prise upwards at the front sides to disengage
if necessary. Take care not to disturb the overheat thermostat
connections.
(c)
Remove the combustion chamber front plate
Remove by releasing the six MS fixing screws.
(d) Remove the burner and pilot assembly
(See Fig. 17 .)
Disconnect the thermocouple nut at the pilot burner assembly
and ease the thermocouple from the assembly.
Carefully pull the electrode lead off the connector tab at the
electrode.
Disconnect the pilot tube within the combustion chamber at
the adaptor.
Release the two extended MS screws securing the burner
manifold block at the front.
Carefully
remove
the burner and pilot assembly.
NOTE:
The
'0'
ring in the burner manifold block which seals
with the gas manifold flange should be
removed
and retained
for reassembly.
4.
CLEANING THE BURNER ASSEMBLY
(See Fig. 17 .)
(a)
Disconnect the pilot pipe from the pilot burner and
remove
the
pilot injector which fits loosely between the pipe and burner.
(b) Release the screw and carefully dismantle the lint arrester
assembly, see Section 17-Instructions 2 and Figs. 15 and 16.
(c)
Carefully
remove
the main injector from the burner and check
that there is no blockage or damage.
(d) Brush the burner blades and check that the flame ports are
clear. Do not use a brush with metallic bristles.
Fig. 15.
Lint arrester assembly
Main burner injector
16
Fig. 16.
Lint arrestor assembly
(e)
Inspect the pilot burner and ignition electrode. Ensure that
they are clean and in good condition. Check that the spark gap
is 3-4mm (0.14 in.). See Fig. 19.
(f)
Check that the thermocouple tip is not burned or cracked. If it
shows any sign of damage a new thermocouple must be fitted.
(g) Clean the lint arrester gauze to
remove
any lint or fluff. Do not
use a brush with metallic bristles.
(h)
Reassemble the burner components in the reverse order, not
forgetting the pilot and main burner injectors. Thread sealing
compound must not be used to seal the injectors. Do not fully
tighten the pilot pipe at this stage.
5.
CLEANING THE HEAT EXCHANGER
(See Fig. 26.)
(a) Cover the pilot gas inlet adaptor and the main gas inlet within
the combustion chamber.
(b) Using a suitable brush, clean the inside surface of the heat
exchanger and the fins.
(c)
Clean the flue duct.
(d) Remove any deposits which fall to the bottom of the boiler
casing.
(e)
Check the condition of the rear, sides and front combustion
chamber insulation.
NOTE:
The insulation used on the inside surfaces of the
combustion chamber is delicate. Take great care not to abrade
this insulation when cleaning the heat exchanger. Do not
attempt to clean the insulation which should be replaced if
there are any signs of deterioration. See Section 17-Replace-
ment of Parts, Instruction 9.
6.
RE-ASSEMBLE THE APPLIANCE
Re-assemble the appliance in the reverse order to the dis-
mantling procedure.
(a)
Replace the flue hood on to the heat exchanger ensuring that
the hood is properly located on the heat exchanger.
(b) Locate the
'J'
bolts in the side brackets, ensuring that they are
hooked into the bracket, and hand tighten. Do not over
tighten.
(c)
Inspect the
'0'
ring seal. Replace the seal if there are any signs
of deterioration.
(d) Refit the
'0'
ring into the burner foot. Replace the burner and
pilot assembly and fit the burner location bracket into the
bracket in the combustion chamger.
(e)
Secure the burner manifold with the extended MS screws.
(f)
Connect and tighten the pilot feed pipe at the adaptor. Fully
tighten the connection at the pilot assembly.
(g)
Reconnect the thermocouple.
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