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SERVICING INSTRUCTIONS - Page 24
PILOT FILTER
The pilot burner is protected from blockage by a pilot filter
situated within the gas control valve. The filter is large and
designed to last the life of the gas control valve under normal
operating conditions. It is therefore unlikely to need
replacing. However in the event of pilot filter blockage being
suspected the complete valve will need replacing.
THERMOCOUPLE
a
Carry out operations A, B, C, D in section 1
PREPARING BOILER FOR SERVICE.
b
Remove two screws securing pilot tube and
thermocouple sealing plate to boiler base.
c
Disconnect thermocouple lead from the interrupter
connection on the gas control valve and at the pilot.
NOTE: The interrupter connector is held in place by the
thermocouple lead. Withdraw thermocouple from
grommet, noting the route the lead takes so that the
replacement can be routed in a similar manner to
eliminate sharp bends.
d
Replacement is the reverse of removal. Ensure on
reassembly that the sealing plate and split grommets
form a tight seal around the pilot tube and thermocouple
capillary.
ELECTRODE
a
Carry out operations A,B,C,D in section 1 PREPARING
BOILER FOR SERVICE.
b
Pull off electrode lead from electrode.
c
Unscrew the nut securing the electrode to the pilot and
withdraw electrode.
d
Replacement is the reverse of removal.
COMBUSTION CHAMBER INSULATION
a
To remove the insulation from the combustion chamber
sides, rear and lower front panel carry out operations
A,B,C,D,G in section 1 PREPARING BOILER FOR
SERVICE. If the insulation is to be removed from the
upper front panel the main burner will also need to be
removed as described under MAIN BURNER
REMOVAL & CLEANING, operations A,B,C,D.
b
The side insulation panels are removed by sliding them
from their retaining chanels.
c
Once the side insulating panels have been removed the
rear insulation can be lifted out and the upper front
insulation can be slid downwards from inside the panel.
d
The lower front insulation is removed by bending back
the retaining tabs. Replacement is the reverse of
removal. Follow the full commissioning procedure as
detailed in the COMMISSIONING section of these
instructions.
SIGHT GLASS
WARNING: GREAT CARE SHOULD BE TAKEN
WHEN HANDLING AND DISPOSING OF A BROKEN
SIGHT GLASS.
a
Carry out operations A,B,C,D in section 1 PREPARING
BOILER FOR SERVICE.
b
Remove three M4 nuts from sight glass retainer and
remove sight glass assembly.
c
Replacement is the reverse of removal taking care that
the clear circle in the sight glass lines up with the hole in
the combustion chamber door. NOTE: new gaskets
must be used when sight glass is fitted.
ELECTRODE LEAD
a
Carry out operations A,B,C,D in section 1 PREPARING
BOILER FOR SERVICE.
b
Remove rear locking nut securing spark generator to its
mounting bracket, withdraw spark generator and pull off
electrode lead. Pull off electrode lead from electrode.
Remove the split grommet and withdraw the electrode
lead through the hole in the boiler base.
c
Replacement is the reverse of removal.
SPARK GENERATOR
a
Carry out operations A,B,C in section 1 PREPARING
BOILER FOR SERVICE.
b
Pull off electrode lead from spark generator, remove
rear locking nut securing spark generator to its mounting
bracket and withdraw spark generator.
c
Replacement is the reverse of removal.
PUMP OVER-RUN THERMOSTAT
a
Carry out operations A,B,C,D in section 1
PREPARING BOILER FOR SERVICE.
b
Remove control box securing screw and lower control
box.
c
Access to the pump over-run thermostat is made easier
by separating the upper assembly of the control box
from the boiler base. This is done by removing the two
hexagonal head screws identified in Fig 21 Tilt the upper
assembly and disconnect the electrical wiring from the
thermostat as follows:-
Black from terminal 1
Red from terminal 2
Brown from terminal 3
d
Replacement is the reverse of removal.
e
Follow the full commissioning instructions as
described in the COMMISSIONING section of these
instructions.
BOILER THERMOSTAT
a
Carry out operations A,B,C,D in section 1
PREPARING BOILER FOR SERVICE.
b
Remove control box securing screw and lower control
box.
c
Pull off the outer thermostat knob.
d
Remove inner thermostat post by undoing the two
securing screws
e
Access to the boiler thermostat is made easier by
separating the upper assembly of the control box from
the boiler base. This is done by removing the two
hexagonal head screws identified in Fig. 21.Tilt the
upper assembly and disconnect the electrical
connections from the rear of the thermostat as follows:-
White from terminal 3
Brown from terminal 2
Refer to Figs 17 & 18.
f
Remove the nut securing the thermostat to the control
box.
24
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