[jonboy]

Please can somebody tell me...........after reading the forum i have come to the conclusion that i need to change the burner module on my Carver Cascade 2 water heater.

I have no worries changing it, but i am concerned that the replacement available will be compatable with my existing model.

The only unit i can find on the market looks identical in every way all but it has just one electrode positioned over the burner and no roller wheel to adjust the temperature.

My existing unit is off a 1990 Avondale caravan and is the type with the red roller wheel to adjust temperature, two electrodes over the burner jets and takes a black din plug.

Will this replacement fit ok?

Thanks for any help.

[Brecon]

The unit you have is an original type.
The temperature adjuster was removed some time ago.
The new versions do only have one electrode over the burner.
New burner modules have both the DIN socket and the flat Molex socket.

It will fit OK

[jonboy]

Thank yuo very much for such a quick reply.

Regards..Jon

[jonboy]

jonboy, on 26 July 2010 - 09:35 AM, said:

Thank yuo very much for such a quick reply.

Regards..Jon

[jonboy]

I am going to my caravan this weekend coming to change the burner module and pressure release valve on my carver cascade 2.

I shall take my usual tool box but is there anything specific i should be taking to carry out the work.

I am aware that the plastic threads on the valve will snap off when i try to remove the it so i shall take a big drill bit and big screwdriver to try an remove the threads.

Any help on what to take and advice on these jobs from people who have done this before would be greatly appreaciated.

Many thanks....Jon

[Brecon]

First of all, the burner module.
Having removed the front cover and module cover from the ouside of the van, with gas OFF, undo the two small screws holding the burner module in place, they should not come righ tout as they have a sealing ring on each.
Gently ease the burner out, undo the DIN connector.
Fit the DIN to the new module, locate the module back in its operating position and gently tighten the screws a bit at a time on each to ensure equal pressure is applied, make sure the top edge of the module sits tight against the casing.
Reconnect the gas and test for leaks.

As for the PRV, DO NOT use a big drill or big screwdriver!!!!!!

If it snaps off, which it probably will, use a junior hacksaw blade with one pin removed from one end, and make 5 equidistant cuts through the plastic still in the heater, but as soon as you feel the difference in smooth cutting from plastic to a dragging as it reaches metal,STOP.

Use a SMALL flat bladed screwdriver to ease one of the segments out, a slight tap (and I mean TAP) with a hammer may be required to move the first bit, the rest will follow quite easily. A pair of long nosed pliers may help here.

Clean up the threads in the heater with towball bolt if you do not have a soft round wire brush, apply a squirt of silicone lubricant or silicone grease to the thread of the new PRV and tighten ONLY until it forms a seal with the O ring which is supplied.
DO NOT overtighten.

[jonboy]

Brecon, on 26 July 2010 - 03:08 PM, said:

First of all, the burner module.
Having removed the front cover and module cover from the ouside of the van, with gas OFF, undo the two small screws holding the burner module in place, they should not come righ tout as they have a sealing ring on each.
Gently ease the burner out, undo the DIN connector.
Fit the DIN to the new module, locate the module back in its operating position and gently tighten the screws a bit at a time on each to ensure equal pressure is applied, make sure the top edge of the module sits tight against the casing.
Reconnect the gas and test for leaks.

As for the PRV, DO NOT use a big drill or big screwdriver!!!!!!

If it snaps off, which it probably will, use a junior hacksaw blade with one pin removed from one end, and make 5 equidistant cuts through the plastic still in the heater, but as soon as you feel the difference in smooth cutting from plastic to a dragging as it reaches metal,STOP.

Use a SMALL flat bladed screwdriver to ease one of the segments out, a slight tap (and I mean TAP) with a hammer may be required to move the first bit, the rest will follow quite easily. A pair of long nosed pliers may help here.

Clean up the threads in the heater with towball bolt if you do not have a soft round wire brush, apply a squirt of silicone lubricant or silicone grease to the thread of the new PRV and tighten ONLY until it forms a seal with the O ring which is supplied.
DO NOT overtighten.

[jonboy]

Thank you for this detailed advice, I shall follow it. It is very kind of you to help me.

Kind regards
Jon

[jonboy]

I have had chance to work on my carver heater tonight and would like to thank BRECON for all the helpfull advice as i now have trouble free hot water.

Thanks again..........Jon

[Brecon]

Thank you Jon, you are welcome.
Glad it all went well for you.