Ferroli Xignal Operating instructions

Stockton Close, Minworth Industrial Park, Minworth, Sutton Coldfield, West Midlands B76 8DHStockton Close, Minworth Industrial Park, Minworth, Sutton Coldfield, West Midlands B76 8DHStockton Close, Minworth Industrial Park, Minworth, Sutton Coldfield, West Midlands B76 8DHStockton Close, Minworth Industrial Park, Minworth, Sutton Coldfield, West Midlands B76 8DHStockton Close, Minworth Industrial Park, Minworth, Sutton Coldfield, West Midlands B76 8DH
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using the applianceusing the applianceusing the applianceusing the applianceusing the appliance
FERROLI HELPLINEFERROLI HELPLINEFERROLI HELPLINEFERROLI HELPLINEFERROLI HELPLINE
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ALWAYS QUOTE YOUR SERIAL NUMBERALWAYS QUOTE YOUR SERIAL NUMBERALWAYS QUOTE YOUR SERIAL NUMBERALWAYS QUOTE YOUR SERIAL NUMBERALWAYS QUOTE YOUR SERIAL NUMBER
FORIMMEDIATEASSISTANCEFORIMMEDIATEASSISTANCEFORIMMEDIATEASSISTANCEFORIMMEDIATEASSISTANCEFORIMMEDIATEASSISTANCE
TECHNICALTECHNICALTECHNICALTECHNICALTECHNICAL
INFORMATIONINFORMATIONINFORMATIONINFORMATIONINFORMATION
INSTALLATIONINSTALLATIONINSTALLATIONINSTALLATIONINSTALLATION
andandandandand
SERVICESERVICESERVICESERVICESERVICE
INSTRUCTIONSINSTRUCTIONSINSTRUCTIONSINSTRUCTIONSINSTRUCTIONS
WALL MOUNTED, ROOM SEALED,WALL MOUNTED, ROOM SEALED,WALL MOUNTED, ROOM SEALED,WALL MOUNTED, ROOM SEALED,WALL MOUNTED, ROOM SEALED,
FAN ASSISTED, GAS COMBINATION BOILER,FAN ASSISTED, GAS COMBINATION BOILER,FAN ASSISTED, GAS COMBINATION BOILER,FAN ASSISTED, GAS COMBINATION BOILER,FAN ASSISTED, GAS COMBINATION BOILER,
COMPUTERISED AND SYNTHESIZED VOICECOMPUTERISED AND SYNTHESIZED VOICECOMPUTERISED AND SYNTHESIZED VOICECOMPUTERISED AND SYNTHESIZED VOICECOMPUTERISED AND SYNTHESIZED VOICE
01/9801/9801/9801/9801/98

2

3
INDEXINDEX
INDEXINDEX
INDEX
Page
4.4.
4.4.
4. Introduction
4.4.
4.4.
4. Related documents
5.5.
5.5.
5. General description
6.6.
6.6.
6. Technical data
7.7.
7.7.
7. Appliance dimensions
8.8.
8.8.
8. Boiler flow diagram
9.9.
9.9.
9. Boiler main parts
10.10.
10.10.
10. Installation details
10.10.
10.10.
10. Location of boiler
10.10.
10.10.
10. Terminal position
10.10.
10.10.
10. Air supply
11.11.
11.11.
11. Minimum clearance
12.12.
12.12.
12. Flue system
12.12.
12.12.
12. Gas supply
12.12.
12.12.
12. Water system
14.14.
14.14.
14. Control heating pump
14.14.
14.14.
14. Additional expansion vessel
15.15.
15.15.
15. Installation of boiler
17.17.
17.17.
17. Preparing flue assembly
18.18.
18.18.
18. Connecting the boiler
20.20.
20.20.
20. Fitting the flue assembly
20.20.
20.20.
20. Electrical installation
21.21.
21.21.
21. Wiring diagram
22.22.
22.22.
22. External sensor location
23.23.
23.23.
23. Gas conversion and adjustments
26.26.
26.26.
26. Control panel
28.28.
28.28.
28. Programming heating
29.29.
29.29.
29. Programming boiler parameters
32.32.
32.32.
32. Switching boiler on and off
33.33.
33.33.
33. Routine maintenance
34.34.
34.34.
34. Diagnosis and troubleshooting

4
IntroductionIntroduction
IntroductionIntroduction
Introduction
The XIGNAL CEXIGNAL CE
XIGNAL CEXIGNAL CE
XIGNAL CE boiler is a high efficiency heat generating appliance of a totally new design. It is
environment friendly, gas fired and prduces hot water for both the central heating system and domestic
hot water.
The new concept of XIGNAL CEXIGNAL CE
XIGNAL CEXIGNAL CE
XIGNAL CE is that it is fitted with a microcomputer to regulate the boiler performance
through technically sophisticated controls. This guarantees correct and optimum operation while being
extremely simple to use. The diagnostic information and the operative status of the boiler are constantly
visible on the display and can also be communicated by synthesized voice.
The boiler operation can be easily programmed be setting four daily heating levels. The fuel management
system incorporates an internal and external sensor accurately calculating the heat output required (the
temperature of the water in the radiators is regulated depending on the external temperature).
XIGNAL CEXIGNAL CE
XIGNAL CEXIGNAL CE
XIGNAL CE has a new generation gas burner ensuring perfect combustion with high flame efficiency and
low emissions of pulluting gases like NOx and CO2. The burner is ignited and monitored electronically
ensuring the burner performance functions completely automatic and safe. This system also isolates the
boiler from the domestic environment, ensuring total safety.
XIGNAL CEXIGNAL CE
XIGNAL CEXIGNAL CE
XIGNAL CE heat exchanger is made entirely of copper this ensures high efficiency even when the heating
is low, protection against rust and oxidation makes the heat exchanger both reliable and long lasting.
Related DocumentsRelated Documents
Related DocumentsRelated Documents
Related Documents
The appliance must be installed strictly in accordance with these instructions:
The Gas Safety Regulations (Installation & Use) 1984.
The Local Building Regulations.
The Building Regulations.
The Building Standards (Scotland - Consolidated) Regulations.
British Standards Codes of Practice:
B.S. 7593 - 1993 Treatment of water in domestic hot water central heating systems.
B.S. 5546 - 1990 Installation of hot water supplies for domestic purposes
B.S. 5440 - Part 1FLUES
B.S. 5440 - Part 2AIR SUPPLY
B.S. 5449 - 1990 FORCED CIRCULATION HOT WATER SYSTEMS
B.S. 6798 - 1987 INSTALLATION OF GAS FIRED HOT WATER BOILERS
B.S. 6891 - 1989 GAS INSTALLATIONS
B.S. 7671 - 1992 IEE WIRING REGULATIONS

5
GENERALDESCRIPTIONGENERALDESCRIPTION
GENERALDESCRIPTIONGENERALDESCRIPTION
GENERALDESCRIPTION
The boiler is able to operate with two types of fuel gas: natural or propane (L.P.G.). The type of gas should
be chosen when the boiler is ordered. Conversions can also be carried out during the installation phase
.Theboileriscontrolled by an internal microcomputer and allsettingsto the regulating systems are carried
out on the assembly line by use of software. This ensures that the set values always remain absolutely
accurate throughout plant use
The user may program and select the various options through the control panel. These functions include
summer/winter operation, choice of the sanitary water temperature and that of the plant delivery, daily
program setting and activation, boiler release.
The heating function is only activated when Winter operation is selected (key ). The microcomputer
handles the heating function either according to the set daily program or according to the temperature
set on the knob of the ambient unit. In both cases, the demand for heat will activate the circulation pump,
the fan and the electronic equipment to start the burner. The burner ignites at a power value that will have
been preset according to the fuelling gas. If the pressure in the heating system is less than 0.5 bar or more
than 2.5 bar, the microcomputer will prevent boiler operation for safety reasons.
During operation, the plant delivery temperature is regulated according to the external temperature
(detected by the relative probe). Temperature regulation will be proportional to the compensating curve
set on installation according to the structural characteristics of both the building and system.
When the temperature of the water in the boiler approaches the value established by the computer, the
valve will reduce the amount of gas (modulating) delivered to the main burner in order to keep the water
temperature near to the required value. If the water temperature reaches the preset value, the burner will
go out and will wait 2 minutes until igniting again. Having terminated the demand for heat, the burner
will stop while the circulator will continue to operate for six minutes so that the temperature is evenly
distributed throughout the system.
If hot water is used during the heating system, the microcomputer will detect this by means of the flowmeter
and will disactivate the heating function. This stops the circulator and activates hot water production. Hot
water is constantly maintained at the set value even during different water flow rates. This is due to a
correct establishment of the outlet flow of hot water and adequate modulation of the burner rating. Once
use of hot water ceases, the computer will wait for 2 minutes before re-activating the heating function.
Only hot water production is activated during "Summer" operation. However, the circulating pump of
the heating function will operate for 1 sec. at the end of each demand for water in order to prevent the
pump itself from sticking.
The microcomputer continuously checks that boiler operation is correct. In the event of faults, these are
immediately visualized (the display will flash) and notified by synthesized voice when the relative button
is depressed. Boiler operation will be inhibited until the fault is rectified or, in some cases, until the boiler
is manually reset.
All faults are memorized by the microcomputer together with the other operational parameters. This
enables the technical assistance service to proceed with a correct diagnosis.

6
Technical dataTechnical data
Technical dataTechnical data
Technical data NATURAL GAS (G20)NATURAL GAS (G20)
NATURAL GAS (G20)NATURAL GAS (G20)
NATURAL GAS (G20) PROPANE LPG (G31)PROPANE LPG (G31)
PROPANE LPG (G31)PROPANE LPG (G31)
PROPANE LPG (G31)
Nominal heat input (gross caloric value) 34.8 kW 34.0 kW
Minimum heat input (gross caloric value) 15.1 kW 14.8 kW
Nominal heat input (net caloric value) 31.3 kW 31.3 kW
Minimum heat input (net caloric value) 13.6 kW 13.6 kW
Nominal heat output 27.9 kW 27.9 kW
Minimum heat output 11.8 kW 11.8 kW
Gas rate 3.27 m3S/h 2.40 kg/h
Burner setting pressure 15,0 mbar (max.) 34,5 mbar (max.)
Minimum burner pressure 3,0 mbar (min.) 6,9 mbar (min.)
Injector manifold Ø 1.15 mm 0.72 mm
Dimensions (o/all)
Height 1020 mm
Width 480 mm
Depth 360 mm
Weight (net) 51 kg
Weight (gross) 53 kg
Electricity supply: 230V - 50 Hz
Fuse rating:
Mains 2 Amp. (main fuse)
on P.C.B. in boiler F2 Amp (Fast)
Electrical input 150 Watt
Domestic Hot Water flow:
(35°C rise) 11.4 l/min.
Minimum Domestic Hot Water Flow 2.5 l/min.
Maximum domestic cold water
Inlet pressure: 10,0 bar
C.H. Safety valve pressure setting 3 bar
C.H. Expansion vessel capacity 7 litre
Min. heating circuit pressure 0,8 bar
Max. heating circuit pressure 3.0 bar
Boiler water capacity:
Heating 1.5 litre
Domestic hot water 0.5 litre
Pipe connections:
Gas 22 mm
Domestic cold water inlet 15 mm
Domestic cold water outlet 15 mm
Central heating flow 22 mm
Central heating return 22 mm
Pressure relief valve drain 15 mm
Min. installation clearances. Sides:
Left hand 5* mm
Right hand 5* mm
Front 50** mm
(plus access for service)
Min. height from worktop to base 200 mm
* If using a side outlet flue then the minimum clearance on the flue outlet side of the appliance is increased to 75 mm (3 in.)
** Access to the front of the boiler must be available for maintenance (min. 600 mm)
The maximum working temperature of the central heating water is 85°C.
The maximum domestic hot water production temperature is 65°C, which can be regulated from 40 to 65°C.

7
KeyKey
KeyKey
Key
1.1.
1.1.
1. Electricity cable entry
2.2.
2.2.
2. Gas supply
3.3.
3.3.
3. Domestic Hot Water outlet
4.4.
4.4.
4. Domestic Cold Water inlet
5.5.
5.5.
5. Central Heating Pressure relief valve
6.6.
6.6.
6. Central Heating Flow outlet
7.7.
7.7.
7. Central Heating Return inlet
Appliance DimensionsAppliance Dimensions
Appliance DimensionsAppliance Dimensions
Appliance Dimensions
TOP VIEWTOP VIEW
TOP VIEWTOP VIEW
TOP VIEW
FRONTVIEWFRONTVIEW
FRONTVIEWFRONTVIEW
FRONTVIEW LEFT SIDE VIEWLEFT SIDE VIEW
LEFT SIDE VIEWLEFT SIDE VIEW
LEFT SIDE VIEW REAR VIEWREAR VIEW
REAR VIEWREAR VIEW
REAR VIEW
480
163
900
370
448
66
213
144
77.5507580505097.5
12 3 4 5 6 7
40
100
60

8
S.p.A.
124749
1...4
MAN
AUTO
Model Water Bye Laws.
Fig. 2
66
66
6
6868
6868
68
9898
9898
98
140140
140140
140 142142
142142
142 141141
141141
141

9
Boiler flow diagramBoiler flow diagram
Boiler flow diagramBoiler flow diagram
Boiler flow diagram
Main partsMain parts
Main partsMain parts
Main parts
11
11
1 Fixing point
55
55
5 Room sealed compartment
66
66
6 Instrument panel
77
77
7 Gas inlet
88
88
8 Domestic hot water outlet
99
99
9 Domestic hot water inlet
1010
1010
10 Central heating flow
1111
1111
11 Central heating return
1212
1212
12 D.H.W. drain point
1414
1414
14 Safety valve
1616
1616
16 Fan
1919
1919
19 Combustion chamber
2020
2020
20 Burner unit
2121
2121
21 Injector manifold
2222
2222
22 Burner
2626
2626
26 Combustion chamber insulation
2727
2727
27 Copper exchanger for C.H. or D.H.W.
2929
2929
29 Flue outlet manifold
3030
3030
30 Excess air chamber
3131
3131
31 Air pressure control damper
3232
3232
32 C.H. pump
3333
3333
33 Heating water circuit
3434
3434
34 Heating temp. sensor
3535
3535
35 Air separator
3636
3636
36 Automatic air vent
3737
3737
37 Cold water inlet filter
4141
4141
41 Domestic hot water circuit
4242
4242
42 D.H.W. temperature sensor
4343
4343
43 Air pressure switch
4444
4444
44 Gas valve
4747
4747
47 Gas valve modulator
4848
4848
48 Burner pressure test point
4949
4949
49 Overheat thermostat
5353
5353
53 Heat exchanger venting point
5454
5454
54 Temperature sensing phial
5656
5656
56 Expansion tank
5757
5757
57 Fan air inlet pressure test point
5858
5858
58 Fan air outlet pressure test point
5959
5959
59 Flue outlet pressure test point
6565
6565
65 230Vlineterminalstripandprobeconnections
6868
6868
68 Control box with P.C.B.
7171
7171
71 Balance tube
8181
8181
81 Ignition electrode
8282
8282
82 Flame sensing electrode
8383
8383
83 Automatic ignition control panel
8484
8484
84 1. gas valve operator 230V
8585
8585
85 2. gas valve operator 230V
8787
8787
87 Venturi test point
9696
9696
96 Control heating limit sensor
9898
9898
98 Main switch
101101
101101
101 P.C.B.
136136
136136
136 Flowmeter
137137
137137
137 Pressure sensor
140140
140140
140 Touch keyboard
141141
141141
141 Loudspeaker
142142
142142
142 Display P.C.B.
158158
158158
158 Gas inlet pressure test point

10
Installation DetailsInstallation Details
Installation DetailsInstallation Details
Installation Details
Gas Safety (Installation & Use) Regulations: 1984
In the interest of safety, it is the law that all gas appliances are installed by a competent person in accordance with
the above Regulations, Building Regulations/Building Standards Scotland, Codes of Practice, current I.E.E.
Regulations and the byelaws of the Local Water Undertaking. Failure to comply with the Regulations may lead
to prosecution; it is in your interest and that of safety to ensure that the law is complied with.
Important -Important -
Important -Important -
Important - If the boiler is to be fitted in a timber framed building it should be fitted in accordance with
the British Gas publication; Guide for Gas Installation in Timber Frame Housing: Reference DM2. If in doubt
advice must be sought from the Local Gas Region of British Gas Plc.
Location of Boiler
The installation of the XIGNAL CEXIGNAL CE
XIGNAL CEXIGNAL CE
XIGNAL CE must be on a suitable non-combustible load bearing wall which will provide
an adequate fixing for the boiler mounting bracket assembly. The location should be in an area where the water
pipes will not be subjected to frost conditions. In siting the combination boiler the following limitations mustmust
mustmust
must be
observed:
The combination boiler may be installed in any room or internal space, although particular attention is
drawn to the requirements of the current, i.e. wiring regulations and in Scotland the electrical provisions of the
building regulations applicable in Scotland, with respect to the installation of the combination boiler in a room or
internal space containing a bath or shower.
Where a room sealed appliance is installed in a room containing a bath or shower any electrical switch or
appliance control utilising mains electricity, should be so situated that it cannot be touched by a person using the
bath or shower.
Terminal Position
POS. MINIMUM SPACING (fig. 3) mm
AA
AA
A Directly below an openable window, air vent, or any other ventilation opening 300
BB
BB
B Below gutters, soil pipes or drainpipes 75
CC
CC
C Below Eaves 100
DD
DD
D Below a Balcony 100
EE
EE
E From vertical drainpipes or soilpipes 75
FF
FF
F From internal or external corners 100
GG
GG
G Above adjacent ground or balcony level 100
HH
HH
H From a surface facing the terminal 600
II
II
I Facing another terminal 1,200
JJ
JJ
J From opening (door/window) in carport into dwelling 1,200
KK
KK
K Vertically from a terminal on the same wall 300
LL
LL
L Horizontally from a terminal on the same wall 300
NN
NN
N Below carport 600
A Quinnel Barrat and Quinnel guard (part. No. C2) should be screwed to the wall centrally over the terminal, when
the distance is less than 2 m from the outside floor.
Air Supply
The room in which the boiler is installed does not require a purpose provided vent. If the boiler is installed in a
cupboard or compartment, permanent air vent are required in the cupboard or compartment, one at high level
one at low level, either direct to the outside air to a room. Both high and low level air vents must communicate with
the same space.
Minimum effective area requirements of compartment air vents (for cooling purposes only) (fig. 4).

11
NOTES
**
**
* If a side outlet flue is to be used, a clearance of 75 mm will be needed on the flue outlet side of the boiler.
** Access to the front of the boiler must be available for maintenance (min. 600 mm).
Fig. 5
Fig. 4
APPLIANCE
FLUE
SYSTEM
APPLIANCE
LOCATION
ROOM-SEALED AIR VENT AREAS
IN ROOM NIL
IN COMPARTMENT
OPEN TO ROOM
IN COMPARTMENT
OPEN TO OUTSIDE
HIGH LEVEL:
252 cm2(38 in.2)
LOW LEVEL:
252 cm2(38 in.2)
HIGH LEVEL:
126 cm2(19 in.2)
LOW LEVEL:
126 cm2(19 in.2)
AIR VENT
AIR VENT
Terminal PositionTerminal Position
Terminal PositionTerminal Position
Terminal Position Air supplyAir supply
Air supplyAir supply
Air supply
Minimum ClearanceMinimum Clearance
Minimum ClearanceMinimum Clearance
Minimum Clearance mm
Fig. 3

12
Flue systemFlue system
Flue systemFlue system
Flue system
The boiler allows the flue outlet to be taken from the rear of the boiler or from either side.
A standard flue length of 0.75 metres is provided. Alternative lengths of two or three metres can be supplied
(equivalent to wall thicknesses of up to 565, 1815 and 2815 mm for rear flues and deduct 91 mm plus distance
from side wall for side outlet flues).
It is absolutely essentialessential
essentialessential
essential, to ensure that products of combustion discharging from the terminal cannot re-enter
the building, or enter any adjacent building, through ventilators, windows, doors, natural air infiltration, or forced
ventilation/air conditioning.
Gas SupplyGas Supply
Gas SupplyGas Supply
Gas Supply
If necessary the local Gas Region 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 notnot
notnot
not be used without prior consultation with the Local Gas Region.
A gas meter can only be connected by the Local Gas Region, or by a Local Gas Region's Contractor.
Installation pipes should be fitted in accordance with BS6891-1988.
Appliance inlet working pressure must be 20 mbar MINIMUM.
Pipework from the meter to the combination boiler must be of an adequate size.
Do not use pipes of a smaller size than the combination boiler inlet gas connection.
The complete installation must be tested for gas soundness and purged as described in BS6981-1988. All pipework
must be adequately supported. An isolating gas valve is provided and should be fitted on the manifold assembly.
Water SystemWater System
Water SystemWater System
Water System
Central HeatingCentral Heating
Central HeatingCentral Heating
Central Heating
It must be a sealed system. Detailed recommendations are given in BS6798, BS5449, BS6700 and CP342 Part.
2. Pipework not forming part of the useful heating surface should be insulated to prevent any heat losses or
possible freezing (i.e. in roof spaces or ventilated underfloor spaces). Drain taps should be positioned at the
lowest point of the system in accessible locations to permit the whole system to be drained down. The drain
tapsshouldbe inaccordancewithBS2879. Copper tubingto BS2871, Part. 1 is recommended for water carrying
pipework. Pipework in horizontal runs should have a gradient where possible to facilitate the removal of air.
It should be ensured that the boiler heat exchanger is not a natural point for collecting air. A typical heating system
with domestic hot water circuit is illustrated in fig. 6.
Important -Important -
Important -Important -
Important - A bypass must be fitted to ensure a minimum flow rate through the boiler of 6 l/min. The bypass should
be fitted as far as possible from the boiler if thermostatic radiator valves are fitted throughout.
Make up WaterMake up Water
Make up WaterMake up Water
Make up Water
Provision must be made for replacing water lost from sealed system. Reference should be made to BS6798, for
methodsoffilling and making up sealed systems.Theremustbenodirectconnectionbetweentheboiler'scentralheating
systemandthe mains water supply. The use of mains water to chargeandpressurisethesystemdirectly,isconditional
uponthe Local WaterBye-law. Again anysuchconnection mustbedisconnected afteruse(fig. 7).
Domestic Hot WaterDomestic Hot Water
Domestic Hot WaterDomestic Hot Water
Domestic Hot Water
Always fit a water softener or descaler in «hard water areas». A 15 mm copper connection point on the boiler
jigbracketforattaching to the main supplyis provided.The maximumdomesticwaterpressurefor the inletsupply is
10bar(145P.S.I.).Ifthecold mains supplyexceeds5bar(72P.S.I.), awatergovernororpressurereducingvalvemust
befittedbythe installer into themains supplyin aninconspicuous butaccessible positionpreferable between 3and 5
metres(10-16 ft)before the appliance.Such avalve mustbe approved bythe WaterResearch Council.
Attention -Attention -
Attention -Attention -
Attention - Is drawn to the Model Water Bye-laws.
Fittings manufactured from duplex (alpha-beta) brass are not acceptable for underground use and certain water
undertakings will not accept their use above ground.

13
Fig. 7
NOTE:NOTE:
NOTE:NOTE:
NOTE: A bypass must be fitted as far as possible from the boiler if thermostatic radiator valves are fitted
throughout.
Fig. 6
Gas
Cold water
Additional expansion vessel C.H.
(if required)
Filling
point C.H.
Bypass
KeyKey
KeyKey
Key
1.1.
1.1.
1. Filling point C.H.
2.2.
2.2.
2. Temporary connection
3.3.
3.3.
3. Cold water supply

14
Built-in Central Heating Water Circulating PumpBuilt-in Central Heating Water Circulating Pump
Built-in Central Heating Water Circulating PumpBuilt-in Central Heating Water Circulating Pump
Built-in Central Heating Water Circulating Pump
The pump head available for circulating the water is given in fig. 8.
N.B. -N.B. -
N.B. -N.B. -
N.B. - The pump is factory set at position 3. The pump is a Grundfos type 15-50 UPS series.
Grundfos Pump performance graph
Note -Note -
Note -Note -
Note - Minimum flow through boiler heat exchanger at any time should not fall below 6 litres per minute.
If required an additional expansion vessel may be fitted to the central heating return inlet.
If the total volume of water in the system exceeds 40 litres an additional expansion vessel must
be fitted to the central heating return inlet.
Pump performance curve Grundfos UPS 15-50Pump performance curve Grundfos UPS 15-50
Pump performance curve Grundfos UPS 15-50Pump performance curve Grundfos UPS 15-50
Pump performance curve Grundfos UPS 15-50
SAFETY VALVESAFETY VALVE
SAFETY VALVESAFETY VALVE
SAFETY VALVE
SETTING (bar)SETTING (bar)
SETTING (bar)SETTING (bar)
SETTING (bar)
VESSELCHARGEVESSELCHARGE
VESSELCHARGEVESSELCHARGE
VESSELCHARGE
PRESSURE (bar)PRESSURE (bar)
PRESSURE (bar)PRESSURE (bar)
PRESSURE (bar)
INITIAL SYSTEMINITIAL SYSTEM
INITIAL SYSTEMINITIAL SYSTEM
INITIAL SYSTEM
PRESSURE (bar)PRESSURE (bar)
PRESSURE (bar)PRESSURE (bar)
PRESSURE (bar)
TOTALWATERTOTALWATER
TOTALWATERTOTALWATER
TOTALWATER
CONTENT of SYSTEMCONTENT of SYSTEM
CONTENT of SYSTEMCONTENT of SYSTEM
CONTENT of SYSTEM
3.0
0.5 1.0 1.5
1.0 1.5 2.0 1.5 2.0 2.0
EXPANSION VESSEL VOLUME (litres)EXPANSION VESSEL VOLUME (litres)
EXPANSION VESSEL VOLUME (litres)EXPANSION VESSEL VOLUME (litres)
EXPANSION VESSEL VOLUME (litres)
LITRES
25 3.5 6.5 13.7 4.7 10.3 8.3
50 7.0 12.9 27.5 9.5 20.6 16.5
75 10.5 19.4 41.3 14.2 30.9 24.8
100 14.0 25.9 55.1 19.0 41.2 33.1
125 17.5 32.4 68.9 23.7 51.5 41.3
150 21.0 38.8 82.6 28.5 61.8 49.6
175 24.5 45.3 96.4 33.2 72.1 57.9
200 28.0 51.8 110.2 38.0 82.4 66.2
0.140 0.259 0.551 0.190 0.412 0.33
For syst. volumes other thanFor syst. volumes other than
For syst. volumes other thanFor syst. volumes other than
For syst. volumes other than
those given above, mult. the syst.those given above, mult. the syst.
those given above, mult. the syst.those given above, mult. the syst.
those given above, mult. the syst.
volume by the factor acrossvolume by the factor across
volume by the factor acrossvolume by the factor across
volume by the factor across
1 2 3 Speed settings
A Boiler pressure drop
B Max. available pump head C.H.
Fig. 8
SIZING OF ADDITIONAL EXPANSION VESSELS:SIZING OF ADDITIONAL EXPANSION VESSELS:
SIZING OF ADDITIONAL EXPANSION VESSELS:SIZING OF ADDITIONAL EXPANSION VESSELS:
SIZING OF ADDITIONAL EXPANSION VESSELS:
Deduct from the value given in the table the 7 litre vessel
supplied.
NoteNote
NoteNote
Note
1.1.
1.1.
1. Fill C.H. installation to min. 1.5 bar.
2.2.
2.2.
2. Select by preference the expansion vessel for
increased system pressure of 2.0 bar
3.3.
3.3.
3. Expansion vessel must be fitted to Central Heating
Return Inlet
4.4.
4.4.
4. The standard 7 litres expansion vessel is charged
to 1 bar

15
InstallationInstallation
InstallationInstallation
Installation
Note -Note -
Note -Note -
Note - To mount the boiler on the wall, a two person lift will be needed.
1.01.0
1.01.0
1.0 UNPACKINGUNPACKING
UNPACKINGUNPACKING
UNPACKING
The appliance is delivered in 2 cartons.
1.1 The large carton contains the boiler, the Installation/Servicing and Users Instructions, external and
internal sensors.
1.2 The second carton contains the mounting jig assembly, complete with isolating valves, the assembly
fixing screws and wall plugs (x4), the boiler mounting nuts and washers (x2), drilling template, flue
assembly and turret.
When the cartons are unpacked examine for any signs of damage in transit. All protective plastic should
be left in place until installation is complete.
2.02.0
2.02.0
2.0 FIXING THE MOUNTING JIG ON THE WALL (Rear Wall Flue Applications)FIXING THE MOUNTING JIG ON THE WALL (Rear Wall Flue Applications)
FIXING THE MOUNTING JIG ON THE WALL (Rear Wall Flue Applications)FIXING THE MOUNTING JIG ON THE WALL (Rear Wall Flue Applications)
FIXING THE MOUNTING JIG ON THE WALL (Rear Wall Flue Applications)
2.1 Select the boiler location carefully ensure that all requirements given in previous text are satisfied.
Fig. 10 will also give guidance to fixing dimensions.
2.2 Locate template on wall, mark the positions of the four jig bracket fixing holes and the flue opening.
2.3 Carefully cut the circular hole (118 mm minimum diameter) for the flue assembly.
2.4 Using a 10 mm drill, drill 70 mm deep holes to accept the wall plugs, and insert wall plugs.
2.5 Fit the mounting jig assembly using the four fixing screws provided (Ensure that all the service
cocks are in the OFF position). Operate valves several times to ensure they are free.
2.6 With the exception of the connection to the pressure relief valve, make all the water and
gas connections to the jig bracket valves. Fully tighten (fig. 11). Water connections can be made
with compression or capillary fittings (before the gas inlet to the boiler there must be at least 100
mm of straight before any bends).
3.03.0
3.03.0
3.0 FIXING THE MOUNTING JIG ON THE WALL (Side Wall Flue Applications)FIXING THE MOUNTING JIG ON THE WALL (Side Wall Flue Applications)
FIXING THE MOUNTING JIG ON THE WALL (Side Wall Flue Applications)FIXING THE MOUNTING JIG ON THE WALL (Side Wall Flue Applications)
FIXING THE MOUNTING JIG ON THE WALL (Side Wall Flue Applications)
3.1 Select the boiler location carefully ensuring that all the requirements given in previous text are
satisfied.
Fig. 10 will aso give guidance.
3.2 Locate the template on wall and mark the position of the four jig bracket fixing holes.
3.3 Using a 10 mm drill, drill 70 mm deep holes to accept the wall plugs, and insert wall plugs.
3.4 Fit the mounting jig assembly using the four fixing screws provided.
3.5 Extend a horizontal line from the centre of the rear flue outlet to the side wall.
3.6 Mark the centre line (vertically) for the flue assembly hole, and mark the centre of the hole.
3.7 Carefully cut the circular hole (118 mm minimum diameter) for the flue assembly.

16
Fig. 10
11
11
1 = Electrical cable entry
22
22
2 = Gas supply
33
33
3 = Domestic Hot Water outlet
44
44
4 = Domestic Cold Water Inlet
55
55
5 = Outlet Central Heating safety valve
66
66
6 = Central Heating flow outlet
77
77
7 = Central Heating return inlet
22
22
2= 22 mm= 22 mm
= 22 mm= 22 mm
= 22 mm
3-4-53-4-5
3-4-53-4-5
3-4-5 = 15 mm= 15 mm
= 15 mm= 15 mm
= 15 mm
6-76-7
6-76-7
6-7 = 22 mm= 22 mm
= 22 mm= 22 mm
= 22 mm
3 Domestic Hot Water
outlet 15 mm
5 Outlet central heating
safety valve 15 mm
Important Note -Important Note -
Important Note -Important Note -
Important Note - Always use two spanners to prevent twisting of soft copper pipework.
Note -Note -
Note -Note -
Note - The central heating safety valve (5) should be piped 15 mm to discharge safely outside the property.
Fig. 11
2 Gas 22 mm
4 Domestic Cold Water inlet 15 mm
6 Central Heating flow outlet 22 mm
7 Central Heating return inlet 22 mm
Important Note -Important Note -
Important Note -Important Note -
Important Note - Always use two spanners to prevent twisting of soft copper pipework on the boiler.
Flush out the water system.
Note -Note -
Note -Note -
Note - The maximum inlet cold water pressure must not exceed 10 bar (145 P.S.I.) and a water governor or a pressure
reducing valve will be required if the pressure is in excess of 5 bar (72 P.S.I.).
Ensure all pipework is adequately supported.
Drilling templateDrilling template
Drilling templateDrilling template
Drilling template
Note -Note -
Note -Note -
Note - Min 91 for side flue outlet
Fixing stud
boiler
Upper bracket
Note -Note -
Note -Note -
Note - Min 75 for
side flue outlet
Rear flue outlet
Diam. min. 118 mm
Boiler = 480 mm
Lower bracket
Side flue outlet
Diam. min.
118 mm

17
Rear flue OutletRear flue Outlet
Rear flue OutletRear flue Outlet
Rear flue Outlet
Fig. 12
Aluminium flue pipe length = Plastic air inlet pipeAluminium flue pipe length = Plastic air inlet pipe
Aluminium flue pipe length = Plastic air inlet pipeAluminium flue pipe length = Plastic air inlet pipe
Aluminium flue pipe length = Plastic air inlet pipe
length plus 50 mm (2") longer.length plus 50 mm (2") longer.
length plus 50 mm (2") longer.length plus 50 mm (2") longer.
length plus 50 mm (2") longer.
4.2.1 Accurately measure the Wall thickness (P2).
4.2.2 Accurately measure the distance from the centre of the stud
fixing of the mounting jig assembly to the side wall (Q2).
4.2.3 From the end opposite to the terminal, cut the plastic air duct
(dimension A2) to length (P2 + Q2 + 125 mm).
Note -Note -
Note -Note -
Note - That the terminal is notnot
notnot
not included in length A2.
4.2.4 Cut the metal flue duct to length (P2 + Q2 + 175 mm)
(dimension F2).
Note -Note -
Note -Note -
Note - The metal flue pipe must be 50 mm (2 inches) longer
than the plastic air inlet pipe.
4.2.5 Drill a 3 mm hole 15 mm from the plain end of plastic air duct.
4.2.6 Place flue components to one side to be used later.
Side Flue OutletSide Flue Outlet
Side Flue OutletSide Flue Outlet
Side Flue Outlet
Fig. 13
4.1.1 Accurately measure the Wall thickness (P1)
4.1.2 From the end opposite to the terminal, cut the plastic
air duct (dimension A1) to length (P1 + 105 mm).
Note -Note -
Note -Note -
Note - That the terminal is notnot
notnot
not included in A1.
4.1.3 Cut the metal flue duct to length (P1 + 155 mm)
(dimensions F1).
Note -Note -
Note -Note -
Note - The metal flue pipe must be 50 mm (2 inches)
longer than the plastic air inlet pipe.
4.1.4 Drill a 3 mm hole 15 mm from the plain end of plastic
air duct.
4.1.5 Place flue components to one side to be used later.
4.2 Side Flue OutletSide Flue Outlet
Side Flue OutletSide Flue Outlet
Side Flue Outlet (fig. 13).
Important -Important -
Important -Important -
Important - The aluminium flue pipe must protrude
into the outside grill by 2 in (50 mm), never cut it to the
same length as the plastic air pipe.
4.04.0
4.04.0
4.0 PREPARING THE FLUE ASSEMBLYPREPARING THE FLUE ASSEMBLY
PREPARING THE FLUE ASSEMBLYPREPARING THE FLUE ASSEMBLY
PREPARING THE FLUE ASSEMBLY
4.1 Rear Flue OutletRear Flue Outlet
Rear Flue OutletRear Flue Outlet
Rear Flue Outlet (fig. 12)
Important -Important -
Important -Important -
Important - The aluminium flue pipe must protrude into the outside grill by 2 in (50 mm), never cut it to the same length
as the plastic air pipe (aluminium flue pipe = plastic air inlet pipe + 50 mm !).
Aluminium flue pipe length = Plastic air inlet pipe length plus 50 mm (2") longer.Aluminium flue pipe length = Plastic air inlet pipe length plus 50 mm (2") longer.
Aluminium flue pipe length = Plastic air inlet pipe length plus 50 mm (2") longer.Aluminium flue pipe length = Plastic air inlet pipe length plus 50 mm (2") longer.
Aluminium flue pipe length = Plastic air inlet pipe length plus 50 mm (2") longer.
F1 (Flue outlet)
Fixing
screw
Air sealing sleeve
Fixing screw
A1 (Air intake)

18
5.05.0
5.05.0
5.0 CONNECTINGTHEBOILERCONNECTINGTHEBOILER
CONNECTINGTHEBOILERCONNECTINGTHEBOILER
CONNECTINGTHEBOILER
5.1 Place the boiler on its back.
5.2 Remove the boiler base plate, four screws (fig. 16). Remove the plugs fitted to the boiler water
connections.
Remove the bag of sealing washers from the boiler pipework. Remove the front panel by sliding
up and pulling away from the main boiler.
5.3 Lift boiler as shown in fig. 15 onto the top studs and fit supplied nuts and washers hand tight.
5.4 Lift at bottom to engage the water and gas connections. Tighten central heating flow and return,
and the domestic hot water inlet and outlet, using appropriate sealing washers. Tighten the gas
union.
5.5 Screw the pressure relief valve adaptor provided, through the jig bracket into the valve, using
the remaining washer (fig. 17).
5.6 Connect the pressure relief valve discharge pipe (15 mm) to the outside of the building, where
possible over a drain. The discharge must be such that it will not be hazardous to occupants or
passers-by cause damage to external electric components or wiring. The pipe should be directed
towards the wall.
It must not discharge above an entrance or window, or any type of public access. The installer must
consider that the overflow could discharge boiling water.
Fig. 14
Fixing
screws
Flue sealing gasket
Air sealing gasket
TOP VIEW BOILER SIDE OUTLET

19
Fixing points
Lift here
Fig. 15
Fixing screws
Fig. 16 Fig. 17

20
6.06.0
6.06.0
6.0 FITTING THE FLUE ASSEMBLYFITTING THE FLUE ASSEMBLY
FITTING THE FLUE ASSEMBLYFITTING THE FLUE ASSEMBLY
FITTING THE FLUE ASSEMBLY
6.1 With Sufficient Clearance To Insert Assembly From InsideWith Sufficient Clearance To Insert Assembly From Inside
With Sufficient Clearance To Insert Assembly From InsideWith Sufficient Clearance To Insert Assembly From Inside
With Sufficient Clearance To Insert Assembly From Inside
6.1.1 Push the air duct seal onto the air duct at the cut end.
6.1.2 Insert the flue assembly into the wall.
6.1.3 Make good internal wall face.
6.1.4 Fully insert the flue assembly into the turret spigot. Insert the self tapping screw supplied. Fully tighten.
6.1.5 Secure the turret.
6.1.6 Slide the air duct seal over the joint.
6.1.7 Check the terminal relationship with the wall as shown in fig. 12.
6.1.8 Make good the outside wall face, re-weatherproof.
6.2 With insufficient Clearance To Insert Assembly From InsideWith insufficient Clearance To Insert Assembly From Inside
With insufficient Clearance To Insert Assembly From InsideWith insufficient Clearance To Insert Assembly From Inside
With insufficient Clearance To Insert Assembly From Inside
6.2.1 From outside, push flue duct, then the air duct through the wall.
6.2.2 Push the air duct seal over the air duct.
6.2.3 Fully insert the flue duct into the turret, then the air duct. Slide, back the seal and secure the air duct with the
self tapping screw provided.
6.2.4 Slide the seal over the joint and secure the turret.
6.2.5 Continue as detailed in 6.1.8 above.
7.07.0
7.07.0
7.0 ELECTRICALINSTALLATIONELECTRICALINSTALLATION
ELECTRICALINSTALLATIONELECTRICALINSTALLATION
ELECTRICALINSTALLATION
Electrical installation must be carried out by a competent electrician. The appliance is to be connected to a 230 V
~ 50 Hz supply (see fig. 18). The supply fuse rating is 3A. The terminals are accessible after removing the white base
plate (see fig. 18).
7.1 ProcedureProcedure
ProcedureProcedure
Procedure
7.1.1 The supply cable must be no less than 0.75 mm (24x0.2 mm) to BS6500 table 16.
7.1.2 The earth conductor must be cut longer than the live and neutral (fig. 19).
Connectthe Supply Cabletothe terminal blockmarked230 V ~50Hz, L, N,thesupply cable istobe connected asfollows:
i) Connect the brown wire to the L (live) terminal).
ii) The blue wire to the N (neutral) terminal.
iii) The green/yellow wire to the (earth) terminal.
7.1.3 Secure thecable with thecableclamp. The supply cable can beconnected to themainssupply by theuse of anunswitched
shuttered socket-outlet in conjunction with the 3A fused 3 pin plug both in accordance with BS 1363. This provides
complete isolation. Alternatively, a fused double pole switch having a contact separation of at least 3 mm, in all poles
and provided just for the boiler and its external controls can be used. A wiring diagram is provided on the appliance,
attached to the rear of the front panel. In addition, there is one in this manual (fig. 25). Attention is drawn to the
requirements of the current I.E.E. Regulation and in Scotland, the electrical provisions of the Building regulations.
Remote sensorsRemote sensors
Remote sensorsRemote sensors
Remote sensors
The XIGNAL CE is supplied with an internal and external sensor to ensure maximum fuel savings.
Room SensorRoom Sensor
Room SensorRoom Sensor
Room Sensor
To be in a position within the property normally used for a room thermostat.
Ensure connections complies with the polarity shown in Figure 18 wired to terminals No. 5 and No. 6.
External SensorExternal Sensor
External SensorExternal Sensor
External Sensor
To be wired to terminals No. 7 and No. 8.
Location of sensor see Figure 21 and 22.
L
N
EXTERNAL
SENSOR
ROOM
SENSOR
3015
20 25
S.p.A.
230 V ~
50Hz
1
2
1
2
3
4
5
6
7
8
9
10
Fig. 18 Fig. 19
Blue
Brown
Screw