Untitled Document

DIpY Loft Conversion*
(*Do It Partly Yourself!)

Boiler Replacement Procedure

Forward planning

Determine pipe arrangement
Determine gas pipe sizes
Calculate quantities required
Establish pipe routing for CH
Add desludging agent to existing system some time prior to scheduled start of replacement work
Order boiler and enough fittings and pipe to make sure all eventualities are covered!

Prep

Ensure hot water at full temp
Turn off boiler

Loft Work

Tie up ballcock in CH header
Drain system - ensure 3 port valve is in centre pos to ensure heating loop is drained.
Cut CH feed and return in loft and loop back. Include gate valve on a tee in loop
Cap pipe ends to prevent seepage

Kitchen

Take static gas pressure reading and ensure loss is zero
Turn off gas
Pull fuse from boiler FCU
Disconnect boiler electrics and remove programmer
Disconnect CH feed and return
Disconnect gas feed
Open boiler
Remove from wall
Remove old flue
fill old flue hole with bricks and mortar
Using template mark out positions
Core bore new flue exit
Fit boiler mounting frame (remove tiles as required)
Connect CH feed and return
Remove existing gas feed pipe to under worktop
Cut new hole through worktop for DHW feed and return, 22mm gas, condensate
Install 22mm gas feed from existing ¾" pipe
Turn off water
Cut in new DHW feed and return and connect with service valves
Install filling loop
Mount boiler on tray
Install new flue
Install condensate drain

Loft

Tie off cistern ballcock
Drain remains of hot water
Disconnect hot water output from cylinder and cap off
Disconnect input mains water from cistern and CH header tank
Disconnect cold shower feed from cistern and connect to rising main

Bathroom

Remove bath panel and identify CH stat wire - join to existing down wire and disconnect from remainder. (Leave remainder available for pulling through new wires later!)

Kitchen

Connect boiler electrics and stat
Carry out any pre checks as per install manual
Purge gas meter and pipework
Carry out gas soundness test
Commission boiler as per manual
Flush as required
Treat with corrosion inhibitor
Remove tanks etc. and cylinder from loft.

Job Done!

One particularly distressing part of the boiler replacement was the discovery of this:-

A section of wallpaper entombed behind the old boiler. Nice huh? And yes it was hung upside down!