202441-4.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

F80

F120

F160

F200

F240

F280

Boiler output

Max

77.9

116.9

155.8

195.4

234.5

273.6

(non-condensing)

Btu/h

265,800

398,900

531,600

666,700

800,100

933,500

Mean 70

Min

23.3

29.1

43.1

47.0

51.0

Btu/h

79,500

99,300

147,050

160,350

174,000

Boiler output

Max

82.2

123.4

164.5

207.8

249.4

290.9

(condensing)

Btu/h

280,450

421,050

561,250

709,000

850,950

992,550

Mean 40

Min

25.8

32.3

47.3

51.6

55.9

Btu/h

88,000

110,200

161,400

176,050

190,750

Boiler Input

Net

120

160

200

240

280

Max Rate

Btu/h

272,950

409,450

545,900

682,400

818,900

955,350

Gross

88.8

133.3

177.7

222.1

266.5

310.9

Btu/h

303,000

454,800

606,300

757,800

909,300

1,060,800

Boiler Input

Net

Min Rate

Btu/h

81,900

102,350

150,150

163,800

177,400

Gross

26.6

33.3

48.9

53.3

57.7

Btu/h

90,750

113,600

166,850

181,850

196,850

Maximum Gas Rate

8.1

12.1

16.1

20.1

24.2

28.2

286

427

569

710

855

996

Approx. flue gas

@ max. rate m

121

182

242

302

363

423

volume (@80

C) i.e. non-condensing ft

4,270

6,410

8,550

10,690

12,820

14,960

Max. Flue Resistance

100

150

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.

Table 2 General Data

Boiler

F80

F120

F160

F200

F240

F280

Gas supply

2H - G20 - 20mbar

Gas supply connection

R (in. BSP)

Flow connection

R (in. BSP)

Return connection

R (in. BSP)

Hydraulic Resistance @ 20

mbar

100

105

Max Press (sealed system)

bar (psi)

6 (87)

Maximum Static Head

m (ft)

61 (200)

Boiler Electricity Supply

230V - 50Hz

Boiler Fuse Rating

External: 3A* Internal: 2AT, 4AT

External: 5A* Internal: 2AT, 4AT

Power Consumption (boiler only)

250

400

Air Inlet

O/D

m m

110

Flue Size dia

m m

150

200

Condensate drain

m m

21.5

Boiler dry weight (unpacked)

kg (lb)

132 (291)

150 (331)

168 (370)

198 (437)

215 (474)

233 (514)

Water Content

l (gal)

11.0 (2.4)

14.3 (3.2)

17.5 (3.9)

18.4 (4.1)

24.0 (5.3)

27.2 (6.0)

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Installation & Servicing

GENERAL

xtra

CONTENTS

Boiler Assembly - exploded view. .................................. 10

Boiler Clearances. ............................................................ 8

Boiler Dimensions. ........................................................... 7

Commissioning and Testing. ......................................... 31

Electrical Connections. .................................................. 13

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

Fault Finding. ................................................................... 42

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

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

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

Hydraulic Resistance. ...................................................... 2

Initial Lighting. ................................................................. 31

Installation. ...................................................................... 10

Locating/Levelling the Boiler. ......................................... 11

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

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

Servicing. ........................................................................ 32

Short List of Parts. ......................................................... 45

Ventilation. ........................................................................ 8

Water Circulation. ............................................................ 5

Water Connections. ......................................................... 7

Water System Requirements. ......................................... 9

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

Wiring Diagrams. ............................................................ 16

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

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 comprehensive boiler controls built into the appliance
include:
-

Volt free 'alarm' contacts (lockout)

Volt free 'boiler run' contacts

Burner hours run meters

System temperatures

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
·

BMS (0-10V) Kit

Control Interface Kit

DHW Sensor Kit

Modulating Sequencer Kit

Outside Sensor Kit

Room Sensor Kit

Tank Sensor Kit

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 and certified by Gastec 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.

FLUE INSTALLATION

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.

Vertical termination is recommended and terminal positions

which could cause problems should be avoided. 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.

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Installation & Servicing

GENERAL

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 100Pa (0.4" w.g.) for F80 and F120, and 150Pa
(0.6" w.g.) for F160, F200, F240 and F280. 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 lengths.

Boiler

F80

F120

F160

F200

F240

F280

Flue Size (mm) Ø150

Ø150

Ø200

Approx. max.
Straight Flue

240

109

100

256

180

138

Length (m)

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

Boiler

F80

F120

F160

F200

F240

F280

Flue Size (mm) Ø150

Ø150

Ø200

Approx. max.
Straight Flue

235

105

136

Length (m)

Flue Pressure

(Pa)

The addition of elbows and their positions in the flue will have a
significant effect on the maximum flue length. 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 type of flue pipe used should be aluminium, 316 grade
Stainless Steel or be of equivalent corrosion resistance unless
the flue is manufactured from aluminium, the condensate
from the flue must be collected and drained before entering
the sump of the boiler. 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.

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

F80

1.78

6.41

0.98

3.53

F120

2.68

9.65

1.47

5.3

F160

3.57

12.85

1.96

7.06

F200

4.51

16.24

2.48

8.93

F240

5.42

19.51

2.98

10.73

F280

6.32

22.75

3.47

12.49

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Installation & Servicing

GENERAL

Note.
·

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

C. High 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

G E Betz Ltd., Sentinel Division, Foundry Lane, Widnes,
Cheshire, WA8 8UD
Tel: +44 (0) 151 424 5351

Notes.
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

A condensate drain is provided on the boiler. This drain 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

Pressure Drop (mbar) @ 11

280

105

347

240

100

330

200

314

160

297

120

281

264

HYDRAULIC RESISTANCE

xtra

Installation & Servicing

GENERAL

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.
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.

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.

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:
700mm 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.

Left Side:
450mm

Right Side:
150mm

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

61 to 150

151 to 300

'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.

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

60 to 150

151 to 300

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

Cold Feed Pipe Sizes

Note. Refer to Frame 22 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

im8280

Rear screw on
both sides to
be left in place

FLUE / AIR DUCT INSTALLATION

The boiler is delivered assembled and protected by a cardboard sleeve and
fittings and fixed on a wooden base. This allows the boiler to be handled by a
forklift.
The packaged boiler will pass through a 800mm wide opening and unpacked
boiler through a 700mm wide opening.
To unpack the boiler:
-

Carefully remove the straps, and lift off the cardboard sleeve.

Remove the protective cardboard fittings.

Safely dispose of all packing materials.

PACKAGING REMOVAL / REMOVAL FROM PALLET / LOCATING & LEVELLING

FLUE

A flue sampling point should be provided in the flue
system.
When fitting the flue to the flue socket take care not to
disturb the lip seal which must be present.
The flue should be supported in such a way as not to
place a load on the flue socket.

IMPORTANT NOTE.
Unless the flue is manufactured from aluminium the
condensate from the flue must be collected and drained
before entering the sump of the boiler. See page 5 for
details on flue system design.

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 (see ventilation page 8).
To draw air direct from outside use any proprietary 110mm
soil/drain pipe. The air duct should be terminated with a
suitable fixed grille to prevent entry of vermin. This
terminal should be positioned as such to avoid blockages
or entry of water.
Where ducting the air from outside is not practical it can
be drawn from the boiler room by assembling the air inlet
pipework as follows into the configuration,shown in fig. 1.
1.

Fit the 93º elbow into the boiler air inlet pipe.

Fit the 112.5º bend into the 93º elbow.

Fit the 110 dia. tube, 590mm long, into the 112.5º
bend.

To remove boiler from base:

1. Remove the 3 front screws on both sides

leaving the 2 rear screws in place.

2. Rotate bottom battens outwards allowing

the front of the base to rest on the floor.

3. Remove 4 screws and retaining brackets.

4. Slide the boiler off the base.

At final location, adjust height of feet as
necessary to level the boiler.

Fit the air inlet grille to 100 dia. tube and fix the 3 off self-
tapping screws provided.

Using the existing screws holding the upper back panel
to the boiler, fit the support bracket assembly and re-
tighten the screws.

With the air inlet pipe assembly in position, retain it with
the pipe clamp, fixed with 2 off M5 screws provided.

With this kit fitted the maximum straight flue length available and
maximum pressure available at the base of the flue to overcome
flue resistance will change, refer to the appropriate table on
page 5.

fig 1

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INSTALLATION

CONDENSATE DRAIN

The condensate drain must be connected to the
condensate bulk head connector on the back of
the boiler 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.
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.

10 BOILER WATER CONNECTIONS

The boiler flow and return pipes are terminated with 2" BSP
male taper threads at the rear of the appliance. Water
returning from the system should be connected to the lower
pipe, with the flow water connection coming from the top pipe.
Refer to Frame 1.
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.

11 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 3

C the boiler will fire at

minimum rate until the flow temperature exceeds 20

C and

the return temperature exceeds 5

C. The pump will stay

running for a further 15 minutes.

Central heating systems fitted wholly inside the building do
not normally require frost protections 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 a frost thermostat should be wired into the
system, see Frame 19.

Bulkhead Connector

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12 GAS CONNECTIONS

The boiler gas supply pipe is terminated in a 1" BSP male
taper connection on the left-hand side of the appliance.

13 ELECTRICAL CONNECTIONS

Warning. This appliance MUST be efficiently earthed.
A mains supply of 230V 50Hz is required. External controls
should NOT be wired in series with this mains input.
Controlling the mains input in this way will prevent the pump
over-run sequence and may cause damage to the boiler. 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 5A for F80-F120 and 7A for F160-F280.
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 boiler 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 15 for terminal strip connections.

14 INSTALLING THE MAINS AND CONTROL WIRING

1. Route the mains supply in at the rear, through

the right hand conduit.

2. Route any remote sensor cables similarly

through the left hand lower conduit.

3. Route mains outputs from optional modulating

sequencer through the left hand upper conduit.

4. Secure the cables with the cable clamps

provided in the controls box.

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 1"BSP to the boiler.

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INSTALLATION

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 2
methods shown below.
A demand for DHW has priority over CH for a period controlled
by parameter 43.
A call for DHW will cause the boiler to run and maintain a set
flow temperature controlled by parameters 1 and 21.
Input terminals are available for connecting a DHW heat
demand by:
1. ON/OFF using a 230V switched to live 'DHW call'

terminal (e.g. a cylinder thermostat and programmer).
A call for heat will cause the boiler to run and maintain a
set flow temperature controlled by parameter 1 +
parameter 21.

17 DHW CONTROLS CONNECTIONS

Input terminals are available for connecting a variety of system
controls for central heating demand.
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 or with the
addition of the Outside Sensor Kit fitted (automatically
detected) the boiler will run at a weather compensated flow
temperature (see instructions with kit for more details).

2. Outside Sensor Kit.

Like in option 1 above the Outside Sensor Kit can be fitted
to the boiler generating a weather compensated flow
temperature. Unlike option 1 this configuration reacts
differently to the application of a 230V switched live to 'CH
call' terminal. When no signal is applied to 'CH call' the
boiler is not switched off but simply reduces the flow
temperature by a fixed value (parameter 20) (see
instructions with kit for more details).

3. 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. Optimised starts are possible and the
addition of an Outside Sensor Kit will enable a weather
compensated flow temperature.

4. 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.)

5. 0-10V BMS Kit

Applying an analogue 0-10V supply to the boiler via this
optional kit can control either the set flow temperature
or the heating capacity. (See instructions with kit for
mode details).

Output terminals 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.

16 CH CONTROL CONNECTIONS

2. ON/OFF using a Tank Sensor Kit.

Connection of this sensor cannot be in conjunction with
a standard programmer. Installation of our
Programmable Room Thermostat Kit provides the facility
to shut off DHW supply during chosen night-time
periods. The Tank Sensor Kit provides actual DHW
temperatures to the boiler allowing closer load matching
when satisfying DHW demands. (See instructions with
kit for more details).

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. The type of pump or valve employed can be
controlled by parameter 46. A pump or valve requiring more
than 1 amp supply current must be connected via a relay.

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INSTALLATION

NTC1

NTC2

NTC5

NTC7

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

KEY

LEGEND

- blue

- black

- brown

- red

- pink

- yellow

y/g

- white

- yellow/green

- grey

- orange

- violet

BS*

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

PWM

TACH

DISPLA

AM3

BOILER ON

VOL

FREE CONT

ACTS

BOILER LOCKOUT

VOL

FREE CONT

ACTS

MCBA5407D

TRANSFORMER

TB1

TB2

X3/4

X10

CONTROLLER

MAINS IN

CH PUMP

DHW PUMP

VALV

SEQ.

SUPPLY

CALL

DHW

CALL

DHW

TEMP

OUTSIDE

TEMP

24V

SUPPRESSOR

y/g

RY1

APS

NTC5

NTC7

NTC1

NTC2

o
g

y/g

FUSE

im8255

18 PICTORIAL WIRING DIAGRAM

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19 INDEPENDENT SYSTEM CONTROLS

If the system controls are to be independent of the boiler, then the following method should be used for connecting the boiler.

No parameter modifications are required.

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

SEQUENCE SUPPLY

DHW PUMP OR VALVE

CH PUMP

MAINS IN

DHW

CALL

im8187

* 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.

20 MAINS VOLTAGE CH AND DHW CONTROLS WITH DHW PUMP OUTPUT

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

Pump

Non return

valve

Non return
valve

Cylinder
thermostat

Programmer

Room
stat

im8191

* 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

SEQUENCE SUPPLY

DHW PUMP OR VALVE

CH PUMP

MAINS IN

DHW

CALL

im8192

D H W

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.

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

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INSTALLATION

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

Parameter modifications see Frames 28 to 32.
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.

If all zones are fitted with individual zone valves a hydraulic
bypass will be required to allow pump overrun. See page 5
and 6 for details.

im8193

Motorised valve

Pump

Cylinder
thermostat

Programmer

Room
stat

* 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

SEQUENCE SUPPLY

DHW PUMP OR VALVE

M V

D H W

CH PUMP

MAINS IN

DHW

CALL

im8194

21 MAINS VOLTAGE CH AND DHW CONTROLS WITH DHW VALVE OUTPUT

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22 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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23 BASIC CONTROLS DISPLAY

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 boiler 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 44 for
Blocking Code references.

3. Error Mode

In error mode the display will show the error code.

Refer to page 42 for error codes.
The boiler 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 boiler
control module 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

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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.

DHW Temperature (

C) (T3)

Instant water heater

Storage Tank

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.

24 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 boiler control module. 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 boiler control module. The following settings can be changed.
1.

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

27 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 boiler to a fixed fan speed proceed to CODE MODE (Page 25) and select 'PARA' mode 47 (Page 26).

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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28 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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29 ADVANCED CONTROLS ACCESS CONT'D

Press

Display

Factory

Setting

Upper

Limit

Lower

Limit

Description

DHW Temperature (

C) T3

Instant water heater

Storage tank

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

note 00 = Off

. 2 5

P18

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

. - 0 5

. 2 0

. - 0 2

. 0 0

. 8 0

. 2 5

. 1 0

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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

Tplus (

Temperature added to DHW temperature set point (parameter 1)

when storage tank used.

P21

Maximum fan speed CH (hundreds)

F80

F120

F160 Do not

Do not

F200 adjust

adjust

F240

F280

P22

30 ADVANCED CONTROLS ACCESS CONT'D

. 0 0

. 1 0

. 2 0

. 4 8

. 0 0

. 4 8

Ignition fan speed (hundreds)

F80

F120

F160

Do not

F200

adjust

F240

F280

. 3 5

P28

P23

Maximum fan speed CH (units)

F80

F120

F160

Do not

F200

adjust

F240

F280

P24

Maximum fan speed DHW (hundreds)

F80

F120

F160

Do not

F200

adjust

F240

F280

. 0 0

P25

Maximum fan speed DHW (units)

F80

F120

F160

Do not

F200

adjust

F240

F280

. 1 2

P26

Minimum fan speed (hundreds)

F80

F120

F160

Do not

F200

adjust

F240

F280

. 1 6

P27

Minimum fan speed (units)

F80

F120

F160

Do not

F200

adjust

F240

F280

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

P29

Fan speed during forced low time (x100 rpm)

F80

F120

F160

Do not

F200

adjust

F240

F280

. 1 6

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INSTALLATION

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 (

. 0 5

P34

CH modulation hysteresis off (

. 0 5

P35

DHW modulation hysteresis on (

-03

. 0 5

P36

DHW modulation hysteresis off (

-03

. 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

DHW detection hysteresis on (

-05

DHW detection hysteresis off (

-20

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...........

31 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

Note -01=RMCI off

P44

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DHW type

x0=N/A

x1=N/A

x2=Storage tank with tank sensor kit

x3=Storage tank with DHW cylinder thermostat

x4=N/A

x5=N/A

x6=N/A

x7=N/A

x8=N/A

x9=External heat request (by control interface kit)

0x=3 way valve normally open

1x=hot water pump

2x=3way valve normally closed

Press

Display

Factory

Setting

Upper

Limit

Lower

Limit

Description

. 0 0

CH type

x0=Room thermostat

x1=Outside temperature

x2=N/A

x3=N/A

x4=0-10V: capacity (using BMS 0-10V kit)

x5=0-10V: temperature (using BMS 0-10V kit)

x6=+/- control

x7=NTC6 on AM4 + RT: capacity

x8=0-10V on AM4 + RT: temperature

0x=N/A - First digit factory set to '0'. Do not adjust

1x=N/A - First digit factory set to '0'. Do not adjust

2x=N/A - First digit factory set to '0'. Do not adjust

3x=N/A - First digit factory set to '0'. Do not adjust

4x=N/A - First digit factory set to '0'. Do not adjust

5x=N/A - First digit factory set to '0'. Do not adjust

6x=N/A - First digit factory set to '0'. Do not adjust

7x=N/A - First digit factory set to '0'. Do not adjust

8x=N/A - First digit factory set to '0'. Do not adjust

P45

. 1 3

P46

. - 0 1

P47

Manual fanspeed (for service use)

-01

100

-01

Note -1=off
00 = min fan speed
50 = mid rate
100 = max fan speed

48
49
50
51

N/A

Low/Off cycle

x0=off

x1=on

Special pump function CH/DHW

0x=CH normal pump function, DHW normal pump function

1x=CH pump off during heat request, DHW normal pump function

2x=CH pump normal function, DHW pump 5 sec on delay after

heat request

3x=CH pump off during heat request, DHW pump 5 sec on delay

after heat request

N/A

Do not

adjust

Slow start
0=CH only

1=CH & DHW

32 ADVANCED CONTROLS ACCESS CONT'D

33 INFORMATION MODE (with code)

See Frame 25.

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34 FAN MODE (with code)

Press

Display

Description

Fan speed

Actual fan speed e.g. 5500rpm

F A N

4 8 0 0

35 COMMUNICATION MODE (with code)

Press

Display

Description

C O N N

In this mode the communication between the boiler control module, optional control interface
kit, and optional programmable room thermostat or modulating sequencer is shown.

No communication

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

There is communication between all devices.

FLASHING

36 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 42 and 43 for full list)

E R RO

1 3 6

FLASHING

Boiler sequence at time of error (refer to Frame 23)

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

37 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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39 INITIAL LIGHTING

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 COCK IS ON.
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 and check that all the

external controls are calling for heat. Check burner switch
is set to on.

6. The boiler 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 actuated. 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 boiler starts operating.
The boiler is held at a low stabilisation rate for the first 50
seconds. After the stabilisation period the boiler modulates
to achieve the set flow temperature at a restricted ramp up
rate. As the boiler gets within 10

C of the set point it is free

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

Gas Rate
7. The gas valves are preset at the factory to nominal values.

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

values at maximum and minimum rates, whilst adjusting
the gas valve if necessary. (Refer to Frame 44).

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

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

9. Set all the boiler parameters (refer to Frame 29) to

appropriate settings.

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.

40 GENERAL CHECKS

38 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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41 HANDING OVER

ROUTINE OPERATION

Full instructions covering routine lighting and operation of the
boiler are given on the Lighting and Operation Instruction
Label located on the inside of 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.

42 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 44 for reference on how to force
the burner to maximum and minimum gas rates. The CO/
CO

ratio of the flue gas should not be greater than 0.004

ratio.

Carry out functional checks as appropriate.

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F80 & F120 models

44 GAS VALVE ADJUSTMENT

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 speed to maximum.

3. To set the fan speed to maximum. Press and hold in the 'mode'

and '+' buttons simultaneously. The display will show
as the first digit indicating the boiler is
operating at maximum rate.

4. Using the maximum rate adjustment screw, adjust the valve

until the CO

value measures 9.7% ± 0.2 (nb clockwise reduces

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

modulating, set the fan speed to minimum

6. To set the fan speed to minimum. Press and hold in the 'mode'

and '-' buttons simultaneously. The display will show
as the first digit indicating the boiler is
operating at minimum rate.

7. Remove the protective cap and then using the offset adjustment

screw, adjust the valve until the CO

value measures 9.5% ± 0.2

(nb anticlockwise reduces the CO

level). The offset adjustment

is a lot more sensitive than the throttle adjustment

8. Re-check the CO

level at maximum rate and repeat steps 3 to 7

if necessary.

9. Press the '+' and '-' buttons simultaneously to return to normal

operating mode.

10. 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 23 under the
heading CH/DHW Systems for guidance.

43 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 44 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

should not be greater than 0.004 ratio. 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
45 to 51 for guidance.

4. Refer to Frame 42.
5. Remove and inspect the fan/venturi assembly. Refer to

Frame 46.

6. Remove the burner manifold and inspect the electrodes and

sightglass. Refer to Frames 47 and 54.

7. Remove and clean the burner. Refer to Frame 48.
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 49.

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

to Frame 50.

10. Clean the condensate trap. Refer to Frame 51.
11. Check that the flue terminal and air inlet are unobstructed

and that the fluing and ducting are correctly sealed.

12. After servicing refer to Frame 42 for final safety checks.

F160 to F280 models

Remove plastic
cap for access

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46 REMOVAL OF FAN / VENTURI INSPECTION

47 REMOVAL OF BURNER MANIFOLD

1. Refer to Frame 42.

2. Refer to Frame 46 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.

7. Refer to Frame 42 for final safety checks.

1. Refer to Frame 42.
2. Remove the jacket front, inner front, jacket right, jacket

top and controls fascia panels. (Refer to Frame 45).

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 (F160-F280
only, F80-F120 employ push fit).

5. Whilst providing temporary support for the gas valve

remove the 4 screws securing the gas valve (F160-
F280) or gas valve outlet elbow (F80-F120) to the
venturi.

6. Remove sensing pipe from venturi (F160-F280 only).

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.

10. Refer to Frame 42 for final safety checks.

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48 REMOVAL / CLEANING OF BURNER

1. Refer to Frame 42.
2. Refer to Frame 47 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.

7. Refer to Frame 42 for final safety checks.

49 REMOVAL OF HEAT EXCHANGER INSPECTION COVERS

1. Refer to Frame 42.
2. Remove the jacket front, inner front,

controls fascia, top and left side
panels. (Refer to Frame 45).

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 42 for final safety

checks.

Inspection cover

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50 REMOVAL OF SUMP COVER

1. Refer to Frame 42.
2. Remove the jacket front and inner

front panels. (Refer to Frame 45).

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.

6. Refer to Frame 42 for final safety

checks.

51 CLEANING CONDENSATE TRAP

1. Refer to frame 42.
2. Remove the jacket front, inner front, controls fascia, top

and left side panels. (Refer to Frame 45).

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.

8. Refer to Frame 42 for final safety checks.

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52 GAS VALVE REPLACEMENT

1. Refer to Frame 42.
2. Remove the jacket front, inner front and

control fascia panels. (Refer to Frame 45).

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 instruciton sheet with spare gas

valve for correct setting procedure.

11. Refer to Frame 42 for final safety checks.

53 AIR PRESSURE SWITCH REPLACEMENT

1. Refer to Frame 42.
2. Remove the jacket front and inner front panels. (Refer to Frame

45).

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
(F80-F120) or venturi gas valve connections (F160-F280) to P2.

7. Refer to Frame 42 for final safety checks.

Pressure
sensing
tubes

F160-F280

F80-F120

Left and right terminals
(no polarity)

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54 IGNITION/DETECTION ELECTRODE TESTING/REPLACEMENT

1. Refer to Frame 42.

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

Frame 45.

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 42 for final safety checks.

55 PRESSURE GAUGE REPLACEMENT

1. Refer to Frame 42, then:
2. Remove the jacket front, control fascia,

top, and right side panels. (Refer to
Frame 45).

3. Unscrew the nut retaining the capillary

from the self sealing fitting. Refer to 'A'
in Frame 56.

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 42 for final safety

checks.

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56 WATER PRESSURE SWITCH REPLACEMENT

1. Refer to Frame 42.
2. Remove the jacket front, control fascia, top

and right side panels. (Refer to Frame 45).

3. Isolate water circuit and drain boiler.
4. Pull off the electrical connections (no

polarity) from the pressure switch.

5. Unscrew the water pressure switch
6. Fit the new water pressure switch.
7. Re-assemble in reverse order.
8. Re-fill the system ensuring all the air in the

heat exchanger is vented.

9. Refer to frame 42 for final safety checks.

57 FLOW / RETURN / HE BLOCK / FLUE THERMISTOR REPLACEMENT

1. Refer to Frame 42
2. Remove the jacket panels as appropriate.

(Refer to Frame 45).

3. Isolate water circuit and drain boiler.
4. Pull off the electrical connections from the

thermistor.

5. Unscrew the thermistor.
6. Fit the new thermistor with built in `O` ring

seal. Do not overtighten.

7. Re-assemble in reverse order.
8. Refill the system ensuring all the air in the

heat exchanger is vented.

9. Refer to Frame 42 for final safety checks.

1. Refer to Frame 42.
2. Remove the jacket front, inner front,

controls fascia and top panels. Refer
to Frame 45.

3. Disconnect the transformer

connection from the boiler control
module. (Refer to 'A' in Frame 59).

4. Remove the 2 screws on the left side

of the transformer whilst supporting
its weight.

5. Disengage the transformer from the 2

retaining lugs by moving it to the left.
Remove from boiler.

6. Re-assemble in reverse order.
7. Refer to Frame 42 for final safety

checks.

58 TRANSFORMER REPLACEMENT

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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 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

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.
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.

Boiler Control Module Error Codes

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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

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

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

If not fitted check parameter 46 settings
Check wiring
Disconnect terminals from tank sensor & confirm open
circuit using meter
Replace tank sensor

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

Boiler Control Module Error Codes Continued

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FAULT FINDING

FAUL

T FINDING FAUL

T FINDING

Code

Description

Action

Air Pressure Switch did not close

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

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

Flue thermistor short circuit

Check wiring

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

Tank sensor open circuit

If not fitted check parameter 46 settings
Check wiring
Disconnect terminals from tank sensor &
confirm open circuit using meter
Replace tank sensor

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

Boiler Control Module Blocking Codes

61 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 6), can be accessed by
removing front panel, (refer to Frame 45).

Key No.

Description

Qty.

Part No.

Per boiler

Pressure Gauge

172 669

Fan

F80-F120

174 375

F160-F280

174 376

Gas Valve

F80-F120

174 377

F160

174 378

F200-F280

174 379

Control Module

F80

174 385

F120

174 386

F160

174 387

F200

174 388

F240

174 389

F280

174 390

Display Board

172 660

Alarm / Boiler Run Relays Board

174 391

Water Pressure Switch

172 667

Burner

F80

174 405

F120

174 406

F160

174 407

F200

174 408

F240

174 409

F280

174 410

Gasket - Burner Manifold

174 412

Gasket - Fan

F80-F280

174 413

Gasket - Fan

F80-F120

174 414

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

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.