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Manafacture: IDEAL INDUSTRIES File size: 4.05 mb File name: Language of manual:

Refer to Frame 61. 2. Pull off the two electrical connections. 3. Remove the two nuts retaining the flue protection thermostat. 4. Replace the thermostat and re-assemble in reverse order 2 3 SERVICING 67 PILOT BURNER REPLACEMENT 1. Refer to Frame 61. 2. Remove the burner and air box assembly. Refer to Frame 54. 3. Remove the electrode retaining nut and remove the pilot shield and electrode. 4. Unscrew the central pilot fixing screw and lift the pilot clear of the pilot injector. The pilot injector may now be unscrewed if required. 5. Replace the pilot burner (injector if necessary) and retain with the M4 screw previously removed. Ensure the copper sealing washer is replaced when refitting the pilot injector. classic HE -Installation & Servicing 6. Replace the electrode and pilot shield, retaining both with the electrode nut. Check the spark gap. 7. Reassemble in reverse order. 8. Check the operation of the boiler. 9. The pilot is factory set to maximum and no further adjustment is possible. Ensure there is an inlet pressure of 20 mbar available. Also check burner ignition and cross-lighting. SERVICING 68 IGNITION ELECTRODE AND LEAD REPLACEMENT 1. Refer to Frame 61. 2. Remove the burner and air box assembly. Refer to Frame 54. 3. Remove the electrode retaining nut. 4. Remove the pilot shield. 5. Remove the ignition electrode and integral lead. 6. Refit the new electrode and lead in reverse order. Ensure that the pilot shield is replaced. 7. Check the spark gap. Refer to Frame 67. 8. Reassemble in reverse order. 9. Check the operation of the boiler. 69 MAIN BURNER AND MAIN BURNER INJECTOR REPLACEMENT SERVICING 1. Refer to Frame 61. 2. Remove the screw retaining the front burner support strap to the combustion chamber. 3. Remove the M5 pozi screw, situated at the left hand bottom rear of the burner. Pull the burner downward to disengage the retention tab and remove the burner. 4. At this stage the main burner injector can be removed, checked, cleaned or replaced as required. Ensure that a new copper sealing washer is used. 5. Fit the new burner, ensuring that the retention tab is correctly located in the air box slot and reassemble in reverse order. 6. Check the burner for cross-lighting and flame stability. 70 GAS CONTROL VALVE REPLACEMENT 1. Refer to Frame 61. 2. Remove the burner and air box assembly. Refer to Frame 54. 3. Remove the control box fixing screws. Swing the control box down into the servicing position. 4. Disconnect the gas control valve electrical leads. 5. Undo the gas cock union . 6. Whilst supporting the gas control valve, remove the 2 screws retaining the manifold to the back panel. 7. Remove the gas control / manifold assembly. 8. Remove the 4 screws retaining the manifold to the gas control valve, and fit the manifold to the new valve. Ensure that the new control is fitted the correct way round (an arrow engraved on back indicates the direction of flow). 9. Transfer the gas cock union to the new gas control valve, using an approved jointing compound. 10. Reassemble in reverse order. 11. Check the operation of the boiler. 12. Refer to Frame 48, item 18 for gas adjustment sealing. classic HE - Installation & Servicing classic HE - Installation & Servicing 39 SERVICING 1. Refer to Frame 61. 2. Remove the two fan electrical connections, the red pressure sensing pipe, the blue CO/CO2 sensing pipe and the two fan fixing screws. 3. Pull the fan forward, remove and retain. 4. Fit the new fan and reassemble in reverse order, ensuring the fan leads, 2 sensing tubes and the two fan fixing screws are reconnected. 5. Check the operation of the boiler. 71 FAN REPLACEMENT 5. Disengage the PCB from the mounting posts and withdraw from the control box. 6. Fit the new PCB and reassemble in reverse order. 7. Check the operation of the boiler. Fuse. To change the fuse, prise it out of the holder and disengage the fuse. Refer to Frame 78 for fuse location. 73 PRINTED CIRCUIT BOARD (PCB) REPLACEMENT 1. Refer to Frame 61. 2. Remove the control box fixing screws and swing the control box down into the servicing position. 3. Disconnect the detection lead from the PCB. 4. Unplug all the Molex connectors from the PCB. 74 COMBUSTION CHAMBER INSULATION REPLACEMENT 1. Refer to Frame 61. 2. Remove the burner and air box assembly. Refer to Frame 54. 3. Remove the 4 tie rods. Note. remove rubber grommets to gain access to side tie rod screwdriver slots. 4. Remove the combustion chamber. 5. Remove the 2 side panel retaining brackets. 6. Remove the side insulation panels. 7. Remove the front and rear insulation panels. 8. Fit the new front and rear insulation panels. 9. Fit the new side panels and retain with the brackets and screws previously removed. 10. Reassemble in reverse order. 72 AIR PRESSURE SWITCH (APS) REPLACEMENT 1. Refer to Frame 61. 2. Remove the APS fixing screw. 3. Remove the 2 sensing tubes from the APS. 4. Remove the 3 electrical connections from the APS. 5. Fit the new APS and reassemble in reverse orde...

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