202863-6.pmd

xtra

Installation & Servicing

GENERAL

CAUTION.

To avoid the possibility of injury during the installation, servicing or cleaning

of this appliance, care should be taken when handling edges of sheet steel components.

Table 1 Performance Data

Boiler

F320

F400

F480

F560

Boiler output

Max

311.6

390.8

469.0

547.2

(non-condensing)

Btu/h

1,063,200

1,333,400

1,600,200

1,867,000

Mean 70

Min

67.8

97.7

105.5

107.7

Btu/h

231,300

333,400

360,000

367,500

Boiler output

Max

329.0

415.6

498.8

581.8

(condensing)

Btu/h

1,122,500

1,418,000

1,701,900

1,985,100

Mean 40

Min

75.3

107.5

116.1

118.3

Btu/h

256,900

366,800

396,100

403,600

Boiler Input

Net

320

400

480

560

Max Rate

Btu/h

1,091,800

1,364,800

1,637,800

1,910,700

Gross

355.4

444.2

533.0

621.8

Btu/h

1,212,600

1,515,600

1,818,600

2,121,600

Boiler Input

Net

100

108

110

Min Rate

Btu/h

238,800

341,200

368,500

375,300

Gross

77.6

110.9

119.8

122.0

Btu/h

264,800

378,400

408,800

416,300

Maximum Gas Rate

32.2

40.2

48.4

56.4

1138

1420

1710

1992

Approx. flue gas

@ max. rate

484

604

726

846

volume (@80

C) i.e. non-condensing ft

17,100

21,380

25,640

29,920

Max. Flue Resistance

145

Flue Gas CO

@ Max Rate

9.3/9.8

G20/LNG @ Min. Rate

9.1/9.6

NOx with O

= 0% mg/kWh

ppm

Seasonal Boiler Efficiency (Building Regs L2)

95.1

95.2

Note.
Natural gas consumption is calculated using a calorific value of
37.8MJ/m

(1038Btu/ft

) gross or 34 MJ/m

(910 Btu/ft

) nett at

C and 1013.25 mbar.

a. For l/s divide the gross heat input (kW) by the gross C.V. of

the gas (MJ/m

)

b. For ft/h

divide the gross heat input (Btu/h) by the gross C.V.

of the gas (Btu/ft

HEALTH & SAFETY DOCUMENT NO. 635

The electricity at work regulations, 1989. The manufacturer's
notes must NOT be taken, in any way, as overriding statutory
obligations.

IMPORTANT. These appliances are CE certified for safety and
performance. It is, therefore, important that no external control
devices, e.g. flue dampers, economisers etc., are directly
connected to these appliances unless covered by these
Installation and Servicing Instructions or as otherwise
recommended by Ideal Stelrad Group in writing. If in doubt
please enquire.
Any direct connection of a control device not approved by Ideal
Stelrad Group could invalidate the certification and the normal
appliance warranty. It could also infringe the Gas Safety
Regulations and the above regulations.

Electricity supply and Fuse rating for pumps etc. refer to manufacturer's instructions.

* OPTIONAL HEADER PACK HAS DN80 CONNECTIONS FOR FLOW AND RETURN AND 2" BSP GAS CONNECTION

Table 2 General Data

Boiler

F320

F400

F480

F560

Gas supply

2H - G20 - 20mbar

Gas supply connection

(in. BSP)

2 x R1

Flow connection

(in. BSP)

2 x R2

Return connection

(in. BSP)

2 x R2

Hydraulic Resistance @ 20

mbar

100

105

110

120

Max Press (sealed system)

bar (psi)

6 (87)

Maximum Static Head

m (ft)

61 (200)

Boiler Electricity Supply

230V - 50Hz

Boiler Fuse Rating

2 x External 5A supplies Internal 2AT.4AT (x2)

Power Consumption (boiler only)

800

Air Inlet

O/D

m m

110x2

Flue Size dia

m m

200

250

Condensate drain

m m

2x21.5

Boiler dry weight

(unpacked exc. headers)

kg (lb)

336 (740)

396 (874)

430 (948)

466 (1028)

Water Content

l (gal)

35 (7.8)

36.8 (8.2)

48.0 (10.6)

54.4 (12.0)

*
*

xtra

Installation & Servicing

GENERAL

xtra

CONTENTS

Boiler Assembly - exploded view. .................................. 11

Boiler Clearances. ............................................................ 9

Boiler Dimensions. ..................................................... 7,8,9

Commissioning and Testing. ......................................... 37

Electrical Connections. .................................................. 18

Electrical Supply. .............................................................. 6

Fault Finding. ................................................................... 50

Flue Installation. ................................................................ 5

Gas Safety Regulations .................................................... 4

Gas Supply. ........................................................................ 4

Hydraulic Resistance. ...................................................... 5

Initial Lighting. ................................................................. 37

Installation. ...................................................................... 11

Option Kits. ........................................................................ 4

Performance Data. ........................................................... 2

Servicing. ........................................................................ 38

Short List of Parts. ......................................................... 54

Ventilation. ........................................................................ 9

Water Circulation. ............................................................ 6

Water Connections. ....................................................... 17

Water System Requirements. ....................................... 10

Water Treatment. ............................................................. 6

Wiring Diagrams. ....................................................... 21,22

Natural Gas only
PI No. 0063 BR 3123
Destination Countries: GB, IE

Key to symbols
IE = Ireland, GB = United Kingdom (Countries of destination)
PMS =

Maximum operating pressure of water

C53 =

A room sealed appliance which is connected
via its separate ducts to two terminals that
may terminate in zones of different pressure.

C63 =

A room sealed appliance intended to be
connected to a separately approved and
marketed system for the supply of
combustion air and discharge of combustion
products. The fan is up stream of the
combustion chamber.

B23 =

An appliance intended to be connected to a
flue which evacuates the products of
combustion to the outside of the room
containing the boiler. The combustion air is
drawn directly from the room. The fan is up
stream of the combustion chamber.

NOTE TO THE INSTALLER: LEAVE THESE INSTRUCTIONS ADJACENT TO THE GAS METER.

xtra

Installation & Servicing

GENERAL

INTRODUCTION

The

xtra

boilers are fully automatically controlled, floor

standing, fanned, super efficient condensing appliances.
The imax xtra comprises of 2 modules, Master and Slave.
The comprehensive boiler controls built into the appliance
include:
-

0-10V Boiler control input

Volt free 'alarm' contacts (lockout)

Volt free 'boiler run' contacts

Burner hours run meters

System temperature indication

The boilers can draw their combustion air from the room or via
ducting from outside.
Through a sophisticated control system combined with premix
burner technology and an aluminium heat exchanger, the boilers
are capable of high operating efficiencies of 93% (gross) and low
emissions.
These boilers are certified to meet the requirements of the EC
Gas Appliance Directive, Boiler Efficiency Directive, EMC and Low
Voltage Directive.

OPTIONAL EXTRA KITS
·

Modulating Sequencer
- DHW Sensor
- Room Sensor

Programmable Room Stat

Outside Sensor
(only suitable for use in conjunction with Prog. Room Stat)

Water and Gas Header Pack

RS Air Duct Connector (F320 and F400 only)

Horizontal Flue Header *

Vertical Flue Header *

* A flue header kit (horizontal or vertical) must be fitted to boiler.

SAFETY

Current Gas Safety (Installation and Use) Regulations or rules in
force
The appliance is suitable only for installation in GB and IE and
should be installed in accordance with the rules in force.
In GB, the installation must be carried out by a CORGI Registered
Installer or in IE by a competent person. It must be carried out in
accordance with the relevant requirements of the:
·

Gas Safety (Installation and Use) Regulations

The appropriate Building Regulations either The Building
Regulations, The Building Regulations (Scotland), Building
Regulations (Northern Ireland).

The Water Fittings Regulations or Water byelaws in Scotland.

The Current I.E.E. Wiring Regulations.

Where no specific instructions are given, reference should be
made to the relevant British Standard Code of Practice.
In IE, the installation must be carried out by a Competent Person
and installed in accordance with the current Building Regulations
and reference should be made to the current ETCI rules for
electrical installation.
The boilers have been tested by Gastec and conform to EN483
and EN677 for use with Natural Gas.

Detailed recommendations are contained in the following
Standards and Codes of Practice:
BS. 5854

Flue and flue Structures in Buildings.

BS. 6644

Installation of gas fired hot water boilers of rated
inputs between 70kW and 1.8MW (net) (2nd and
3rd family gases).

BS. 6880

Low temperature hot water heating systems of
output greater than 45kW.

Part 1

Fundamental and design considerations.

Part 2

Selection of equipment.

Part 3

Installation, commissioning and maintenance.

IGE/UP/1

Soundness testing and purging of industrial and
commercial gas installations.

IGE/UP/2

Gas installation pipework, boosters and
compressors on industrial and commercial
premises.

IGE/UP/10

Installation of gas appliances in industrial and
commercial premises.

SAFE HANDLING OF SUBSTANCES

No asbestos, mercury or CFCs are included in any part of the
boiler or its manufacture.

FOUNDATION / LOCATION OF BOILER

The boiler must stand on a floor which must be flat, level and of a
suitable load bearing capacity to support the weight of the boiler
(when filled with water) and any ancillary equipment.
Ideally the boiler should be placed on a plinth exceeding the plan
area of the boiler by 75mm on each side and at least 100mm high.
The boiler must not be fitted outside.

GAS SUPPLY

The local gas supplier should be consulted, at the installation
planning stage, in order to establish the availability of an adequate
supply of gas. An existing service pipe must NOT be used without
prior consultation with the local gas supplier.
A gas meter can only be connected by the local gas supplier or by a
registered CORGI engineer or in IE by a competent person.
An existing meter should be checked, preferably by the gas
supplier, to ensure that the meter is adequate to deal with the rate
of gas supply required. A minimum working gas pressure of
15mbar MUST be available at the boiler inlet for Natural gas.
Do not use pipes of smaller size than the boiler inlet gas
connection.
The complete installation MUST be tested for gas soundness and
purged in accordance with the appropriate standards.
Gas Boosters
A gas booster is required if the gas pressure available at the boiler
is lower than that required by the boiler manufacturer to attain the
flow rate for maximum burner input rating.
Location of the booster requires careful consideration but should
preferably be closer to the burner rather than the gas meter.
Ventilation should also be considered to ensure ambient
temperature do not exceed designed recommendations. Further
guidance is provided in IGE/UP/2.

xtra

Installation & Servicing

GENERAL

FLUE INSTALLATION

The appropriate Ideal Flue Header Kit (veritcal or horizontal)
must be fitted to these boilers.
IMPORTANT. It is the responsibility of the installer to ensure, in
practice, that products of combustion discharging from the
terminal cannot re-enter the building or any other adjacent
building through ventilators, windows, doors, other sources of
natural air infiltration, or forced ventilation / air conditioning.
If this should occur the appliance MUST be isolated from the
gas supply and labelled as 'unsafe' until corrective action can be
taken.
Terminal Position
Due to the high efficiency of the boilers pluming will occur.
Particular care should be taken in the case of large output boiler
installations, and complying with the requirements of the Clean
Air Act.
The flue must be installed in accordance with the appropriate
Building Regulations and standards listed on page 4 and in
compliance with BS6644. In IE refer to I.S.820:2000.

FLUE SYSTEM DESIGN

Due to the high efficiency of these boilers, the flue gas
temperatures are low and the buoyancy in the stack will be
relatively small. The boiler is supplied with an integral fan which
is fully matched to the boiler in each case to provide correct
combustion air flow and overcome the flue resistance.
The power of this fan is such that there is a large reserve of
pressure available to overcome a significant length of flue
without affecting the combustion performance of the boiler. The
maximum pressure available at the base of the flue to overcome
flue resistance is 145Pa (0.58" w.g.) for F320, F400, F480 and
F560. This includes the resistance of any air ducts used to
connect the air inlet direct to outside air. Care should be taken
with tall flue systems to ensure excess buoyancy is not created.
A negative pressure must not be created at the boiler flue outlet.
See table below for approximate maximum straight flue length.

Boiler

F320

F400

F480

F560

Flue Size (mm)

Ø200

Ø250

Approx. max.
Straight Flue

109

235

162

116

Length (m)

If the high level air inlet kit, supplied with this appliance, is to be
utilised, the following table shows the approximate maximum
straight flue lengths and pressures available.

Boiler

F320

F400

F480

F560

Flue Size (mm)

Ø200

Ø250

Approx. max.
Straight Flue

129

Length (m)
Flue Pressure (Pa)

The addition of elbows and their positions in the flue will have a
significant effect on the maximum allowable flue and air duct
lengths. Consult with your flue supplier for detailed design
work.

IMPORTANT NOTE.
If combustion air is drawn from within the boiler room, ensure

no dust or airborne debris can be ingested into the appliance.

Dusty concrete flooring should be sealed to reduce the

presence of dust. Ideally where possible duct the air supply

into the boiler room from a clean source outside the boiler

room / building.

Material
With no requirement for buoyancy to discharge flue products and
with low flue gas temperatures, single wall flues are suitable for
most installations. Care should still be taken to maintain
compliance with building regulations and relevant standards.
The flue used should be a suitably approved flue for use on a
pressurised condensing flue system. Materials choice includes
plastic, aluminium and 316 grade stainless steel. Unless the
flue is manufactured from aluminium, the condensate from
the flue must be collected and drained before entering the
sump of the boiler (when employing the vertical combined flue
outlet header, a flue condensate drain is provided for this
purpose). Advice regarding the availability of proprietary types of
flue system can be obtained by contacting Ideal Stelrad Group.
All joints or connections in the flue system must be impervious
to condensate leakage. Low points in the flue system should be
drained using pipe of material resistant to condensate
corrosion. All drains in the flue should incorporate a water trap.
Care should also be taken in the selection of flue terminals as
these tend to accentuate the formation of a plume and could
freeze in cold weather conditions.
Care should be taken to ensure the specification of the chimney
is suitable for the application by reference to the manufacturers
literature.

xtra

Installation & Servicing

GENERAL

WATER CIRCULATION SYSTEM

A circulation pump MUST be connected to the boiler, see below.
The boiler must NOT be used for direct hot water supply. The
hot water storage cylinder MUST be of the indirect type.
Single feed, indirect cylinders are not recommended and MUST
NOT be used on sealed systems.
The appliances are NOT suitable for gravity central heating nor
are they suitable for the provision of gravity domestic hot water.
The hot water cylinder and ancillary pipework, not forming part of
the useful heating surface, should be lagged to prevent heat
loss and any possible freezing - particularly where pipes run
through roof spaces and ventilated underfloor spaces.
The boiler must be vented. There must be no low points
between the boiler flow connection and a system vent point,
which should be positioned as close as practically possible to
the boiler flow connection.
Draining taps MUST be located in accessible positions, which
permit the draining of the whole system - including the boiler
and hot water storage vessel. They should be at least 1/2" BSP
nominal size and be in accordance with BS. 2879. Do not use
the boiler drain tap to drain the system as this can induce
sludge into the heat exchanger.
The central heating system should be in accordance with the
relevant standards listed on page 4.
Due to the compact nature of the boiler the heat stored within
the castings at the point of shutdown of the burner must be
dissipated into the water circuit in order to avoid overheating. In
order to allow pump operation after burner shutdown the boiler
control box incorporates a 5 minute pump overrun facility. In
order to make use of this, a pump must be supplied from the
terminals inside the boiler. Note: for pumps requiring greater
than 1.0 amp current, they must be connected via a relay.
When sizing pumps, reference should be made to the Hydraulic
Resistance Table on page 6 which show the boiler resistance
against flow rates, to achieve the required temperature
differential.
Flow rates for common systems using either 11

C or 20

temperature differentials are given in the table below.

Water flow rate temp.

difference 11

C (20

difference 20

C (36

l/s

F320

7.14

25.70

3.93

14.15

F400

9.02

32.47

4.96

17.86

F480

10.83

38.99

5.96

21.46

F560

12.63

45.47

6.95

25.02

Note.
·

With the boiler firing at maximum rate, the temperature
differential should not be less than 10

C. Higher flow rates

required for lower temperature differentials could lead to
erosion of the heat exchanger water ways.

With the boiler firing at minimum rate, the temperature
differential should not be greater than 35

C. Lower flow rates

generating higher temperature differentials will lead to lock
out of the boiler.

The lower the return temperature to the boiler, the higher the
efficiency. At return temperatures of 55

C and below, the

difference becomes marked because the water in the flue
gases starts to condense, releasing its latent heat.

In installations where all radiators have been provided with
thermostatic radiator valves, it is essential that water circulation
through the boiler is guaranteed. A mixing header will perform
this task. Alternatively this can be best achieved by means of a
differential pressure valve, which is installed in a bypass

between the flow and return pipes. The bypass should be fitted
at least 6m from the boiler, and should be capable of allowing a
minimum flow rate to achieve a temperature differential of no
greater than 35

C at minimum rate.

WATER TREATMENT

These boilers incorporate an ALUMINIUM heat exchanger.
IMPORTANT. The application of any other treatment to this
product may render the guarantee of Ideal Stelrad Group
INVALID.
Ideal Stelrad Group recommend Water Treatment in
accordance with Guidance Notes on Water Treatment in Central
Heating Systems.
Ideal Stelrad Group recommend the use of Fernox Copal or
MB1 or GE Betz Sentinel X100 inhibitors and associated water
treatment products, which must be used in accordance with the
manufacturers' instructions.
For further information contact:
Fernox Manufacturing Co. Ltd., Cookson Electronics,
Forsyth Road, Sheerwater, Woking, Surrey, GU21 5RZ
Tel: +44 (0) 1799 521133 or

Sentinel Performance Solutions.,
The Heath Business & Technical Park, Runcorn, Cheshire, WA7 4QX
Tel: 0800 389 4670. www.sentinel-solutions.net

1. It is most important that the correct concentration of the water

treatment products is maintained in accordance with the
manufacturers' instructions.

2. If the boiler is installed in an existing system any unsuitable

additives MUST be removed by thorough cleansing.

3. In hard water areas, treatment to prevent limescale may be

necessary - however the use of artificially softened water is
NOT permitted.

4. Under no circumstances should the boiler be fired before

the system has been thoroughly flushed.

ELECTRICAL SUPPLY

WARNING. This appliance must be earthed.
Wiring external to the appliance MUST be in accordance with the
current I.E.E. (BS7671) Wiring Regulations and any local
regulations which apply. For Ireland reference should be made
to the current ETCI rules for electrical installations.
The point of connection to the mains should be readily
accessible and adjacent to the boiler.

CONDENSATE DRAIN

Condensate drains are provided on the boiler. These drains
must be connected to a drainage point on site. All pipework and
fittings in the condensate drainage system MUST be made of
plastic - no other materials may be used.
IMPORTANT. Any external runs must be insulated to avoid
freezing in cold weather causing blocking.

Boiler

Pressure Drop

(mbar) @ 20

(mbar) @ 11

F320

297

F400

314

F480

100

330

F560

105

347

HYDRAULIC RESISTANCE

xtra

Installation & Servicing

GENERAL

BOILER DIMENSIONS AND CONNECTIONS
(Optional water and gas header kit and rs air duct connector (F320 & F400 only) fitted)

Note. F320 Model shown

VENTILATION

The ventilation requirements of these boilers are dependant
on the type of flue system used, and their heat input. All vents
must be permanent with no means of closing, and positioned
to avoid accidental obstructions by blocking or flooding.
Detail reference should be made to BS. 6644 for inputs
between 70kW and 1.8MW (net). In IE refer to the current
edition of I.S.820. The following notes are for general
guidance only:
Dust contamination in the combustion air may cause blockage
of the burner slots. Unless the boiler room provides a dust
free environment then direct connection of the air intake via
ducting to clean outside air should be used.
IMPORTANT NOTE.
If combustion air is drawn from within the boiler room,

ensure no dust or airborne debris can be ingested into the

appliance. Dusty concrete flooring should be sealed to
reduce the presence of dust.
The temperature within a boiler room shall not exceed 25

within 100 mm of the floor, 32

C at mid height and 40

C within

100 mm of the ceiling.

Open Flued Installations
If ventilation is to be provided by means of permanent high and
low vents communicating direct with outside air, then reference
can be made to the sizes below. For other ventilation options
refer to BS. 6644. In IE refer to the current edition of I.S.820.
Required area (cm

) per kW of total rated input (net)

Boiler Room

Enclosure

Low level (inlet)

High level (outlet)

Note: Where a boiler installation is to operate in summer
months (e.g. DHW) additional ventilation requirements are
stated, if operating for more than 50% of time (refer to BS6644).

Room Sealed Installations
A minimum of 2cm

free area per kW of net heat input at both

high and low level is required for boiler rooms. For enclosures
refer to BS6644.

BOILER CLEARANCES

The minimum dimensions as indicated must be respected to
ensure good access around the boiler.
Recommended minimum clearances are as follows.
Rear: 1000mm or adequate space from the rear of the jacket
to make the flue connections and access to the flue sample
point, drain connection, flue and any safety or control devices.

All dimensions shown in mm

SIDE VIEW

im9159

REAR VIEW

Flow

connection

Return
connection

Left Side: 450mm
Right Side: 450mm
Front: 600mm; except, access doors may be closer, but
not less than 200mm and 600mm must still be available
for service across the width of the boiler.
Top: 500mm.

xtra

Installation & Servicing

GENERAL

Rated output

Minimum bore

Nominal Size (DN)

m m

301 to 600

'Steel pipe sizes complying with medium or heavy quality or BS 1387.

Detail reference should be made to the appropriate standards listed on
page 4.
The information and guidance given below is not intended to override any
requirements of the above publications or the requirements of the local
authority, gas or water undertakings.
The vertical distance between the pump and feed/expansion cistern MUST
comply with the pump manufacturer's minimum requirements, to avoid
cavitation. Should these conditions not apply either lower the pump
position or raise the cistern above the minimum requirement specified by
Ideal Stelrad Group. The isolation valves should be fitted as close to the
pump as possible.
The information provided is based on the following assumptions:
1. An independent open vent/safety pipe connection is made immediately

after the system flow pipe connection.

2. An independent cold feed/expansion pipe connection is made

immediately after the open vent/safety pipe connection.

3. The maximum flow rate through the boiler is based on a temperature

difference of 11

C at full boiler output.

4. The boiler is at the highest point of circulation in the system. Systems

designed to rise above the boiler flow tappings will automatically
require a minimum static head higher than that shown.

5. The position of the open vent/safety pipe above the expansion cistern

water level is given as a guide only. The final position will depend upon
the particular characteristics of the system. Pumping over of water into
the expansion cistern must be avoided.

6. Both open vent/safety pipe and cold feed/expansion pipes must be of

adequate diameter to suit the output of the boiler. Refer to Tables
below and BS 6644:2005.

OPEN VENTED SYSTEM REQUIREMENTS

Note.
·

With a cold feed head of <8m, the pump
must be fitted on the return to the boiler.

This diagram does not show safety valves,
water flow switches, etc. necessary for the
safe operation of the system.

SEALED SYSTEM REQUIREMENTS

Open Vent Pipe Sizes

Rated output

Minimum bore

Nominal Size (DN)

m m

301 to 600

'Steel pipe sizes complying with medium or heavy quality or BS 1387.

Cold Feed Pipe Sizes

Note. Refer to Frame 29 for typical system arrangements.

Feed/expansion

cistern

Open vent
safety pipe

3 m
minimum
see notes

System
flow

Shunt Pump

(if required)

Inverted

cold feed

entry

Cold

Feed

Water

level

(cold)

Open vent

System
return

im8250

Connections

to boiler

Working pressure 6 bar maximum.
Particular reference should be made to BS. 6644 and
Guidance note PM5 "Automatically controlled steam and hot
water boilers" published by the Health and Safety Executive.
The information and guidance given below is not intended to
override any requirements of either of the above publications or
the requirements of the local authority, gas or water
undertakings.
In general commercial closed pressurised systems are
provided with either manual or automatic water make up.
In both instances it will be necessary to fit automatic controls
intended to protect the boiler, circulating system and ancillary
equipment by shutting down the boiler plant if a potentially
hazardous situation should arise.
Examples of such situations are low water level and operating
pressure or excessive pressure within the system. Depending
on circumstances, controls will need to be either manual or
automatic reset. In the event of a shutdown both visual and
audible alarms may be necessary.

Expansion vessels used must comply with BS. 4814 and must
be sized on the basis of the total system volume and initial
charge pressure.
Initial minimum charge pressure should not be less than 0.5
bar (7.2psi) and must take account of the static head and
specification of the pressurising equipment. The maximum
water temperatures permissible at the point of minimum
pressure in the system are specified in Guidance Note PM5.
When make up water is not provided automatically it will be
necessary to fit controls which shut down the plant in the event
of the maximum system pressure approaching to within
0.35bar (5psi) of the safety valve setting.
Other British Standards applicable to commercial sealed
systems are:
BS. 6880: Part 2
BS. 1212
BS. 6281: Part 1
BS. 6282: Part 1
BS. 6283: Part 4

xtra

Installation & Servicing

INSTALLATION

im8481

Rear screw on
both sides to
be left in place

The boiler comprises of an equally sized Master
and Slave Module, separately packed on their
own pallets. This allows the boiler to be
handled by a forklift.

The packaged boiler will pass through a
930mm wide opening. Removing the casing
assembly pack from the Master Module will
allow Modules through a 700mm wide opening.

PACKAGING REMOVAL / REMOVAL FROM PALLET

To unpack the modules:

Carefully remove the straps, and lift off the casing assembly pack -
master only.

Open Master Module box and remove literature pack.

Remove the protective cardboard fittings.

Safely dispose of all packing materials.

To remove the Modules from base:

1. Remove 2 screws securing casing support outrigger and discard

item (Master only).

2. Remove the 3 front screws (2 screws on 320 model) on both sides

leaving the 2 rear screws in place.

3. Rotate bottom battens outwards allowing the front of the base to rest

on the floor.

4. Remove 4 screws and retaining brackets.

5. Slide the module off the base.

Repeat Steps 2 - 5 for slave module.

INST

ALLA

TION

xtra

Installation & Servicing

INSTALLATION

REAR VIEW

Flue

Sampling

Point

Air inlet duct O110

See Table on page 5 for guidance on maximum permissible
flue and air duct system design.
FLUE
Construct either the horizontal or vertical combined flue outlet
ductwork to create the manifold arrangement depicted. The
horizontal combined flue outlet can be installed with its outlet
facing left or right dependent upon the demands of each
particular installation.
A tube of ductwork seal lubricant is provided within the flue kit.
To ease flue connections lubricate all flue seals before
assembly. Flue sampling points are fitted within the ductwork
legs A and B as depicted to facilitate flue products sampling of
each boiler module.

IMPORTANT NOTES.
1. The flue manifold should be supported in such a way as

not to place load on the boiler module flue outlet sockets.
Propriety flue duct brackets must be used to provide
support as appropriate.

2. Unless the connecting flue is manufactured from

aluminium the condensate generated within the flue must
be collected and drained before entering the combined flue
outlet ductwork. When employing the vertical combined
flue outlet header, a flue condensate drain is provided for
this purpose.

12 FLUE / AIR DUCT INSTALLATION

KEY
A Flue Tube

D Bend x 45

B Flue Tube

E Connector

C Bend x 87

F Adaptor

REAR VIEW

Flue

Sampling

Point

im9161

Air inlet duct O110

AIR DUCT
Combustion air can be drawn directly from the boiler room
using the high level air inlet kit provided or ducted in from
outside the building in which the boiler is installed.

IMPORTANT NOTE. If combustion air is drawn from within the
boiler room, ensure no dust or airborne debris can be
ingested into the appliance. Dusty concrete flooring should
be sealed to reduce the presence of dust. Ideally where
possible duct the air supply into the boiler room from a clean
source outside the boiler room / building.

To draw air direct from outside, connection can be made using
separate ducts to each boiler Module. This can be done using
any propriety 110mm soil / drain pipe. Expansion to a larger
diameter may be required to reduce resistance, dependant on
total flue / air duct lengths required. (See Flue System Design
on Page 5). The air duct should be terminated with a suitable
fixed grille to prevent entry to vermin. This terminal should be
positioned as such to avoid blockages or entry of water.

An optional RS duct connector kit allows for the two individual
module air inlet connections to be combined into a single
200mm boiler air supply connection to simplify installation and
increase permissible air duct length (F320 and F400 only)

HORIZONTAL FLUE HEADER ARRANGEMENT

KEY
A Flue Tube

C Flue Tee Manifold

B Flue Tube

D Flue Condensate Drain Trap

VERTICAL FLUE HEADER ARRANGEMENT

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Installation & Servicing

INSTALLATION

REAR VIEW

RETURN

FLOW

(Must be

connected

opposite side

to flow

connection)

(Must be

connected

opposite side

to return

connection)

im8482

13 CONDENSATE DRAIN (Slave and Master)

A condensate drain must be connected to the

condensate bulk head connector on the back of each

module and then connected to a drainage point,

preferably within the building.
The pipe size from the condensate connector on the

lower rear panel is 21.5mm.
The routing of the drain must be made to allow a

minimum fall of 1 in 20 away from the boiler, throughout

its length.

14 BOILER WATER CONNECTIONS

The boiler flow and return pipes are terminated with 2 x R2" BSP male
connections at the rear of the appliance. Water returning from the system
should be connected to a lower header pipe, with the flow water connection
coming from a top header pipe. An optional pre-
fabricated header pipe kit is available.
Refer to Frames 1 and 2 for dimensional
positions.
All flow and return pipework must be
independently supported.
Plastic plugs fitted on the open ends of the flow
and return pipes must be removed before
connecting the system pipework.
An air vent must be provided immediately after the
flow connection.
If installing the boiler onto an existing system it is
strongly recommended that the system be
thoroughly flushed before connecting the boiler.
When connecting to a new system it is still
important to flush the whole system in accordance
with the relevant standards.

Condensate Bulkhead Connector

If the vertical flue header is specified the flue manifold

condensate drain connection must also be connected in the

same manner.
IMPORTANT. Any external runs must be kept to a minimum

and insulated. This is to avoid freezing in cold weather

causing blocking.
All pipework and fittings in the condensate drain system

must be made of plastic. No other materials may be used.

Note.
Connection to the boilers using manifolds must
use a reverse return principle to ensure equal flow
distribution through both of the modules, see
example below.
Connection of opposing flow and return points can
be made either on the LH side or RH side,
dependent upon the particular needs of the boiler
installation.

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18 INSTALLING THE MAINS AND CONTROL WIRING (MASTER AND SLAVE MODULES)

1. Route all 230V circuits in at the rear, through

conduit no. 1 on both Master and Slave
Modules.

2. Route all low voltage remote sensor/control

cables for the master module through conduit
no. 2.

3. Secure the cables with the cable clamps

provided on the main controls panel.

16 GAS CONNECTIONS

The boiler gas supply pipe is terminated in 2 x R1" BSP male
taper connections on the left-hand sides of the modules.
A gas header kit is available to combine the inlet connections
to a 2" manifold.

All gas supply pipework must be independently supported.
A minimum working gas pressure of 15mbar (6" w.g.) must
be available at the boiler inlet with the boiler firing.
Fit a gas supply pipe NOT LESS THAN 2" BSP to the boiler.

17 ELECTRICAL CONNECTIONS

Warning. This appliance MUST be efficiently earthed.
A mains supply of 230V 50Hz is required to be fitted to both the
Master and Slave Modules (see terminals marked 'Mains In'
Frame 19). External controls should NOT be wired in series
with these mains inputs. Controlling the boiler in this way will
prevent the pump over-run sequence and may cause damage
to the modules. The supply wiring MUST be suitable for mains
voltage. Wiring should be 3 core PVC insulated cable NOT
LESS than 0.75mm

(24 x 0.2 mm) and to BS. 6500, Table 16.

The fuse rating should be 7A.
Wiring external to the boiler MUST be in accordance with the
current I.E.E. (BS7671) wiring Regulations and any local
regulations. For Ireland reference should be made to the
current ETCI rules for electrical installations.

Connection should be made in a way that allows complete
isolation of the electrical supply - such as a double pole
switch, having a 3mm (1/8") contact separation in both poles,
or a plug and unswitched socket serving only the boiler and
system controls. The means of isolation must be accessible
to the user after installation.
When making mains electrical connections to the modules it
is important that the wires are prepared in such a way that the
earth conductor is longer than the current carrying conductors,
such that if the cord anchorage should slip the current carrying
conductors become taut before the earthing conductor.
WARNING. Sensor cables must be separated from cables in
the 230V circuit. For this purpose three conduits are
provided. Refer to Frame 19 for terminal strip connections.

15 FROST PROTECTION

The boiler has built into its control system the facility to protect
the boiler only against freezing.
If the boiler flow temperature T

, falls below 7

C the pump will

be activated without the boiler firing.
If the flow temperature falls below 5

C the boiler will fire until

the flow temperature exceeds 10

C. The pump will stay

running for a further 5 minutes.

Central heating systems fitted wholly inside the building do
not normally require frost protection as the building acts as a
'storage heater' and can normally be left at least 24 hours
without frost damage. However, if parts of the pipework run
outside the building or if the boiler will be left off for more than
a day or so, then frost protection for the system is
recommended.

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19 INSTALLER CONNECTIONS

230V AC
permanent
mains supply

230V AC permanent
mains supply

230V AC
output for CH
system pump.
max 1 amp

Optional 230V AC
output for DHW pump
or divertor valve.
max 1 amp.

Optional call for CH

Optional call for DHW

im8483

MASTER MODULE

SLAVE MODULE

Optional connections for

programmable room stat

and modulating sequencer kits

Optional volt free connections for

boiler alarm during lock out condition.

(Closed circuit during lock out)

Optional connections for outside

temperature sensor kit

Optional connections 0-10V

boiler control

Test point for measuring

flame ionisation current using

0-10V DC meter - see Frame 61

Test point for measuring

flame ionisation current using

0-10V DC meter - see Frame 61

Optional volt free connections for

boiler 'run' inidication

(Closed circuit during burner on operation)

0-10V

Ground

Note.

BOTH OT CENTERS MUST BE CONFIGURED IN ACCORDANCE WITH BOILER CONTROL INPUT OPTION CHOSEN.
(See Frame 22 for details)

Input terminals are available for connecting a variety of system

controls for central heating demand. Only one method should

be employed on an individual boiler. OT Centers to be

configured in accordance with choice mode (see to Frame 22).
Heating demand can be controlled by:
1. ON/OFF using a 230V switched live to 'CH call' terminal.

(e.g. programmer and/or room thermostat).

A call for heat will cause the boiler to run and maintain a set

flow temperature controlled by parameter 4* (see Frame 31).
Connect switched live to Master Module terminal marked 'CH

CALL'.

2. Programmable Room Thermostat Kit.

The programmable room thermostat kit incorporates a room

temperature sensor and a programmer capable of

controlling the heat output from the boiler to satisfy different

temperature requirements at different time periods. The

addition of an Outside Sensor Kit will enable a weather

compensated flow temperature (see Instructions with kit for

more details).
Connect Programmable Room Thermostat to Master Module

using terminals marked 'CONTROLLER'. Wires have no

polarity and are low voltage control cables.

3. Modulating Sequencer Kit.

A Modulating Sequencer Kit is capable of controlling the

heat demand on up to 5 boilers simultaneously. (See

instructions with kit for more details.)
Connect Modulating Sequencer Kit to Master Module

using terminals marked 'CONTROLLER'. Wires have no

polarity and are low voltage control cables.

4. 0-10V

A call for heat can be generated using a 0-10V input with

the flow temperature setpoint controlled by the voltage

signal. 10V generates a maximum flow temperature top

limited by parameter 4* (see Frame 31).
Connect 0-10V signal to Master Module using terminals

marked '0-10V INPUT'. The ground wire should be

connected to the lower terminal and the 0-10V

modulating signal to the upper terminal.

CH Pump
Output terminals marked 'CH PUMP' are provided for a

circulating pump which must be connected to allow the

pump overrun function to operate. A pump requiring more

than 1 amp supply current must be connected via a relay.

20 CH CONTROL CONNECTIONS

* Changes to parameter 4 must be carried out in common to

both Master and Slave Modules.

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Rear of OT Center

23 FITTING OT CENTER

22 OT CENTER CONFIGURATION

The OT Centers on each module are factory pre-set as
master and slave units for CH ON/OFF call for heat.
To check the settings or to configure for alternative control
options remove the OT Center and set switches "S1 and "S2"
according to the tables below (See Frame 67 for details of
how to remove and replace OT Centers).

If the boiler is providing both CH and DHW, and the CH circuit
is to operate for periods at a reduced temperature (i.e.
weather compensated), then it is necessary to differentiate
between CH and DHW heat demands. For this purpose a
DHW demand can be placed on the boiler using the method
shown below.
A demand for DHW has priority over CH by parameter 43 (see
Frame 38).
A call for DHW will cause the boiler to run and maintain a set
flow temperature of 80

21 DHW CONTROLS CONNECTIONS

DHW heat demand can be controlled by:
1. ON/OFF using a 230V switched to live 'DHW call' terminal

(e.g. a cylinder thermostat and/ or programmer).
A call for heat will cause the boiler to run and maintain a set
flow temperature of 80

Output terminals are provided for a DHW pump or valve. This
output can be used to control the diversion of flow to the DHW
circuit. A pump or valve requiring more than 1 amp supply
current must be connected via a relay.

* Changes to parameter 4 must be carried out in common to

both Master and Slave Modules.

Position S2

Function

Master - Module

Slave Module

Position S1

Function

N/A

Opentherm programmable
room stat or sequencer kit

CH ON-OFF call for heat

0 to 10 V Input

Note.
Both OT Centers (Master and Slave Modules) must
be configured similarly.

1. Locate the communication lead attached to the OT Center on the Master Module.
2. Route cable through grommet, and across behind control panels and back out

through grommet.

3. Plug remaining end into either

socket on Slave Module OT
Center.

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24 PICTORIAL WIRING DIAGRAM (MASTER BOILER)

Damper

r
ansformer

4321

MCBA5407D

3456

789

X3/4

SUPPRESSOR

1234

789

910

1213

1415

X10

AM3

MASTER

CENTER

Connection to

Slave Wiring

Centre

TB1

CONTROLLER

DHW

CALL

DHW PUMP

OR VA

CH PUMP

MAINS IN

OUTSIDE

TEMP

0-10V

INPUT

BS*

* Note. For BS open circuit is on, closed circuit is of

TTL

DISPLA

TB2

FUSE

LEGEND

NTC1

NTC2

NTC5

NTC7

PS1

KEY

Flow thermistor

Return thermistor

Flue thermistor

Heat exchanger thermistor

ter pressure switch

Relay 1 230V

AC coil

Relay 2 230V

AC coil

Relay 1 Switch (signal)

Relay 2 Switch (signal)

Gas valve

Burner switch

Air pressure switch

y/g

white

yellow/green

grey

orange

violet

blue

black

brown

red

pink

yellow

y/g

PWM

ELN

TACH

APS1

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26 CH ON/OFF NO SEPARATE DHW DEMAND

For simple ON/OFF control of the boiler with a fixed flow temperature setpoint (see parameter 4 Frame 31), then the following
method should be used for connecting the boiler.

27 MAINS VOLTAGE CH AND DHW CONTROLS WITH DHW PUMP OUTPUT

No parameter
modifications are
required.
Alternatives: The
Ideal programmable
room thermostat and
outside sensor kit
provides enhanced
user comfort. Full
instructions provided
with kits.

Pump

Non return

valve

Non return
valve

Cylinder
thermostat

Programmer

Room
stat

im8191

This system provides heating to one zone at a time with
DHW priority controlled by parameter 43. To heat more
than one zone simultaneously, use zone
thermostats to energise individual zone valves
with all calls for heat applied to 'CH CALL'.
The boiler will be limited to responding with
a set flow temperature set by parameter 4
(see Frame 31).
If all zones are fitted with individual zone
valves a hydraulic bypass will be required to
allow pump overrun. See pages 6 and 10
for details.

Frost Stat if required*

230 VAC

Permanent

mains supply

Switched live (230 VAC)
from external controls
generating call for heat*

System pump

(maximum load 1 amp)

connect via a relay for

greater currents

CALL

DHW PUMP OR VALVE

CH PUMP

MAINS IN

DHW

CALL

230 VAC

Permanent

mains supply

MAINS IN

im8485

* The switched live from
external controls must be
from the same phase
supply as the boiler mains
supply to ensure that
when the boiler supply is
switched off the controls
are also isolated.

MASTER MODULE

SLAVE MODULE

No parameter modifications are required.

* The switched live from external controls must be from the same phase supply as the boiler
mains supply to ensure that when the boiler supply is switched off the controls are also isolated.

230 VAC

Permanent

mains supply

If either pump requires more than
1 amp supply current, connection

must be made via a relay

Room
stat

Cyl

stat

DHW

External 230 VAC
Programmer *

CALL

DHW PUMP OR VALVE

CH PUMP

MAINS IN

DHW

CALL

D H W

230 VAC

Permanent

mains supply

MAINS IN

im8486

SLAVE MODULE

MASTER MODULE

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INSTALLATION

Alternatives: The Ideal programmable room thermostat and outside sensor kit provides enhanced user comfort. Full
instructions provided with kits.

Parameter modifications see Frames 35 to 39.
Parameter 46 = 03 If a live output is required for positioning of
the valve to satisfy CH demand.
Parameter 46 = 23 If a live output is required for positioning of
the valve to satisfy DHW demand.

This system provides heating to one zone at a time with DHW
priority controlled by parameter 43. To heat more than one
zone simultaneously, use zone thermostats to energise
individual zone valves with all calls for heat applied to 'CH
CALL'. The boiler will be limited to responding with a set flow
temperature set by parameter 4 (see Frame 31).

If all zones are fitted with individual zone valves a hydraulic
bypass will be required to allow pump overrun. See page 6
and 10 for details.

im8193

Motorised valve

Pump

Cylinder
thermostat

Programmer

Room
stat

28 MAINS VOLTAGE CH AND DHW CONTROLS WITH DHW VALVE OUTPUT

* The switched live from external controls must be from the same phase supply as the boiler
mains supply to ensure that when the boiler supply is switched off the controls are also isolated.

230 VAC

Permanent

mains supply

If pump requires more

than 1 amp supply current,

connection must be made

via a relay

Motorised

Valve

(Not Mid-position)

Room
stat

Cyl

stat

DHW

External 230 VAC
Programmer *

CALL

DHW PUMP OR VALVE

M V

D H W

CH PUMP

MAINS IN

DHW

CALL

230 VAC

Permanent

mains supply

MAINS IN

im8487

SLAVE MODULE

MASTER MODULE

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29 EXAMPLES OF HEATING SYSTEMS

Heating system with DHW production (storage tank Output = Boiler Output) and mixing header.

Flow

Return

Primary

System

Pump

Filter

Mixing

Header

Heating circuit

Heating

System

Pump

im8196

Storage

tank output

boiler output

3 way diverting valve

Primary

System

Pump

Filter

Mixing

Header

Heating circuit

Heating

System

Pump

im8197

Flow

Return

Note.
If PARA '46' 1st digit is set to 2, it means you wish to have a 3
way valve normally open towards the CH circuit (radiator
circuits from AB to A). Upon DHW request, terminal 'L' on
'DHW PUMP OR VALVE' is energised which, through a relay,
powers the 3-way valve, thus closing port A and opening port B.
Simultaneously terminal 'L' on 'CH PUMP' is energised which,
through another relay, powers the primary system pump.

If PARA '46' 1st digit is set to 0, it means you wish to have a 3
way valve normally open towards the storage tank (DHW
circuit from AB to B). Upon CH request, terminal 'L' on 'DHW
PUMP OR VALVE' is energised which, through a relay, powers
the 3-way valve, thus closing port B and opening port A.
Simultaneously terminal 'L' on 'CH PUMP' is energised which,
through another relay, powers the primary system pump.

Heating system with one group of radiators (controlled by thermostatic valves)

DHW storage tank with DHW pump installed on the secondary circuit, in parallel with the heating circuit

im8198

Filter

Primary

System

Pump

Mixing header

non return
valve

Heating circuit

Heating
system pump

DHW
pump

DHW

tank

Flow

Return

Note.
The primary system pump would be off while the DHW pump is running with PARA '46' 1st digit set to '1x'. This would only give
adequate circulation if the DHW pump was connected into the primary circuit, shown to the left of the mixing header above.
However, in the case shown it will be necessary to run the primary system pump with the DHW pump for correct circulation. To
achieve this set PARA '46' 1st digit '2x'.

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30 BASIC CONTROLS DISPLAY (MASTER PANEL SHOWN)

During the operation of the

xtra

, the status of the

appliance can be determined by the display.
1. Normal Operation Mode

The unit will either be in standby or in operation. The first
digit on the display shows the boiler status (see table). The
last 3 digits show the flow temperature.

2. Blocking Mode

The Module will enter blocking mode under certain fault
conditions. Whilst in blocking mode the burner is switched
off. Once the fault conditions are clear the boiler will
automatically reset itself. In blocking mode the display will
alternate between showing a '9' in digit one, along with the
flow temperature in digits 2, 3 and 4.

9 9 6

Followed by the blocking code 'bxx'. Refer to page 54 for
Blocking Code references.

3. Error Mode

In error mode the display will show the error code.

Refer to Page 52 for error codes.
The Module will enter error mode under certain fault
conditions. The unit will be inoperative until the fault is
rectified. The reset button is used to reset the Module
control box after an error has occurred.

Self Check and Anti-seize Modes

After switching on the mains power or after a reset, the
boiler performs a selfcheck, i.e. the DHW valve is
energised and the CH pump is switched on for 10
seconds. This cycle repeats itself every 24hrs, as long as
no heat request is given in 24hrs.

Burner on/off switch

With the burner switch set to 'off' the boiler will not
respond to a CH demand. However, it will respond to a
DHW demand and the pump anti-seize and frost
protection modes are still operational any one of which
could cause the boiler to fire. Note. The burner switch is
NOT a mains isolation switch.

CH/DHW Systems

In standby mode pressing and holding the '+' button for 3
seconds turns the CH system on/off.
In standby mode pressing and holding the '-' button for 3
seconds turns the DHW system on/off.

E 3 6

Sequence

Boiler Status

DHW valve energised

Standby, no heat request

Pre-purge, post purge

Ignition

Burner on in CH mode

Burner on in DHW mode

Waiting for air pressure switch to open or close

Burner off because a set value has been

reached

Pump overrun in CH mode

Pump overrun in DHW mode

e.g.

A. Burner switch

B. Pressure gauge

C. Display

D. Reset button

E. Mode button

F. Step button

G. Store button

H. + button (to increase

values)

I. - button (to decrease

values)

xtra

MODE

STEP

STORE

RESET

im8219

MASTER MODULE

CONTROL PANEL

b 1 8

Both Master and Slave Modules employ a control panel.
Slave control panel can be fully accessed by first removing cover (see Frame 52).

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Press the 'step' button until the desired parameter is displayed.
The dot after the 1st digit is illuminated to indicate that the boiler is in 'PARA' mode.

N/A

Do not

adjust

Press

Display

Factory

Setting

Upper

Limit

Lower

Limit

Description

DHW System

00 = Off

01 = On
02 = Off + pump continuous
03 = On + pump continuous

1. 6 0

2. 0 1

CH System

00 = Off
01 = On

02 = Off + pump continuous
03 = On + pump continuous

3. 0 1

CH Flow Temperature (

C) (T1)

4. 8 2

Press the '+' or '-' buttons to change the values.
The parameter setting can be stored by pressing and releasing the 'store' button, the new setting flashes twice to show it
has been accepted. The new setting will become active when the parameter mode is left.

31 STANDARD CONTROLS ACCESS

Modes of Operation

The standby, parameter and information modes are accessible without the service code.

Standby Mode

P A R A

Press

Display

The standby mode will be shown after start up or reset of the Module control box. If no buttons are pressed for 20
minutes the display will automatically be set to standby mode. If new parameters have been stored they will then
become active.

Parameter Mode

S t b y

P A R A

In parameter mode it is possible to change the settings of the Module control box. The following settings can be changed.

NOTE. Changes to these parameters MUST be done in common to both Master and Slave Modules.

DHW Temperature (T3)

DHW System ON/OFF

CH System ON/OFF

Flow Temperature (T1)

Parameter settings and limits are listed below.
Parameter mode is entered from standby mode by pressing the 'mode' button once.

continued...........

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Service Mode

34 STANDARD CONTROLS ACCESS CONT'D

L 6 0

H 8 0

It is possible for servicing purposes to run the boiler on maximum or minimum loads.
This mode is entered from normal operating mode.

As found

Press

Display

Description

Standby display

X X X X

S t b y

0 2 8

Normal Display

several times

Press the 'mode' and '-' button simultaneously for 3 seconds.

L 6 0

Press

Display

Description

'Min. Load'. Run for 15 mins

Press the 'mode' and '+' button simultaneously for 3 seconds.

H 8 0

Press

Display

Description

'Max. Load'. Run for 15 mins

Last 3 digits are actual flow temperature

This mode will end automatically after 15 minutes. Alternatively to escape sooner press the '+' and '-' simultaneously.
In order to set the Module to a fixed fan speed proceed to CODE MODE (Page 32) and select 'PARA' mode 47 (Page 28).

Wait a few

seconds

Press

Display

Description

Info mode cont'd.........

Burner Run Hours, DHW
100 thousands/10 thousands

N. 0 0

Burner Run Hours, DHW
thousands/hundreds

Burner Run Hours, DHW
tens/units

I. 0 0

I . 0 0

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35 ADVANCED CONTROLS ACCESS

C O D E

Press

Display

C X X

Press

Display

C 5 4

Press

Display

C 5 4

Press

Display

FLASHING

There is little requirement for advanced controls access as factory preset values are satisfactory for most parameters. If
parameter changes are required with the optional kits then further instructions are provided with them.
This mode must only be entered by a competent engineer. This level of access MUST NOT be entered by the user.
Code Mode

By entering the service code the following additional features are accessible:
·

Parameters 5 to 53

Fan Speed Mode

Communication Mode

Error Mode

Code Mode is entered from 'standby' mode by pressing and holding the 'mode' and 'step' buttons. When the display
shows 'CODE' release the buttons.

Press the 'step' button once and the display will show 'C' as the first digit and a random number in the 3rd and 4th digits.

Use the '+' or '-' button to change the Code to 54.

Press and release the 'store' button, the display flashes to show the code has been accepted.

continued...........

Press the 'mode' button until the mode you want is displayed.

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36 ADVANCED CONTROLS ACCESS CONT'D

Press

Display

Factory

Setting

Upper

Limit

Lower

Limit

Description

N/A

Do not

adjust

P A R A

1. 6 0

2. 0 1

CH System

00 = Off

01 = On
02 = Off + pump continuous
03 = On + pump continuous

3. 0 1

DHW System

00 = Off

01 = On
02 = Off + pump continuous
03 = On + pump continuous

CH flow temperature (

C) T1 (max.)

CH flow temperature (min) (

Lowest set flow temperature on the warmest day (papa 12)

4. 8 2

. 2 0

P10 appears

for 1 second then

Minimum outside temperature (

-20

-05

Coldest outside temp. the system is designed to work against

P11

Maximum outside temperature (

Warmest outside temp. the system is designed to work against

P12

Outside temperature (

-30

-02

(at which frost protection starts)

P13

Steps 5 to 9 are not accessible.

Outside temperature correction (

-05

(for boiler reading of outside temperature)

P14

N/A

P15

N/A

P16

N/A

P17

Blocking CH flow temperature (

Boiler will not fire if the CH flow temperature set point is less than this

Do not

note 00 = Off

adjust

. 2 5

P18

continued...........

. - 0 5

. 2 0

. - 0 2

. 0 0

. 8 0

. 2 5

. 1 0

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INSTALLATION

Press

Display

Factory

Setting

Upper

Limit

Lower

Limit

Description

Booster time (minutes)

note 00 = Off

P19

CH flow parallel shift

For use with outside temperature sensor

P20

N/A

Do not

adjust

P21

Maximum fan speed CH (hundreds)

F320

F400

F480 Do not

Do not

F560 adjust

adjust

P22

37 ADVANCED CONTROLS ACCESS CONT'D

. 0 0

. 1 0

. 2 0

. 4 8

. 0 0

. 4 8

Ignition fan speed (hundreds)

F320

F400

F480 Do not

Do not

F560 adjust

adjust

. 3 5

P28

P23

Maximum fan speed CH (units)

F320

F400

F480 Do not

Do not

F560 adjust

adjust

P24

Maximum fan speed DHW (hundreds)

F320

F400

F480 Do not

Do not

F560 adjust

adjust

. 0 0

P25

Maximum fan speed DHW (units)

F320

F400

F480 Do not

Do not

F560 adjust

adjust

. 1 2

P26

Minimum fan speed (hundreds)

F320

F400

F480 Do not

Do not

F560 adjust

adjust

. 1 6

P27

Minimum fan speed (units)

F320

F400

F480 Do not

Do not

F560 adjust

adjust

continued...........

P29

Fan speed during forced low time (x100rpm)

F320

F400

F480 Do not

Do not

F560 adjust

adjust

. 1 6

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DHW priority time over CH (secs)

120

0 = DHW always has priority
1-120 mins
The DHW has priority over CH until priority is switched back to CH.

Press

Display

Factory

Setting

Upper

Limit

Lower

Limit

Description

Forced low time (x 9 seconds)

Do not

adjust

P30

Slow start

P31

CH post pump time (minutes)

Note 0 = 10 seconds
Do not set below 05

. 0 5

P32

DHW post pump time (x 10 seconds)

. 0 3

P33

CH modulation hysteresis on (

Do not

Do not 05

(Master)

adjust

adjust 02

(Slave)

. 0 5

P34

CH modulation hysteresis off (

Do not

Do not 05

(Master)

adjust

adjust 10

(Slave)

. 0 5

P35

DHW modulation hysteresis on (

Do not

Do not 03

(Master)

adjust

adjust 02

(Slave)

. 0 5

P36

DHW modulation hysteresis off (

Do not

Do not 03

(Master)

adjust

adjust 10

(Slave)

. 0 5

P37

. 0 3

. 0 0

Blocking time DHW to CH (seconds)

0=switch with burner on
(x10.2 seconds)

. 0 0

. 2 5

P38

N/A

Do not

adjust

N/A

Do not

adjust

Blocking time CH (seconds)

Minimum off period between CH demands to reduce cycling

Blocking time DHW (seconds)

Minimum off period between DHW demands to reduce cycling

P39

P40

P41

P42

P43

continued...........

38 ADVANCED CONTROLS ACCESS CONT'D

TIME - Temp. differential between flow temp &

set point at which slow start ends.

TIME - Modulation rate in slow start X 400rpm/min

. 0 0

RMCI address

Do not

Note -01=RMCI off

adjust

P44

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41 FAN MODE (with code)

Press

Display

Description

Fan speed

Actual fan speed e.g. 5500rpm

F A N

4 8 0 0

42 COMMUNICATION MODE (with code)

Press

Display

Description

C O N N

In this mode the communication between the boiler control module, optional control interface.

No communication

There is only communication between the boiler control module and controls interface kit.

There is communication between all devices.

FLASHING

43 ERROR MODE (with code)

Press

Display

Description

In error mode the last error is shown, and the boiler status and readings at that time are available
The 1st digit flashes and shows the current step.
The last two digits show the error code.

Error code
(see Table on pages 52 and 53 for full list)

E R RO

1 3 6

FLASHING

Boiler sequence at time of error (refer to Frame 30)

2 0 0

Flow temperature T1 at time of error

Return temperature T2 at time of error

3 0 0

4 0 0

DHW temperature T3 at time of error

5 - 3 6

Heat exchanger block temperature T4 at time of error

6 - 3 6

44 RETURN TO NORMAL OPERATING MODE

Press

Display

Description

Press the reset button, or press 'MODE' several times, to return to (Stby) normal operating
mode or
if no buttons are touched the boiler will automatically reset after 15 mins.

0 2 1

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INSTALLATION

46 INITIAL LIGHTING

NOTE.
MASTER MODULE LEADS THE SLAVE MODULE WITH
SYNCHRONISED FIRING
1. Check that the system has been filled and the boiler is not

air locked - air in the boiler could damage the heat
exchanger. For this reason if an automatic air vent has
been fitted it must never be off.

2. Check that all the drain cocks are closed and any valves in

the flow and return are open.

3. Check that the GAS SERVICE COCKS ARE OPEN.
4. Check the indication on the pressure gauge. If the

pressure is less than 0.8 bar the installation should be
filled up first (sealed system only).

5. Switch the electricity supply ON to both modules and check

that all the external controls are calling for heat. Check
burner switch is set to on (Master module only).

6. The Master module will commence the ignition sequence.

The circulation pump is energised, whilst operating a DHW
valve if required. The fan is run up to starting speed and
the air pressure switch activated. The fan then carries out a
pre-purge before moving to ignition speed. A spark is
started and the gas valve opens. Ignition must occur in 3
seconds and once detected the module starts operating.

7. The Slave module will now start to operate as described in

no. 6, follow the sequence to ignition and operation. After
the stabilisation period both modules modulate to achieve
the set flow temperature at a restricted ramp up rate. As
each module gets within 10

C of the set point it is free to

modulate at normal rate.
If after 5 attempts the module has failed to light then it will
lock out. Press the reset button to restart the ignition
sequence.

8. The gas valves are preset at the factory to nominal values.

Dependant on site installation conditions (e.g. flue length)
the module performance can vary slightly. To check the
performance, measure the CO

values at maximum and

minimum rates whilst adjusting the gas valves if necessary
(Refer to Frame 51).

9. Operate the boiler for 10 minutes and check the gas rate

(Table 1). You should obtain a value at least 90% of the
nominal.

10. Set all the Module parameters (Master and Slave) to

appropriate settings (refer to Frame 35).

11. Fit outer fascia panel to Slave Module and secure with 2 x

M5 screws.

12. Fit the front panel by engaging the bottom retaining lugs

and then pushing home.

Make the following checks for correct operation.
1. The correct operation of ANY secondary system controls

should be proved. Operate each control separately and
check that the main burner or circulating pump, as the case
may be, responds.

2. Water circulation system;

a. With the system HOT examine all water connections for

soundness.

b. With the system still HOT, turn off the gas, water and

electricity supplies to the boiler and drain down to
complete the flushing process.

c. Refill and vent the system, clear all air locks and again

check for water soundness.

d. Balance the system.

3. Check the condensate drain for leaks and check it is

discharging correctly.

4. Finally set the controls to the User's requirements.
Note. If optional kits are fitted then refer to the instructions
supplied with the kits.

47 GENERAL CHECKS

45 COMMISSIONING AND TESTING

A. ELECTRICAL INSTALLATION

1. Checks to ensure electrical safety should be carried out

by a competent person.

2. ALWAYS carry out the preliminary electrical system

checks, i.e. earth continuity, polarity, resistance to earth
and short circuit, using a suitable meter.

WARNING. Whilst effecting the required gas soundness test and purging air from the gas

installation, open all windows and doors, extinguish naked lights and DO NOT SMOKE.

B. GAS INSTALLATION

1. The whole of the gas installation, including the meter,

should be inspected and tested for soundness and
then purged in accordance with the recommendations
of the relevant standards listed on page 4.

In IE refer to I.S.820:2002.

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48 HANDING OVER

ROUTINE OPERATION
Full instructions covering routine lighting and operation of the
boiler are given on the Lighting and Operation Instruction
Label located behind the lower front door.
Draw the attention of the boiler owner or his representative to
the Lighting and Operating Instruction Label. Give a practical
demonstration of the lighting and shutting down of the boiler.
Describe the function of the boiler and system controls and
show how they are adjusted and used.
Hand these Installation and Servicing Instructions/User's
Instructions and Log book to the customer and request him to
keep them in a safe place for ready reference. For IE, it is
necessary to complete a "Declaration of Conformity" to
indicate compliance to the appropriate standard.

IMPORTANT.
Point out to the owner that the boiler must have regular
maintenance and cleaning, at least annually, in order to ensure
reliable and efficient operation. Regular attention will also
prolong the life of the boiler and should preferably be
performed at the end of the heating season.
After servicing, complete the service section of the log book and
return to the owner or their representative.
Recommend that a contract for this work should be made with
the regional gas authority or a CORGI registered heating
installer. In IE servicing work must be carried out by a
competent person.

49 SAFETY

It is the law that any service work must be carried out by a
registered CORGI installer. In IE service work must be carried
out by a competent person.
WARNING. Always turn off the gas supply at the gas service
cock, and switch off and disconnect the electricity supply to
the appliance and any external controls before servicing or
replacing components.
NOTE. When the burner switch is in the off position the boiler
control module remains live.
IMPORTANT. After completing the servicing or replacement of
components always:
·

Test for gas soundness.

Test the burner manifold flanges for soundness. This can be
done with leak detection spray whilst operating the boiler.
The gas valve and controls must be shielded from the spray.

Check the water system is correctly filled and free of air.
Air in the boiler could cause damage to the heat
exchanger. For this reason if an automatic air vent is fitted
it must never be shut off.

Check the inner front and outer jacket panels are correctly
fitted.

With the system hot examine all water connections for
soundness.

Check the gas rate and measure the combustion CO/CO

content. Refer to Frame 51 for reference on how to force
the burner to maximum and minimum gas rates. The
CO/CO

ratio of the flue gas on each module should not

be greater than 0.004 ratio. The CO

values should be

correct to the figures in Table 1 on Page 2.

Carry out functional checks as appropriate.

50 SERVICING SCHEDULE

To ensure the continued safe and efficient operation of the
appliance it is recommended that it is checked at regular
intervals and serviced as necessary. The frequency of
servicing will depend upon the installation condition and
usage but should be carried out at least annually.
Ideal Stelrad Group does not accept any liability resulting from
the use of unauthorised parts or the repair and servicing of
appliances not carried out in accordance with the Company's
recommendations and specifications.
Note.
Some aluminium oxide build-up within the heat exchanger
assembly is quite usual with this type of condensing boiler.
Though removal and cleaning is recommended annually, the
heat exchanger, sump and condensate trap must be inspected
and cleaned after a maximum of 2 years operation.
1. Light the boiler and carry out function checks, noting any

operational faults.

2. Run the boiler for 10 minutes and then check the gas

consumption rate. Refer to Frame 51 for reference on how
to force the burner to maximum and minimum rates.

3. For correct boiler operation the CO/CO

ratio of the flue gas

on each module should not be greater than 0.004 ratio and
the CO

values should be correct to the figures in Table at

front of book. If this is the case and the gas input is at least

90% of the nominal, once compliance with the note above is
ensured, then no further action need be taken. If not proceed
to 4. Refer to Frames 52 to 58 for guidance.

4. Refer to Frame 49.
5. Remove and inspect the fan/venturi assembly. Refer to

Frame 53.

6. Remove the burner manifold and inspect the electrodes and

sightglass. Refer to Frames 54 and 61.

7. Remove and clean the burner. Refer to Frame 55.
8. Inspect the heat exchanger through the burner opening.

Optionally remove the inspection covers on the left hand side
of the heat exchanger. If there are signs of aluminium oxide
build up, spray water down the flueways taking care not to
get water on the gas valve and controls. Refer to Frame 56.

9. Remove the sump cover and scrape out any deposits. Refer

to Frame 57.

10. Clean the condensate trap. Refer to Frame 58.
11. Check that the flue terminal and air inlet are unobstructed

and that the fluing and ducting are correctly sealed.

REPEAT PROCEDURE FOR BOTH SLAVE AND MASTER
MODULES.
12. After servicing refer to Frame 49 for final safety checks.

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51 GAS VALVE ADJUSTMENT

The boiler contains 2 Modules with individual gas valves. Both
must be adjusted.
Maximum rate adjustment
1. Switch the boiler on and operate for 10 minutes.
2. To ensure the boiler operates at maximum rate without

modulating set the fan speeds to maximum.

3. Remove the outer fascia panel on the Slave Module (see

Frame 52).

4. To set the fan speed to maximum. Press and hold in the

'mode' and '+' buttons simultaneously on the Master
Module. The display will show as the first digit
indicating the boiler is operating at maximum rate.
Repeat on the Slave Module.

5. Connect a suitable flue analyser to the flue sampling point

of the Master Module (see Frame 12).

6. Using the maximum rate adjustment screw, adjust the

master module gas valve until the CO

measures 9.7% ±

0.2 (nb. clockwise reduces CO

7. Connect a suitable flue analyser to the flue sampling point

of the Slave Module (see Frame 12).

8. Using the maximum rate adjustment screw, adjust the

Slave Module gas valve until the CO

measures 9.7% ± 0.2

(nb. clockwise reduces CO

Maximum Rate Adjustment Screw
(Firstly remove plastic cap for access)

Minimum rate adjustment
9. To ensure the boiler operates at minimum rate without

modulating, set the fan speeds to minimum.

10. To set the fan speed to minimum. Press and hold in the

'mode' and '-' buttons simultaneously on the Master
Module. The display will show as the first digit
indicating the boiler is operating at minimum rate.
Repeat on the Slave Module.

11. Connect a suitable flue analyser to the flue sampling point

of the Master Module - see Frame 12.

12. Remove the protective cap and then using the offset

adjustment screw, adjust the valve on the master module
until the CO

value measures 9.5% ± 0.2 (nb. anti-

clockwise reduces CO

level). The offset adjustment is a

lot more sensitive than the throttle adjustment.

13. Connect a suitable flue analyser to the flue sampling point

on the Slave Module (see Frame 12).

14. Remove the protective cap and then using the offset

adjustment screw, adjust the valve on the Slave Module
until the CO

value measures 9.5% ± 0.2 (nb. anti-

clockwise reduces CO

level).

15. Re-check the CO

level at maximum rate and repeat steps

3 to 15 if necessary.

16. Press the '+' and '-' buttons simultaneously to return to

normal operating mode.

17. Seal adjustment screw with tamper proof paint.

Note.
It is possible to switch off the CH/DHW systems if the mode and +/- buttons are not held simultaneously. Refer to Frame 30
under the heading CH/DHW Systems for guidance.

Offset Adjustment Screw
(Firstly remove plastic cap for access)

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53 REMOVAL OF FAN / VENTURI INSPECTION

54 REMOVAL OF BURNER MANIFOLD

1. Refer to Frame 49.

2. Refer to Frame 53 for removal of fan/venturi

assembly.

3. Disconnect the ignition and earth lead from the

electrodes.

4. Whilst providing temporary support for the burner

manifold remove the 4 retaining nuts.

5. Withdraw the burner manifold from the boiler taking

care not to damage the electrodes.

6. Re-assemble in reverse order, replacing any seals/

gaskets which show signs of wear. The nyloc nuts
should be renewed. Ensure the short earth lead is
secured under the top LH nut.

REPEAT PROCEDURE FOR SLAVE MODULE.

7. Refer to Frame 49 for final safety checks.

1. Refer to Frame 49.
2. Remove the jacket front, inner front, jacket right, jacket

top and controls fascia panels. (Refer to Frame 52).

3. Disconnect the electrical connections from the fan.

4. Remove 4 bolts securing inlet air pipe/silencer to the

venturi taking care to retain O ring seal.

5. Whilst providing temporary support for the gas valve

remove the 4 screws securing the gas valve to the
venturi

6. Remove sensing pipe from venturi.

7. Whilst providing temporary support for the fan/venturi

remove the 4 fasteners securing the fan outlet
connection. Lift the fan/venturi assembly clear of the
boiler taking care to retain the fan outlet gasket.

8. Remove the 4 screws securing the venturi to the fan

inlet, taking care to retain the O ring.

9. Re-assemble in reverse order replacing any seals/

gaskets which show signs of wear.

REPEAT PROCEDURE FOR SLAVE MODULE.

10. Refer to Frame 49 for final safety checks.

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55 REMOVAL / CLEANING OF BURNER

1. Refer to Frame 49.
2. Refer to Frame 54 for removal of burner

manifold.

3. Remove the gasket from the 4 studs.
4. Draw the burner out of the heat exchanger.
5. The burner can be cleaned on the inside

surface using a soft brush and/or vacuum.
The metal fibre outer surface must not be
brushed. If the burner is showing signs of
damage it must be replaced.

6. Re-assemble in reverse order replacing

any seals/gaskets which show signs of
wear. When re-fitting the burner there are 2
small lugs cast into the end of the
combustion chamber which support the
end of the burner.

REPEAT PROCEDURE FOR SLAVE MODULE.
7. Refer to Frame 49 for final safety checks.

56 REMOVAL OF HEAT EXCHANGER INSPECTION COVERS

1. Refer to Frame 49.
2. Remove the jacket front, inner front,

controls fascia, top and left side
panels. (Refer to Frame 52).

3. Remove the 6 securing nuts on each

inspection cover and withdraw, taking
care to retain the gasket.

4. Re-assemble in reverse order

replacing the gasket if it is showing
signs of wear.

5. Refer to Frame 49 for final safety

checks.

Inspection cover

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SERVICING

57 REMOVAL OF SUMP COVER

1. Refer to Frame 49.
2. Remove the jacket front and inner front

panels. (Refer to Frame 52).

3. Remove the 6 nuts and withdraw the sump

cover plate taking care to retain the gasket.

4. Scrape out any deposits within the sump.
5. Re-assemble in reverse order replacing the

sump cover plate gasket if it is showing
signs of wear.

REPEAT PROCEDURE FOR SLAVE MODULE.
6. Refer to Frame 49 for final safety checks.

58 CLEANING CONDENSATE TRAP

1. Refer to Frame 49.
2. Remove the jacket front, inner front, controls fascia, top

and side panels. (Refer to Frame 52).

3. Place a container beneath the condensate trap to

collect the condensate contained within.

4. Remove bottom nut/plug from the condensate trap

whilst collecting the condensate which will drain out.

5. Withdraw the cartridge and ball from within the

condensate trap. Thoroughly clean the cartridge and
ball by flushing with water.

6. If deposits are visible in the condensate trap body, it

can be removed by unscrewing the inlet and outlet
nuts. Thoroughly flush the body with water.

7. Re-assemble in reverse order, replacing the

condensate trap if there are signs of wear to any seals
or the ball.

REPEAT PROCEDURE FOR SLAVE MODULE.

8. Refer to Frame 49 for final safety checks.

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59 GAS VALVE REPLACEMENT

1. Refer to Frame 49.
2. Remove the jacket front, inner front and control

fascia panels. (Refer to Frame 52).

3. Remove the 4 screws securing the controls

fascia support bracket and withdraw.

4. Disconnect the electrical connections from the

gas valve.

5. Release the securing clip and disconnect the

pressure sensing tube from the gas valve.

6. Whilst providing temporary support for the inlet

gas pipe, remove the 4 screws securing the
inlet flange.

7. Whilst providing temporary support for the gas

valve, remove the 4 screws securing the gas
valve outlet.

8. Withdraw the gas valve taking care to retain the

inlet and outlet O rings.

9. Re-assemble in reverse order. Re-secure the

clip over the pressure sensing tube using
pliers to apply the grip. Replace gas valve inlet/
outlet O rings if showing signs of wear.

10. Refer to instruction sheet with spare gas valve

for correct setting procedure.

11. Refer to Frame 49 for final safety checks.

60 AIR PRESSURE SWITCH REPLACEMENT

1. Refer to Frame 49.
2. Remove the jacket front and inner front panels. (Refer

to Frame 52).

3. Remove the 2 electrical connections from the air

pressure switch (no polarity) which is located at the top
rear of the main control panel.

4. Release the securing clips and disconnect the

pressure sensing tubes.

5. The air pressure switch can now be unclipped from its

supporting cradle.

6. Re-assemble in reverse order. Connect the sensing

tube from the T-piece to P1 and the sensing tube from
the gas valve outlet elbow to P2.

7. Refer to Frame 49 for final safety checks.

Pressure
sensing
tubes

Left and right terminals
(no polarity)

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61 IGNITION/DETECTION ELECTRODE TESTING/REPLACEMENT

1. Refer to Frame 49.

2. Remove the jacket front and inner front panels. Refer to

Frame 52.

3. It is possible to measure the ionisation current with a

voltmeter set at 0-10VDC. (0-10VDC = 0-10 micro amps
ionisation current).

4. With the boiler running, connect a meter between the

terminal marked and earth.

5. A reading below 3V indicates a fault.

6. To replace the ignition/detection electrode remove the

controls fascia, pull off the HT and earth leads from the
spark/detection electrode.

7. Remove the 2 nuts and washers.

8. Check the electrode gap is 4.0mm.

9. Replace the electrode using the new gasket provided.

10. Re-assemble in reverse order.

11. Refer to Frame 49 for final safety checks.

62 PRESSURE GAUGE REPLACEMENT (MASTER BOILER ONLY)

1. Refer to Frame 49, then:
2. Remove the jacket front, control fascia,

top, and right side panels. (Refer to
Frame 52).

3. Unscrew the nut retaining the capillary

from the self sealing fitting. (Refer to
'A' in Frame 63).

4. Compress the retaining lugs and

push forwards to remove the gauge
from the bracket.

5. Replace the pressure gauge.
6. Reassemble in reverse order.
7. Refer to Frame 49 for final safety

checks.

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69 MOTORISED DAMPER MOTOR REPLACEMENT

70 AIR DAMPER REPLACEMENT

1. Refer to Frame 49.
2. Loosen 2 securing screws from motor

cover and remove cover.

3. Disconnect electrical connections.
4. Remove 2 x M5 nuts and washers

located behind mounting plate and
remove motor.

5. Replace with new motor.
6. Re-assemble and re-wire in reverse

order.

7. Refer to Frame 49 for final safety

checks.

1. Refer to Frame 49.
2. Remove front and inner front panels (Refer to

Frame 52).

3. If replacing Slave Module air damper first remove

boiler LHS panel (Refer to Frame 52).

4. Remove 4 x M6 nuts, bolts and washers locating

air duct flange to venturi assembly on the module
that the air damper is to be removed.

5. Remove 2 x M5 nuts retaining air duct lower

support bracket on module that the air damper is
to be removed. Remove bracket.

6. Pull air duct assembly forward and pull air duct

flanges out of automatic air duct inlet and outlet
connections.

Inspection and Replacement:
7. Check butterfly flaps within air damper move

freely without sticking. Remove any dust/debris
with a soft brush. Check integrity of O-ring seals
within flange connectors.

8. Re-fit damper ensuring it is orientated such that

the butterfly flaps open inwards towards the front
of the boiler module. Also ensure inspection
window faces uppermost.

9. Re-fit ductwork in reverse order to disassembly.

Check venturi flange O-ring seal is in good
condition and correctly located in its groove
during assembly.

10. Refer to Frame 49 for final safety checks.

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FAULT FINDING

FAUL

T FINDING FAUL

T FINDING

Before attempting any electrical fault finding ALWAYS carry out
the preliminary electrical system checks as detailed in the
Instructions for the British Gas Multimeter or other similar
commercially available meter.
The preliminary electrical system checks are the FIRST
electrical checks to be carried out during a fault finding
procedure.
On completion of any service/fault finding task which has
required the breaking and remaking of electrical connections
the following checks MUST be repeated:
a

Earth continuity

Polarity

Resistance to earth

Detailed instructions on the replacement of faulty components
are contained in the 'Servicing' section of these Installation &
Servicing Instructions.
Before carrying out Fault Finding ensure that all external controls
are calling for heat. There should be 230V ± 10% available at the
control box connection. ALSO CHECK BOTH OT CENTERS ARE
CORRECTLY CONFIGURED (SEE FRAME 22).
The boiler control module has replaceable fuses protecting the
230V and 24V circuits. A common reason for the 230V fuse to
blow would be if the pump connected to the boiler was drawing
more than 1 amp.
If the 230V fuse has blown, the display will be blank. Check for
short circuits and pump loads before replacing the fuse.

OT CENTER FAULT FINDING

1. Top LED (Red)

Regular flashing indicates correct communication with OT Center
and electrical control module located to the right of the OT Center.
If regular flashing is not evident check:
a. Integrity of wiring between OT Center and electrical control

module.

b. Correct communication with electrical control module. (Refer to

Frame 42).

c. Correct fitment of Opentherm clip-in device. (Refer to Frame 66).

2. Middle LED (Yellow)

This indicates failure of boiler. If yellow LED is showing check fault
finding codes.

3. Bottom LED (Green)

Regular flashing indicates correct Center communication with OT
Center and connecting OT Center on adjoining module. If regular
flashing is not evident check correct fitment of both OT Centers and
adjoining communications lead. (Refer to Frame 23).

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Installation & Servicing

FAULT FINDING

FAUL

T FINDING FAUL

T FINDING

Code

Description

Action

FUSE 24V circuit dead

Check Transformer & replace if necessary
Check 24V fuse on Control Board
If 24V fuse blown check for short circuits before replacing

Flame Error (signal present when there should not be)

Replace Control Module

No ignition after restart

Check inlet gas pressure
Check wiring to ignition/detection electrode
Check condition of ignition/detection electrode
If above OK replace control module

Internal Failure

Check gas valve wiring
Check gas valve solenoids not open circuit
Check general wiring harness and connections
If all OK. replace control module

Non-volatile lockout

Press reset

Internal failure

Check wiring harness & connections
If wiring OK replace control module

Internal failure

Check wiring harness & connections
If wiring OK replace control module

Internal failure

Check wiring harness & connections
If wiring OK replace control module

Air Pressure Switch did not close

Check motorised damper operating
Check air damper is opening
Check flue for blockage
Check/clean burner
Check Air Pressure Switch sensing pipes condition
Check fan speed
Check air Pressure Switch & replace if necessary

EPROM read/write error

Press reset. If fault keeps re-occuring Replace Control Module.

24V fuse blown

Check 24V fuse on Control Board
If 24V fuse blown check for short circuits before replacing
Check gas valve leads & solenoids for short circuit

Internal failure

Check wiring harness & connections
If wiring OK replace control module

Internal failure

Check wiring harness & connections
If wiring OK replace control module

Internal failure

Check wiring harness & connections
If wiring OK replace control module

Internal failure

Check wiring harness & connections
If wiring OK replace control module

Internal failure

Check wiring harness & connections
If wiring OK replace control module

Flow temperature too high

Check no air in system or boiler
Check adequate flow of water through boiler

Return temperature too high

Check no air in system or boiler
Check adequate flow of water through boiler

Flow temperature rise too fast

Check no air in system or boiler
Check adequate flow of water through boiler

No tacho signal from fan

Check wiring to fan
If wiring OK replace fan

MASTER AND SLAVE BOILER CONTROL MODULE ERROR CODES

xtra

Installation & Servicing

FAULT FINDING

FAUL

T FINDING FAUL

T FINDING

Code

Description

Action

Incorrect tacho signal from fan

Check wiring to fan. If wiring OK replace fan.

Flow/return temperature differential too high

Check no air in system or boiler
Check adequate flow of water through boiler

Flow thermistor short circuit

Check wiring

Disconnect terminals from thermistor & confirm short
circuit using meter
Replace thermistor

Return thermistor short circuit

Check wiring
Disconnect terminals from thermistor & confirm short
circuit using meter
Replace thermistor

Tank sensor short circuit

Not fitted check parameter 46 settings

Flue thermistor short circuit

Check wiring

Disconnect terminals from thermistor & confirm short
circuit using meter
Replace thermistor

Flow thermistor open circuit

Check wiring

Disconnect terminals from thermistor & confirm open
circuit using meter
Replace thermistor

Return thermistor open circuit

Check wiring
Disconnect terminals from thermistor & confirm open
circuit using meter
Replace thermistor

Tank sensor open circuit

Not fitted check parameter 46 settings

Flue thermistor open circuit

Check wiring

Disconnect terminals from thermistor & confirm open
circuit using meter
Replace thermistor

Internal Failure

Check wiring harness & connections
If wiring OK replace control module

Flue gas temperature too high

Check no air in system or boiler
Check adequate flow of water through boiler

Error reading parameters

Press reset. If fault keeps re-occuring replace control module.

Air pressure switch closed when it should be open

Check for blockages in air pressure switch sensing pipes
Check air pressure switch and replace if necessary

107

Heat exchanger thermistor short circuit

Check wiring
Disconnect terminals from thermistor & confirm short
circuit using meter

108

Heat exchanger thermistor open circuit

Check wiring
Disconnect terminals from thermistor & confirm open
circuit using meter
Replace thermistor

109

Heat exchanger temperature too high

Check no air in system or boiler
Check adequate flow of water through boiler

110

Heat exchanger temperature too low

Check no air in system or boiler
Check adequate flow of water through boiler

111

Heat exchanger to return temperature differential too high

Check no air in system or boiler
Check adequate flow of water through boiler

112

Heat exchanger temperature rise too fast

Check no air in system or boiler
Check adequate flow of water through boiler

113

No valid mains frequency detected

Check power supply to boiler

114

Invalid or conflicting cascade address

Press reset. If fault keeps re-occuring replace control module.

115

Internal error

Check wiring harness & connections
If wiring OK replace control module

MASTER AND SLAVE BOILER CONTROL MODULE ERROR CODES CONTINUED

xtra

Installation & Servicing

FAULT FINDING

FAUL

T FINDING FAUL

T FINDING

Code

Description

Action

Air Pressure Switch did not close

Check motorised damper operating
Check air damper is opening
Check flue for blockage
Check/clean burner
Check Air Pressure Switch sensing pipes
condition
Check fan speed
Check air Pressure Switch & replace if
necessary

Flow temperature too high

Check no air in system or boiler
Check adequate flow of water through boiler

Return temperature too high

Check no air in system or boiler
Check adequate flow of water through boiler

Return temperature > Flow temperature for excessive time

Check no air in system or boiler
Check adequate flow of water through boiler

Flow temperature rise too fast

Check no air in system or boiler
Check adequate flow of water through boiler

No tacho signal from fan

Check wiring to fan
If wiring OK replace fan

Incorrect tacho signal from fan

Check wiring to fan. If wiring OK replace fan.

Flow/return temperature differential too high

Check no air in system or boiler
Check adequate flow of water through boiler

Tank sensor short circuit

Not fitted check parameter 46 settings

Flue thermistor short circuit

Check wiring

Disconnect terminals from thermistor &
confirm short circuit using meter
Replace thermistor

Tank sensor open circuit

Not fitted check parameter 46 settings

Flue thermistor open circuit

Check wiring

Disconnect terminals from
thermistor & confirm open circuit using meter
Replace thermistor

Parameter values in EEPROM values out of range

Replace control module.

Flue gas temperature too high

Check no air in system or boiler
Check adequate flow of water through boiler

Fanspeed during start not within the dead band

Check wiring to fan. If wiring OK replace fan.

109

Heat exchanger temperature too high

Check no air in system or boiler
Check adequate flow of water through boiler

116

Mains frequency deviation > 1.5Hz or processor oscillator error

If mains supply frequency OK replace control module.

118

Flame current lost during burner on

Check wiring
Check condition of ignition/detection
electrode & replace if necessary

MASTER AND SLAVE BOILER CONTROL MODULE BLOCKING CODES

71 TECHNICAL CHARACTERISTICS - TEMPERATURE SENSORS

The table below gives the relationship between temperature and resistance for the following sensors; flow thermistor, return
thermistor, flue thermistor, heat exchanger thermistor, outside temperature sensor and DHW tank sensor.

Temperature in

Resistance in ohm

Temperature in

Resistance in ohm

22,800

32,250

14,700

2,340

9,800

1,710

6,650

1,260

4,610

100

950

xtra

Installation & Servicing

SHORT LIST OF PARTS

The following are parts commonly required as replacements,
due to damage or expendability.

A full list of spares is held by Ideal Stelrad Group distributors
and merchants.

Their failure or absence will affect the safety and/or
performance of this appliance.

When ordering spare parts please quote:
1. Boiler model
2. Boiler serial no. (refer to the data plate on boiler*)
3. Boiler P.I. No. (refer to the data plate on boiler*)
4. Description
5. Quantity
6. Part no.

* Note. Data plate, (refer to Frame 7), can be accessed by
removing front panel, (refer to Frame 52).

Key No.

Description

Qty.

Part No.

Per Module

Pressure Gauge

172 669

Fan

174 376

Gas Valve

F320

174 378

F400-F560

174 379

Control Module

F320 Master

174 667

F320 Slave

174 668

F400 Master

174 669

F400 Slave

174 670

F480 Master

174 671

F480 Slave

174 672

F560 Master

174 673

F560 Slave

174 674

Display Board

172 660

Alarm / Boiler Run Relays Board

174 391

Water Pressure Switch

172 667

Burner

F320

174 407

F400

174 408

F480

174 409

F560

174 410

Gasket - Burner Manifold

174 412

Gasket - Fan

174 413

Thermistor (temperature sensor)

174 415

Air Pressure Switch

174 418

Transformer

172 657

Relay

172 658

Ignition / Detection Electrode

174 432

Control Module Fuses

172 663

Mains Fuse

174 449

OT Center

174 679

Flue Damper Actuator

174 686

When replacing any part on this appliance use only spare parts that you can be assured conform to the safety and performance
specification that we require. Do not use reconditioned or copy parts that have not been clearly authorised by Ideal boilers.

Note. Each spares kit ordered contains only one replacement part.