background image

29

4000116705-2

17 Routine Cleaning and Inspection

17.8 Burner, refer to diagram 17.3.

• Undo main gas supply nut from under the sealed chamber.

Note: The washer between main burner and main burner gas
supply must be kept for use on reassembly.

• Pull off ignition leads from ignition unit.

• Pull off flame sense lead from flame sense electrode.

• Unscrew and remove burner support bracket securing screw
and remove bracket.

• Remove burner from boiler by lifting up and pulling forwards
easing the leads through the grommet, taking care not to
damage insulation.

• Clean burner by washing in soapy water.  Dry thoroughly
before refitting.

• When refitting burner ensure that rear of burner locates into
location slot and the injector locates correctly through the
grommet.

Note: To gain access to injectors for removal, refer to 

Section,

20.24 in Replacement of Parts

.

9341

Diagram 17.3

11755

9345

MAIN GAS
SUPPLY NUT

GROMMET

BURNER
SUPPORT
BRACKET

BURNER
LOCATION
SLOT

FLAME
SENSE
LEAD

IGNITION
LEADS

11756

17.9 Heat exchanger, refer to diagram 17.4.

• Disconnect electrical connections from fan.

• Unscrew and remove two fan retaining screws from the right
hand side edge of fan mounting plate.

• Remove fan with mounting plate attached by pulling forward
and out of boiler.

• Remove air pressure switch sensing tube at rear of flue hood.

• From front of boiler carefully unclip wire spring retainers from
side of flue hood.

• Remove the overheat thermostat by unclipping from the
heating return pipe.

• Lift flue hood clear of heat exchanger and examine for debris.

• Using a soft brush or vacuum clean as required.

DO NOT USE ANY TOOL LIKELY TO DAMAGE PAINTED
FINISH OF HEAT EXCHANGER.

Note: When re-fitting fan, make sure that the two lugs on the fan
mounting plate engage in the flue hood

11757

Diagram 17.4

11760

11759

AIR PRESSURE SWITCH
SENSING TUBE

WIRE SPRING
RETAINER
2 OFF

FAN
RETAINING
SLOTS

OVERHEAT
THERMOSTAT

11758

Summary of Contents for XTRAMAX

Page 1: ...d gas installer in accordance with the manufacturer s recommendations We strongly recommend regular servicing of your gas appliance but where the condition is not met any chargeable spare parts or com...

Page 2: ...ation 10 18 Horizontal Telescopic Top Flue Installation 11 19 Horizontal Top Flue Installation 11a 20 Electrical Connection 12 22 Commissioning 13 23 Safety Devices 14 26 Changing Gas Type 15 27 Setti...

Page 3: ...e INSULATION PADS CERAMIC FIBRE These can cause irritation to skin eyes and the respiratory tract If you have a history of skin complaint you may be suscepti ble to irritation High dust levels are usu...

Page 4: ...e system will pass directly to the rear or to either side to the terminal fitted on the outside wall face Appliance Introduction The installation of this boiler must be carried out by a competent pers...

Page 5: ...icing and Maintenance To ensure the continued efficient and safe operation of the appliance it is recommended that it is checked and serviced as necessary at regular intervals The frequency of servici...

Page 6: ...most likely fault is that the gas supply to the boiler has not been turned on or that there is no pressure in the heating system These are indicated as follows Other faults These are indicated on the...

Page 7: ...water 2 Press the mode button to select the summer symbol Press the mode button to select the winter symbol The flame symbol appears when the boiler is running The actual temperature of the heating s...

Page 8: ...setting the Temperatures T1 T2 and T3 The programmes use three temperature settings which you can adjust Recommended first use settings are T1 16 T2 19 T3 21 Iftheradiatorsinyourinstallationareequippe...

Page 9: ...p time 4 min Time to reheat 70 of storage to 60 C 5 min Expansion valve setting 6 bar Expansion vessel charge pressure 3 5 bar Maximum operating pressure 3 5 bar Maximum supply pressure 16 bar Minimum...

Page 10: ...lteration that is not approved by Hepworth Heating Ltd could invalidate the warranty and could also infringe the current issue of the Statutory Requirements 1 3 Gas Supply The gas installation must be...

Page 11: ...to avoid any air pockets and facilitate permanent venting of the installation Bleed fittings must be provided at every high point of the system and on all radiators The total volume of water permitted...

Page 12: ...sure losses should be avoided A flow restrictor limiting the flow through the boiler to a maximum of 16 l min is fitted to the boiler The boiler will operate with a minimum supply pressure of 0 7 bar...

Page 13: ...e boiler is not suitable for fitting outdoors Any electrical switch or boiler control using mains electricity must be positioned so that a person using a bath or shower cannot touch it 6 2 Clearances...

Page 14: ...e terminal to obstructions and ventilation openings are shown in diagram 6 2 The boiler must be installed so that the terminal is exposed to the external air Warning Do not obstruct the outside termin...

Page 15: ...ischarge pipe D1 from temperature relief valve to turndish Tundish Supplied Fixed grating Trapped gully Safety device eg temperature relief valve 500mm max 300mm min 9131 7 Safety Discharge 8 Fixing J...

Page 16: ...uld terminate in a safe place where there is no risk to persons in the vicinity of the discharge be of metal and a Be at least one pipe size larger than the nominal outlet size ofthesafetydeviceunless...

Page 17: ...e H Hot water supply from boiler C Reduced cold water supply MIX Thermostatically controlled outlet Warning It is strongly recommended that the cold water supply to the mixing valve is taken from the...

Page 18: ...around the boiler Remove front panel put in a safe place to avoid damaging it Ensure the plastic plugs are removed from water and gas pipes NOTE There will be some spillage of water Remove transportat...

Page 19: ...f the air duct pipe A Fit air flue duct pipe assembly into wall from the outside with rubber sealing collar to the outside Pull pipe assembly inwards to bring rubber sealing collar hard up against ext...

Page 20: ...t hand applications measure wall thickness e plus inside of wall to side of boiler a minus 25 mm for the outer air duct and wall thickness e plus inside of wall to side of boiler a add 70 mm for the i...

Page 21: ...sembly inwards to bring rubber sealing collar F hard up against external wall while carefully pushing the fixing collar seal onto the elbow ensuring that the flue duct pipe locates into the flue elbow...

Page 22: ...link fitted between the two terminals of the connector E is left in place see diagrams 12 2 and 12 3 Alternatively a 24V room thermostat can be used but do not makeanyconnectiontothecompensatingresis...

Page 23: ...ater and air bled from the system If these conditions are not met the system may be noisy Bleed the air in the radiators and adjust the pressure if system requires If the system requires filling too o...

Page 24: ...ntral heating system Gases driven towards the boiler will be automatically released through the automatic air vent The gases trapped at the highest point of the system must be released by bleeding the...

Page 25: ...tment of the heating output does not affect the hot water output 11843 setting flue length setting flue length 0 0 3m 0 0 5m 1 0 6m 1 1m 2 1m 2 2m 3 1 2m 3 3m 4 1 5m 4 4 5m 5 2m 5 6m 6 2 2m 6 7m 7 2 5...

Page 26: ...ll be ready to operate when the fault has been cleared 14 5 Overheat safety In case of boiler overheating the overheat thermostat will turn the boiler off The thermostat located on the heat exchanger...

Page 27: ...gures specified refer to diagram 1 1 turn clockwise to close the valve Diagram 16 1 9349 a Should it become necessary to change the gas type a modification kit will be required This modification must...

Page 28: ...oiler Unhook grille from rear of boiler and remove Remove three screws from front of each side panel Lift each panel up and then forward to remove 17 7 Combustion chamber cover Unscrew the two screws...

Page 29: ...R LOCATION SLOT FLAME SENSE LEAD IGNITION LEADS 11756 17 9 Heat exchanger refer to diagram 17 4 Disconnect electrical connections from fan Unscrew and remove two fan retaining screws from the right ha...

Page 30: ...y and turn on gas Light burner by opening a hot water tap Check that fan operates when burner lights and stops when it goes out 17 15 Cold water inlet filter Drain down domestic hot water circuit of b...

Page 31: ...ibed previously and measure the voltages according to table 2 Table 2 Voltage Measured value Measuring point 230 Volt 230 V AC Between terminals H8 1 and H8 2 24 Volt maximum 33V DC Between terminals...

Page 32: ...CUIT CHECK RESISTANCE OF THE THERMISTOR 12500 ohms AT 20 C 1750 ohms AT 70 C UNCLIP THE THERMISTOR FROM THE PIPE IF THE BOILER RE LIGHTS WHEN THE THERMISTOR IS OPEN CIRCUIT REPLACE THE THERMISTOR 05 0...

Page 33: ...D AT 3A PLUG FUSE 125mAT H3 H6 H1 H4 H5 H8 H2 J5 J9 J8 J4 SW3 S2 S1 J19 J16 J6 J2 J3 ON OFF SWITCH AIR PRESSURE SWITCH FAN THREE WAY VALVE SENSE ELECTRODE IGNITION ELECTRODES g y g y g y g y g y br br...

Page 34: ...or Fit leads to replacement thermistor and fit thermistor to pipe The polarity is not important 20 2 Central heating thermistor Before starting refer to the front of Section 20 Important information R...

Page 35: ...unting plate attached by pulling forwards out of the boiler Remove fan from mounting plate Fit replacement fan Note When re fitting make sure that the two lugs on the fan mounting plate engage in the...

Page 36: ...3 Lower the control panel refer to Section 17 5 For ease of access if required remove the left hand side panel refer to Section 17 6 Drain down central heating water circuit of the boiler only see di...

Page 37: ...valve bypass housing to storage vessel Remove central heating flow pipe from 3 way valve bypass housing to fixing jig From underneath boiler undo two screws securing 3 way valve bypass housing and li...

Page 38: ...control valve assembly mounting bracket Undo main gas supply nut from main burner see diagram 17 3 Note The washer must be kept for use on reassembly Undo main gas union nut between gas control valve...

Page 39: ...Apply a small quantity of silicon grease to the safety valve O ring prior to fitting 20 19 Main heat exchanger Before starting refer to the front of Section 20 Important information Remove the front...

Page 40: ...lugs remove the front insulation panel free from retaining lugs on combustion chamber cover Rear panel insulation Pull rear insulation panel free from retaining lug at rear of combustion chamber by ti...

Page 41: ...20 Important information Remove the front panel refer to Section 17 3 Remove sealed chamber cover refer to Section 17 4 Lower the control panel refer to Section 17 5 Remove combustion chamber cover r...

Page 42: ...er to Section 17 6 Drain down domestic hot water circuit of boiler only see diagram 20 1 Undo pipe coupling on domestic hot water expansion vessel Unscrew and remove domestic hot water expansion vesse...

Page 43: ...bar Disconnecttheinlineelectricalplugconnectiontothedomestic hot water storage vessel thermistor The thermistor is located on the right hand side of the domestic hot water storage vessel Removetopand...

Page 44: ...7250 E37302 4 Fan 57238 E37371 5 Air pressure switch 57237 E37237 6 Domestic water flow sensor 57202 E37368 7 Printed circuit board 57248 E37374 8 Pump 57207 E37411 9 3 way valve head 57206 E37413 10...

Reviews: