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16 Routine service

ID fan

Remove ID fan by unplugging the electrical

connection from the burner/control

assembly and loosening the fan securing

pinch screw. If a flue is fitted, this must be

disconnected. The fan will now slip off the

emitter tube. Inspect the main fan impeller

and remove any dust by brushing with a

soft brush. Similarly remove any dust from

the finger guard covering the secondary

(cooling) impeller and the mesh aperture

in the motor cover. Ensure that the impeller

turns freely and that there is not excessive

play in the bearings. Do not replace fan until

emitter tube inspection has been completed.

Emitter tube inspection

Brush away any dust on the exterior of the

emitter tubes.

Inspect the emitter tubes internally. If there

is any appreciable build up of dust or

deposits the tubes should be cleaned

internally. Remove the burner/control

assembly as directed below.

Detach return bend and remove the

turbulators where fitted. The two tubes can

then be cleaned by passing rods and a

suitable scraper through them or by use of

an industrial vacuum cleaner with a long

extension tube.

Reflector

Although not considered part of an annual

routine service, the condition of the reflector

should be noted and the user's attention

drawn to any cleaning necessary. The

reflectors can be simply withdrawn for

cleaning by removing the M6 nuts and bolts

securing them and sliding them out of the

suspension brackets once the reflector end

caps have been removed. The reflectors can

be cleaned with a soft cloth and detergent

in water. A mild non abrasive metal polish

may be used in cases of extreme

discolouration. Dirty reflectors will increase

the heat radiation upwards into the roof

space by 3-4%.

Removal of burner/control assembly

Remove the burner/control assembly by

disconnecting the gas and electrical

supply, fresh air inlet (if fitted) and the

fan electrical connection. Slacken the

burner fixing pinch screws and draw the

assembly off the emitter tube.

Burner/electrode assembly

Inspect the burner electrode assembly by

removing six dome head screws securing

the combustion chamber's cover plate on

top of the burner box, taking care not to

damage the sealing gasket. Remove the

burner head by unscrewing it from the

injector, taking care not to drop it onto

the leads of the ignition electrodes.

Pepper pot burner heads should be

examined every 6 months for signs of

debris and cleaned by blowing compressed

air in reverse direction to flow. Renew the

electrode assembly if it is not in good con-

dition. The assembly is then lifted out of

the combustion chamber and the two

connection cables disconnected.

If the electrode assembly is in good order

check the spark electrode gap. This should

be 3.5mm ± 0.5mm. Adjust the gap if

necessary by bending the earth rod. Refit

the electrode assembly in the reverse order

of removal, ensuring that the electrical

connections to the assembly are the

correct way round and secure.

Inspect the injector and clean as necessary.

Do not broach out. To remove the injector

with the burner head removed, unscrew

the injector from its carrier using a spanner

on the hexagon portion of its body. When

replacing the injector ensure that it is fully

tightened in its carrier. Replace the burner

head. Replace the combustion chamber

plate cover, renewing the sealing gasket if

this is not in good condition.

17 Replacement of components

Health and safety

Isolate gas and electrical supplies before

carrying out any repair work. Always test

for gas soundness with a suitable leak

detection fluid.

To replace ID fan

Remove ID fan connecting plug from the

burner control assembly. Disconnect flue if

fitted. Slacken pinch screw securing fan to

emitter tube. Draw fan off tube. Remove three

M5 screws securing fan support to fan

casting. Refit support flange to new fan with

the pinch bolt facing in the same direction as

the flue outlet. Refit the fan to the heater,

ensuring that the fan discharge faces upwards

for flued heaters or horizontally away from

the burner for unflued heaters.

To replace any components in

the burner/control assembly

This assembly should be removed from the

heater by first disconnecting the gas and

electrical supplies and the fan electrical con-

nection. Slacken the securing pinch screws

and draw the burner/control assembly off the

emitter tube. When refitting the burner

assembly to the heater ensure the box is

horizontal ie. with indicator lamps

downwards.

To replace electrode assembly

Remove top cover of combustion chamber

by removing the six dome headed fixing

screws, taking care not to damage the gasket.

Remove the M4 screws securing the electrode

assembly and pull off the two electrode

cable connectors. Reconnect the cable

connectors to the new electrode assembly

(the two connectors are non interchangeable)

and refit the electrode assembly. Refit the

combustion chamber cover plate and sealing

gasket. Replace the sealing gasket if this

is damaged.

To replace burner head

Remove combustion chamber as above.

Unscrew burner head from the injector,

taking care not to drop it onto the ignition

leads. Refit new burner head and replace

combustion chamber cover plate, replacing

the gasket if this is damaged.