IDEAL F400 User manual

installation and
servicing
Your Ideal installation and servicing guide
See reverse for users guide
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.
xtra
Models F320, F400, F480, F560
xtra
February 2010 UIN 202863 A06

2
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- Installation & Servicing
GENERAL
CAUTION. To avoid the possibility of injury during the installation, servicing or cleaning
of this appliance, care should be taken when handling edges of sheet steel components.
Table 1 Performance Data
Boiler F320 F400 F480 F560
Boiler output Max kW 311.6 390.8 469.0 547.2
(non-condensing) Btu/h 1,063,200 1,333,400 1,600,200 1,867,000
Mean 70oC Min kW 67.8 97.7 105.5 107.7
Btu/h 231,300 333,400 360,000 367,500
Boiler output Max kW 329.0 415.6 498.8 581.8
(condensing) Btu/h 1,122,500 1,418,000 1,701,900 1,985,100
Mean 40oC Min kW 75.3 107.5 116.1 118.3
Btu/h 256,900 366,800 396,100 403,600
Boiler Input Net kW 320 400 480 560
Max Rate Btu/h 1,091,800 1,364,800 1,637,800 1,910,700
Gross kW 355.4 444.2 533.0 621.8
Btu/h 1,212,600 1,515,600 1,818,600 2,121,600
Boiler Input Net kW 70 100 108 110
Min Rate Btu/h 238,800 341,200 368,500 375,300
Gross kW 77.6 110.9 119.8 122.0
Btu/h 264,800 378,400 408,800 416,300
Maximum Gas Rate m3/h 32.2 40.2 48.4 56.4
ft3/h 1138 1420 1710 1992
Approx. flue gas @ max. rate m3/h 484 604 726 846
volume (@80oC) i.e. non-condensing ft3/h 17,100 21,380 25,640 29,920
Max. Flue Resistance Pa 145 145 145 145
Flue Gas CO2@ Max Rate % 9.3/9.8 9.3/9.8 9.3/9.8 9.3/9.8
G20/LNG @ Min. Rate % 9.1/9.6 9.1/9.6 9.1/9.6 9.1/9.6
NOx with O2= 0% mg/kWh 35 26 26 26
ppm 20 15 15 15
Seasonal Boiler Efficiency (Building Regs L2) 95.1 95.2 95.2 95.2
Note.
Natural gas consumption is calculated using a calorific value of
37.8MJ/m3(1038Btu/ft3) gross or 34 MJ/m3(910 Btu/ft3) nett at
15oC and 1013.25 mbar.
a. For l/s divide the gross heat input (kW) by the gross C.V. of
the gas (MJ/m3)
b. For ft/h3divide the gross heat input (Btu/h) by the gross C.V.
of the gas (Btu/ft3).
HEALTH & SAFETY DOCUMENT NO. 635
The electricity at work regulations, 1989. The manufacturer's
notes must NOT be taken, in any way, as overriding statutory
obligations.
IMPORTANT. These appliances are CE certified for safety and
performance. It is, therefore, important that no external control
devices, e.g. flue dampers, economisers etc., are directly
connected to these appliances unless covered by these
Installation and Servicing Instructions or as otherwise
recommended by Ideal Stelrad Group in writing. If in doubt
please enquire.
Any direct connection of a control device not approved by Ideal
Stelrad Group could invalidate the certification and the normal
appliance warranty. It could also infringe the Gas Safety
Regulations and the above regulations.
Electricity supply and Fuse rating for pumps etc. refer to manufacturer's instructions.
* OPTIONAL HEADER PACK HAS DN80 CONNECTIONS FOR FLOW AND RETURN AND 2" BSP GAS CONNECTION
Table 2 General Data
Boiler F320 F400 F480 F560
Gas supply 2H - G20 - 20mbar
Gas supply connection (in. BSP) 2 x R1 2 x R1 2 x R1 2 x R1
Flow connection (in. BSP) 2 x R2 2 x R2 2 x R2 2 x R2
Return connection (in. BSP) 2 x R2 2 x R2 2 x R2 2 x R2
Hydraulic Resistance @ 20oC mbar 100 105 110 120
Max Press (sealed system) bar (psi) 6 (87) 6 (87) 6 (87) 6 (87)
Maximum Static Head m (ft) 61 (200) 61 (200) 61 (200) 61 (200)
Boiler Electricity Supply 230V - 50Hz
Boiler Fuse Rating 2 x External 5A supplies Internal 2AT.4AT (x2)
Power Consumption (boiler only) W 800 800 800 800
Air Inlet O/D m m 110x2 110x2 110x2 110x2
Flue Size dia m m 200 250 250 250
Condensate drain m m 2x21.5 2x21.5 2x21.5 2x21.5
Boiler dry weight (unpacked exc. headers) kg (lb) 336 (740) 396 (874) 430 (948) 466 (1028)
Water Content l (gal) 35 (7.8) 36.8 (8.2) 48.0 (10.6) 54.4 (12.0)
*
*

3
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- Installation & Servicing
GENERAL
xtra
CONTENTS
Boiler Assembly - exploded view. .................................. 11
Boiler Clearances. ............................................................ 9
Boiler Dimensions. ..................................................... 7,8,9
Commissioning and Testing. ......................................... 37
Electrical Connections. .................................................. 18
Electrical Supply. .............................................................. 6
Fault Finding. ................................................................... 50
Flue Installation. ................................................................ 5
Gas Safety Regulations .................................................... 4
Gas Supply. ........................................................................ 4
Hydraulic Resistance. ...................................................... 5
Initial Lighting. ................................................................. 37
Installation. ...................................................................... 11
Option Kits. ........................................................................ 4
Performance Data. ........................................................... 2
Servicing. ........................................................................ 38
Short List of Parts. ......................................................... 54
Ventilation. ........................................................................ 9
Water Circulation. ............................................................ 6
Water Connections. ....................................................... 17
Water System Requirements. ....................................... 10
Water Treatment. ............................................................. 6
Wiring Diagrams. ....................................................... 21,22
Natural Gas only
PI No. 0063 BR 3123
Destination Countries: GB, IE
Key to symbols
IE = Ireland, GB = United Kingdom (Countries of destination)
PMS = Maximum operating pressure of water
C53 = A room sealed appliance which is connected
via its separate ducts to two terminals that
may terminate in zones of different pressure.
C63 = A room sealed appliance intended to be
connected to a separately approved and
marketed system for the supply of
combustion air and discharge of combustion
products. The fan is up stream of the
combustion chamber.
B23 = An appliance intended to be connected to a
flue which evacuates the products of
combustion to the outside of the room
containing the boiler. The combustion air is
drawn directly from the room. The fan is up
stream of the combustion chamber.
NOTE TO THE INSTALLER: LEAVE THESE INSTRUCTIONS ADJACENT TO THE GAS METER.

4
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- Installation & Servicing
GENERAL
INTRODUCTION
The
xtra
boilers are fully automatically controlled, floor
standing, fanned, super efficient condensing appliances.
The imax xtra comprises of 2 modules, Master and Slave.
The comprehensive boiler controls built into the appliance
include:
- 0-10V Boiler control input
- Volt free 'alarm' contacts (lockout)
- Volt free 'boiler run' contacts
- Burner hours run meters
- System temperature indication
The boilers can draw their combustion air from the room or via
ducting from outside.
Through a sophisticated control system combined with premix
burner technology and an aluminium heat exchanger, the boilers
are capable of high operating efficiencies of 93% (gross) and low
emissions.
These boilers are certified to meet the requirements of the EC
Gas Appliance Directive, Boiler Efficiency Directive, EMC and Low
Voltage Directive.
OPTIONAL EXTRA KITS
•Modulating Sequencer
- DHW Sensor
- Room Sensor
•Programmable Room Stat
•Outside Sensor
(only suitable for use in conjunction with Prog. Room Stat)
•Water and Gas Header Pack
•RS Air Duct Connector (F320 and F400 only)
•Horizontal Flue Header *
•Vertical Flue Header *
* A flue header kit (horizontal or vertical) must be fitted to boiler.
SAFETY
Current Gas Safety (Installation and Use) Regulations or rules in
force
The appliance is suitable only for installation in GB and IE and
should be installed in accordance with the rules in force.
In GB, the installation must be carried out by a CORGI Registered
Installer or in IE by a competent person. It must be carried out in
accordance with the relevant requirements of the:
• Gas Safety (Installation and Use) Regulations
• The appropriate Building Regulations either The Building
Regulations, The Building Regulations (Scotland), Building
Regulations (Northern Ireland).
• The Water Fittings Regulations or Water byelaws in Scotland.
• The Current I.E.E. Wiring Regulations.
Where no specific instructions are given, reference should be
made to the relevant British Standard Code of Practice.
In IE, the installation must be carried out by a Competent Person
and installed in accordance with the current Building Regulations
and reference should be made to the current ETCI rules for
electrical installation.
The boilers have been tested by Gastec and conform to EN483
and EN677 for use with Natural Gas.
Detailed recommendations are contained in the following
Standards and Codes of Practice:
BS. 5854 Flue and flue Structures in Buildings.
BS. 6644 Installation of gas fired hot water boilers of rated
inputs between 70kW and 1.8MW (net) (2nd and
3rd family gases).
BS. 6880 Low temperature hot water heating systems of
output greater than 45kW.
Part 1 Fundamental and design considerations.
Part 2 Selection of equipment.
Part 3 Installation, commissioning and maintenance.
IGE/UP/1 Soundness testing and purging of industrial and
commercial gas installations.
IGE/UP/2 Gas installation pipework, boosters and
compressors on industrial and commercial
premises.
IGE/UP/10 Installation of gas appliances in industrial and
commercial premises.
SAFE HANDLING OF SUBSTANCES
No asbestos, mercury or CFCs are included in any part of the
boiler or its manufacture.
FOUNDATION / LOCATION OF BOILER
The boiler must stand on a floor which must be flat, level and of a
suitable load bearing capacity to support the weight of the boiler
(when filled with water) and any ancillary equipment.
Ideally the boiler should be placed on a plinth exceeding the plan
area of the boiler by 75mm on each side and at least 100mm high.
The boiler must not be fitted outside.
GAS SUPPLY
The local gas supplier should be consulted, at the installation
planning stage, in order to establish the availability of an adequate
supply of gas. An existing service pipe must NOT be used without
prior consultation with the local gas supplier.
A gas meter can only be connected by the local gas supplier or by a
registered CORGI engineer or in IE by a competent person.
An existing meter should be checked, preferably by the gas
supplier, to ensure that the meter is adequate to deal with the rate
of gas supply required. A minimum working gas pressure of
15mbar MUST be available at the boiler inlet for Natural gas.
Do not use pipes of smaller size than the boiler inlet gas
connection.
The complete installation MUST be tested for gas soundness and
purged in accordance with the appropriate standards.
Gas Boosters
A gas booster is required if the gas pressure available at the boiler
is lower than that required by the boiler manufacturer to attain the
flow rate for maximum burner input rating.
Location of the booster requires careful consideration but should
preferably be closer to the burner rather than the gas meter.
Ventilation should also be considered to ensure ambient
temperature do not exceed designed recommendations. Further
guidance is provided in IGE/UP/2.

5
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- Installation & Servicing
GENERAL
FLUE INSTALLATION
The appropriate Ideal Flue Header Kit (veritcal or horizontal)
must be fitted to these boilers.
IMPORTANT. It is the responsibility of the installer to ensure, in
practice, that products of combustion discharging from the
terminal cannot re-enter the building or any other adjacent
building through ventilators, windows, doors, other sources of
natural air infiltration, or forced ventilation / air conditioning.
If this should occur the appliance MUST be isolated from the
gas supply and labelled as 'unsafe' until corrective action can be
taken.
Terminal Position
Due to the high efficiency of the boilers pluming will occur.
Particular care should be taken in the case of large output boiler
installations, and complying with the requirements of the Clean
Air Act.
The flue must be installed in accordance with the appropriate
Building Regulations and standards listed on page 4 and in
compliance with BS6644. In IE refer to I.S.820:2000.
FLUE SYSTEM DESIGN
Due to the high efficiency of these boilers, the flue gas
temperatures are low and the buoyancy in the stack will be
relatively small. The boiler is supplied with an integral fan which
is fully matched to the boiler in each case to provide correct
combustion air flow and overcome the flue resistance.
The power of this fan is such that there is a large reserve of
pressure available to overcome a significant length of flue
without affecting the combustion performance of the boiler. The
maximum pressure available at the base of the flue to overcome
flue resistance is 145Pa (0.58" w.g.) for F320, F400, F480 and
F560. This includes the resistance of any air ducts used to
connect the air inlet direct to outside air. Care should be taken
with tall flue systems to ensure excess buoyancy is not created.
A negative pressure must not be created at the boiler flue outlet.
See table below for approximate maximum straight flue length.
Boiler F320 F400 F480 F560
Flue Size (mm) Ø200 Ø250 Ø250 Ø250
Approx. max.
Straight Flue 109 235 162 116
Length (m)
If the high level air inlet kit, supplied with this appliance, is to be
utilised, the following table shows the approximate maximum
straight flue lengths and pressures available.
Boiler F320 F400 F480 F560
Flue Size (mm) Ø200 Ø250 Ø250 Ø250
Approx. max.
Straight Flue 57 129 67 40
Length (m)
Flue Pressure (Pa) 76 80 60 50
The addition of elbows and their positions in the flue will have a
significant effect on the maximum allowable flue and air duct
lengths. Consult with your flue supplier for detailed design
work.
IMPORTANT NOTE.
If combustion air is drawn from within the boiler room, ensure
no dust or airborne debris can be ingested into the appliance.
Dusty concrete flooring should be sealed to reduce the
presence of dust. Ideally where possible duct the air supply
into the boiler room from a clean source outside the boiler
room / building.
Material
With no requirement for buoyancy to discharge flue products and
with low flue gas temperatures, single wall flues are suitable for
most installations. Care should still be taken to maintain
compliance with building regulations and relevant standards.
The flue used should be a suitably approved flue for use on a
pressurised condensing flue system. Materials choice includes
plastic, aluminium and 316 grade stainless steel. Unless the
flue is manufactured from aluminium, the condensate from
the flue must be collected and drained before entering the
sump of the boiler (when employing the vertical combined flue
outlet header, a flue condensate drain is provided for this
purpose). Advice regarding the availability of proprietary types of
flue system can be obtained by contacting Ideal Stelrad Group.
All joints or connections in the flue system must be impervious
to condensate leakage. Low points in the flue system should be
drained using pipe of material resistant to condensate
corrosion. All drains in the flue should incorporate a water trap.
Care should also be taken in the selection of flue terminals as
these tend to accentuate the formation of a plume and could
freeze in cold weather conditions.
Care should be taken to ensure the specification of the chimney
is suitable for the application by reference to the manufacturers
literature.

6
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- Installation & Servicing
GENERAL
WATER CIRCULATION SYSTEM
A circulation pump MUST be connected to the boiler, see below.
The boiler must NOT be used for direct hot water supply. The
hot water storage cylinder MUST be of the indirect type.
Single feed, indirect cylinders are not recommended and MUST
NOT be used on sealed systems.
The appliances are NOT suitable for gravity central heating nor
are they suitable for the provision of gravity domestic hot water.
The hot water cylinder and ancillary pipework, not forming part of
the useful heating surface, should be lagged to prevent heat
loss and any possible freezing - particularly where pipes run
through roof spaces and ventilated underfloor spaces.
The boiler must be vented. There must be no low points
between the boiler flow connection and a system vent point,
which should be positioned as close as practically possible to
the boiler flow connection.
Draining taps MUST be located in accessible positions, which
permit the draining of the whole system - including the boiler
and hot water storage vessel. They should be at least 1/2" BSP
nominal size and be in accordance with BS. 2879. Do not use
the boiler drain tap to drain the system as this can induce
sludge into the heat exchanger.
The central heating system should be in accordance with the
relevant standards listed on page 4.
Due to the compact nature of the boiler the heat stored within
the castings at the point of shutdown of the burner must be
dissipated into the water circuit in order to avoid overheating. In
order to allow pump operation after burner shutdown the boiler
control box incorporates a 5 minute pump overrun facility. In
order to make use of this, a pump must be supplied from the
terminals inside the boiler. Note: for pumps requiring greater
than 1.0 amp current, they must be connected via a relay.
When sizing pumps, reference should be made to the Hydraulic
Resistance Table on page 6 which show the boiler resistance
against flow rates, to achieve the required temperature
differential.
Flow rates for common systems using either 11oC or 20oC
temperature differentials are given in the table below.
Water flow rate temp. Water flow rate temp.
difference 11oC (20oF) difference 20oC (36oF)
l/s m3/h l/s m3/h
F320 7.14 25.70 3.93 14.15
F400 9.02 32.47 4.96 17.86
F480 10.83 38.99 5.96 21.46
F560 12.63 45.47 6.95 25.02
Note.
• With the boiler firing at maximum rate, the temperature
differential should not be less than 10oC. Higher flow rates
required for lower temperature differentials could lead to
erosion of the heat exchanger water ways.
• With the boiler firing at minimum rate, the temperature
differential should not be greater than 35oC. 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 55oC 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 35oC 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: [phone] or
Sentinel Performance Solutions.,
The Heath Business & Technical Park, Runcorn, Cheshire, WA7 4QX
Tel: [phone]. www.sentinel-solutions.net
1. It is most important that the correct concentration of the water
treatment products is maintained in accordance with the
manufacturers' instructions.
2. If the boiler is installed in an existing system any unsuitable
additives MUST be removed by thorough cleansing.
3. In hard water areas, treatment to prevent limescale may be
necessary - however the use of artificially softened water is
NOT permitted.
4. Under no circumstances should the boiler be fired before
the system has been thoroughly flushed.
ELECTRICAL SUPPLY
WARNING. This appliance must be earthed.
Wiring external to the appliance MUST be in accordance with the
current I.E.E. (BS7671) Wiring Regulations and any local
regulations which apply. For Ireland reference should be made
to the current ETCI rules for electrical installations.
The point of connection to the mains should be readily
accessible and adjacent to the boiler.
CONDENSATE DRAIN
Condensate drains are provided on the boiler. These drains
must be connected to a drainage point on site. All pipework and
fittings in the condensate drainage system MUST be made of
plastic - no other materials may be used.
IMPORTANT. Any external runs must be insulated to avoid
freezing in cold weather causing blocking.
Boiler Pressure Drop Pressure Drop
(mbar) @ 20oC (mbar) @ 11oC
F320 90 297
F400 95 314
F480 100 330
F560 105 347
HYDRAULIC RESISTANCE

7
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- Installation & Servicing
GENERAL
1 BOILER DIMENSIONS AND CONNECTIONS - HORIZONTAL FLUE CONNECTION KIT
FITTED
All dimensions shown in mm
im9615
Boiler Size
SIDE VIEW FRONT VIEW
PLAN VIEW
REAR VIEW
G (Flow & Return)
17 (Condensate Drain)
110
91 (Gas)
113 (Air Inlet)
Flow
Connections
R2"
Return Connection R2"
Gas R1"
Air Inlet Ducts O110
Slave Module
High Level Air Inlet Kit (If Fitted)
Master Module

8
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- Installation & Servicing
GENERAL
1 CONT'D...BOILER DIMENSIONS AND CONNECTIONS - VERTICAL FLUE CONNECTION
KIT FITTED
All dimensions shown in mm
110
High Level Air Inlet Kit (If Fitted)
Boiler Size
REAR VIEW
Return Connection R2" Air Inlet Ducts O110
Slave Module
Condensate
Drain
Master Module
SIDE VIEW FRONT VIEW
PLAN VIEW
im9616

9
xtra
- Installation & Servicing
GENERAL
2 BOILER DIMENSIONS AND CONNECTIONS
(Optional water and gas header kit and rs air duct connector (F320 & F400 only) fitted)
Note. F320 Model shown
4 VENTILATION
The ventilation requirements of these boilers are dependant
on the type of flue system used, and their heat input. All vents
must be permanent with no means of closing, and positioned
to avoid accidental obstructions by blocking or flooding.
Detail reference should be made to BS. 6644 for inputs
between 70kW and 1.8MW (net). In IE refer to the current
edition of I.S.820. The following notes are for general
guidance only:
Dust contamination in the combustion air may cause blockage
of the burner slots. Unless the boiler room provides a dust
free environment then direct connection of the air intake via
ducting to clean outside air should be used.
IMPORTANT NOTE.
If combustion air is drawn from within the boiler room,
ensure no dust or airborne debris can be ingested into the
appliance. Dusty concrete flooring should be sealed to
reduce the presence of dust.
The temperature within a boiler room shall not exceed 25oC
within 100 mm of the floor, 32oC at mid height and 40oC within
100 mm of the ceiling.
Open Flued Installations
If ventilation is to be provided by means of permanent high and
low vents communicating direct with outside air, then reference
can be made to the sizes below. For other ventilation options
refer to BS. 6644. In IE refer to the current edition of I.S.820.
Required area (cm2) per kW of total rated input (net)
Boiler Room Enclosure
Low level (inlet) 4 10
High level (outlet) 2 5
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 2cm2free area per kW of net heat input at both
high and low level is required for boiler rooms. For enclosures
refer to BS6644.
3 BOILER CLEARANCES
The minimum dimensions as indicated must be respected to
ensure good access around the boiler.
Recommended minimum clearances are as follows.
Rear: 1000mm or adequate space from the rear of the jacket
to make the flue connections and access to the flue sample
point, drain connection, flue and any safety or control devices.
All dimensions shown in mm
SIDE VIEW
im9159
REAR VIEW
Flow
connection
Return
connection
Left Side: 450mm
Right Side: 450mm
Front: 600mm; except, access doors may be closer, but
not less than 200mm and 600mm must still be available
for service across the width of the boiler.
Top: 500mm.

10
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- Installation & Servicing
GENERAL
Rated output Minimum bore Nominal Size (DN)
kW m m in
301 to 600 50 2
'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 11oC at full boiler output.
4. The boiler is at the highest point of circulation in the system. Systems
designed to rise above the boiler flow tappings will automatically
require a minimum static head higher than that shown.
5. The position of the open vent/safety pipe above the expansion cistern
water level is given as a guide only. The final position will depend upon
the particular characteristics of the system. Pumping over of water into
the expansion cistern must be avoided.
6. Both open vent/safety pipe and cold feed/expansion pipes must be of
adequate diameter to suit the output of the boiler. Refer to Tables
below and BS 6644:2005.
5 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.
6 SEALED SYSTEM REQUIREMENTS
Open Vent Pipe Sizes
Rated output Minimum bore Nominal Size (DN)
kW m m in
301 to 600 38 1 1/2
'Steel pipe sizes complying with medium or heavy quality or BS 1387.
Cold Feed Pipe Sizes
Note. Refer to Frame 29 for typical system arrangements.
Feed/expansion
cistern
Open vent
safety pipe
3 m
minimum
see notes
System
flow
Shunt Pump
(if required)
Inverted
cold feed
entry
Cold
Feed
Water
level
(cold)
Open vent
System
return
im8250
Connections
to boiler
Working pressure 6 bar maximum.
Particular reference should be made to BS. 6644 and
Guidance note PM5 "Automatically controlled steam and hot
water boilers" published by the Health and Safety Executive.
The information and guidance given below is not intended to
override any requirements of either of the above publications or
the requirements of the local authority, gas or water
undertakings.
In general commercial closed pressurised systems are
provided with either manual or automatic water make up.
In both instances it will be necessary to fit automatic controls
intended to protect the boiler, circulating system and ancillary
equipment by shutting down the boiler plant if a potentially
hazardous situation should arise.
Examples of such situations are low water level and operating
pressure or excessive pressure within the system. Depending
on circumstances, controls will need to be either manual or
automatic reset. In the event of a shutdown both visual and
audible alarms may be necessary.
Expansion vessels used must comply with BS. 4814 and must
be sized on the basis of the total system volume and initial
charge pressure.
Initial minimum charge pressure should not be less than 0.5
bar (7.2psi) and must take account of the static head and
specification of the pressurising equipment. The maximum
water temperatures permissible at the point of minimum
pressure in the system are specified in Guidance Note PM5.
When make up water is not provided automatically it will be
necessary to fit controls which shut down the plant in the event
of the maximum system pressure approaching to within
0.35bar (5psi) of the safety valve setting.
Other British Standards applicable to commercial sealed
systems are:
BS. 6880: Part 2
BS. 1212
BS. 6281: Part 1
BS. 6282: Part 1
BS. 6283: Part 4

11
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- Installation & Servicing
INSTALLATION
7 BOILER ASSEMBLY
Legend
2. Burner switch
3. Pressure gauge
8. Fan
9. Gas Valve
11. Venturi
12. Control Module
14. Damper Relay Board
19. Union Gas cock
20. Levelling feet
22. Heat exchanger
24. Sightglass
27. Burner manifold
31. Thermistor (flow)
33. Air pressure switch
37. Relay
38. Cable conduit
47. Ignition / detection electrode
54. OT Center
8
2
3
9
11
33
22
31
31
24
27
47
12
38
38
37
14
20
Data
Plate
19
54
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INSTALLATION

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INSTALLATION
im8481
2
4
3
5
3
Rear screw on
both sides to
be left in place
1
The boiler comprises of an equally sized Master
and Slave Module, separately packed on their
own pallets. This allows the boiler to be
handled by a forklift.
The packaged boiler will pass through a
930mm wide opening. Removing the casing
assembly pack from the Master Module will
allow Modules through a 700mm wide opening.
8 PACKAGING REMOVAL / REMOVAL FROM PALLET
To unpack the modules:
- Carefully remove the straps, and lift off the casing assembly pack -
master only.
- Open Master Module box and remove literature pack.
- Remove the protective cardboard fittings.
- Safely dispose of all packing materials.
To remove the Modules from base:
1. Remove 2 screws securing casing support outrigger and discard
item (Master only).
2. Remove the 3 front screws (2 screws on 320 model) on both sides
leaving the 2 rear screws in place.
3. Rotate bottom battens outwards allowing the front of the base to rest
on the floor.
4. Remove 4 screws and retaining brackets.
5. Slide the module off the base.
Repeat Steps 2 - 5 for slave module.
INSTALLATION

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INSTALLATION
1. Fit spacers x 4 to the LH side corners of the Master Module chassis (located inside casing assembly pack).
2. Control Fascia Panel - Master Module: Remove the 2
screws securing the control fascia panel. Carefully lift it
slightly and lower the top forwards allowing it to rest on the
hinge lugs.
6. Remove and discard fascia retaining bracket (x 4) from Slave and Master modules.
9 ASSEMBLING THE MODULES
4. Control Fascia Panel - Slave Module: Remove 2 screws
securing the outer fascia panel. Lift and remove fascia,
store safely.
3. Release the ribbon cable from the display board.
Raise control fascia slightly and withdraw. Store safely.
5. Remove 2 screws securing inner fascia panel. Lift and
support panel while releasing ribbon cable from the
display board. Remove fascia and store safely.
Spacers (x4)
INSTALLATION

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INSTALLATION
10. Replace with the one piece front controls channel and
secure with 6 screws (located in casing assembly pack).
7. Position Master Module and level feet using a 13mm spanner. Check module with spirit level.
IMPORTANT. ENSURE MODULE IS LEVEL IN BOTH DIRECTIONS TO ENSURE SATISFACTORY ASSEMBLY.
9. Remove 4 screws on each control box support
channel and discard channels.
8. Position Slave Module to LH side of Master Module (ensuring not to disturb levelled Master Module) and
repeat levelling process.
10 ASSEMBLING THE MODULES .... CONTINUED
INSTALLATION

15
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INSTALLATION
11. Remove 4 screws on each rear gas pipe support
channel and discard channels.
16. Fit Slave inner fascia panel to Slave Module securing with 2
x M5 screws whilst re-fitting ribbon cable to display board.
12. Replace with the one piece rear gas pipe support channel and
secure with 6 screws (located in casing assembly pack).
15. Fit master fascia panel securing with 2 x M4
screws. Ensure ribbon cable is re-fitted.
14. Place top panel onto both modules and
secure at rear with 2 x M5 screws
(supplied).
13. Tie support the thermistor harnesses on each boiler
module. The thermistor harness is located towards the rear
of each boiler module. Using the 4 tie wraps supplied in the
casing assembly pack, tie the harnesses to the 4 holes
located on the inside face of the rear support channel.
11 ASSEMBLING THE MODULES .... CONTINUED
INSTALLATION

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INSTALLATION
REAR VIEW
Flue
Sampling
Point
Air inlet duct O110
A
F
B
C
D
E
See Table on page 5 for guidance on maximum permissible
flue and air duct system design.
FLUE
Construct either the horizontal or vertical combined flue outlet
ductwork to create the manifold arrangement depicted. The
horizontal combined flue outlet can be installed with its outlet
facing left or right dependent upon the demands of each
particular installation.
A tube of ductwork seal lubricant is provided within the flue kit.
To ease flue connections lubricate all flue seals before
assembly. Flue sampling points are fitted within the ductwork
legs A and B as depicted to facilitate flue products sampling of
each boiler module.
IMPORTANT NOTES.
1. The flue manifold should be supported in such a way as
not to place load on the boiler module flue outlet sockets.
Propriety flue duct brackets must be used to provide
support as appropriate.
2. Unless the connecting flue is manufactured from
aluminium the condensate generated within the flue must
be collected and drained before entering the combined flue
outlet ductwork. When employing the vertical combined
flue outlet header, a flue condensate drain is provided for
this purpose.
12 FLUE / AIR DUCT INSTALLATION
KEY
AFlue Tube DBend x 45o
BFlue Tube EConnector
CBend x 87oF Adaptor
REAR VIEW
Flue
Sampling
Point
A
D
B
C
im9161
Air inlet duct O110
AIR DUCT
Combustion air can be drawn directly from the boiler room
using the high level air inlet kit provided or ducted in from
outside the building in which the boiler is installed.
IMPORTANT NOTE. If combustion air is drawn from within the
boiler room, ensure no dust or airborne debris can be
ingested into the appliance. Dusty concrete flooring should
be sealed to reduce the presence of dust. Ideally where
possible duct the air supply into the boiler room from a clean
source outside the boiler room / building.
To draw air direct from outside, connection can be made using
separate ducts to each boiler Module. This can be done using
any propriety 110mm soil / drain pipe. Expansion to a larger
diameter may be required to reduce resistance, dependant on
total flue / air duct lengths required. (See Flue System Design
on Page 5). The air duct should be terminated with a suitable
fixed grille to prevent entry to vermin. This terminal should be
positioned as such to avoid blockages or entry of water.
An optional RS duct connector kit allows for the two individual
module air inlet connections to be combined into a single
200mm boiler air supply connection to simplify installation and
increase permissible air duct length (F320 and F400 only)
HORIZONTAL FLUE HEADER ARRANGEMENT
KEY
AFlue Tube CFlue Tee Manifold
BFlue Tube DFlue Condensate Drain Trap
VERTICAL FLUE HEADER ARRANGEMENT
INSTALLATION

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INSTALLATION
12 AIR DUCT CONT'D....
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 & 2.
1. Fit the 93º elbow into the boiler air inlet pipe.
2. Fit the 112.5º bend into the 93º elbow.
3. Fit the 110 dia. tube into the 112.5º bend.
4. Fit the air inlet grille to 110 dia. tube and fix with the 3 off self
tapping screws provided.
5. Using the existing screws holding the upper or centre back
panel to the boiler, fit the support bracket assembly and re-
tighten the screws.
6. With the air inlet pipe assembly in position, retain it with the
pipe clamp, fixed with the 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
54
6
3
2
1
fig 2
54
6
3
2
1
INSTALLATION

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INSTALLATION
REAR VIEW
RETURN
FLOW
(Must be
connected
opposite side
to flow
connection)
(Must be
connected
opposite side
to return
connection)
im8482
13 CONDENSATE DRAIN (Slave and Master)
A condensate drain must be connected to the
condensate bulk head connector on the back of each
module and then connected to a drainage point,
preferably within the building.
The pipe size from the condensate connector on the
lower rear panel is 21.5mm.
The routing of the drain must be made to allow a
minimum fall of 1 in 20 away from the boiler, throughout
its length.
14 BOILER WATER CONNECTIONS
The boiler flow and return pipes are terminated with 2 x R2" BSP male
connections at the rear of the appliance. Water returning from the system
should be connected to a lower header pipe, with the flow water connection
coming from a top header pipe. An optional pre-
fabricated header pipe kit is available.
Refer to Frames 1 and 2 for dimensional
positions.
All flow and return pipework must be
independently supported.
Plastic plugs fitted on the open ends of the flow
and return pipes must be removed before
connecting the system pipework.
An air vent must be provided immediately after the
flow connection.
If installing the boiler onto an existing system it is
strongly recommended that the system be
thoroughly flushed before connecting the boiler.
When connecting to a new system it is still
important to flush the whole system in accordance
with the relevant standards.
Condensate Bulkhead Connector
If the vertical flue header is specified the flue manifold
condensate drain connection must also be connected in the
same manner.
IMPORTANT. Any external runs must be kept to a minimum
and insulated. This is to avoid freezing in cold weather
causing blocking.
All pipework and fittings in the condensate drain system
must be made of plastic. No other materials may be used.
Note.
Connection to the boilers using manifolds must
use a reverse return principle to ensure equal flow
distribution through both of the modules, see
example below.
Connection of opposing flow and return points can
be made either on the LH side or RH side,
dependent upon the particular needs of the boiler
installation.
INSTALLATION

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INSTALLATION
18 INSTALLING THE MAINS AND CONTROL WIRING (MASTER AND SLAVE MODULES)
1. Route all 230V circuits in at the rear, through
conduit no. 1 on both Master and Slave
Modules.
2. Route all low voltage remote sensor/control
cables for the master module through conduit
no. 2.
3. Secure the cables with the cable clamps
provided on the main controls panel.
2
1
16 GAS CONNECTIONS
The boiler gas supply pipe is terminated in 2 x R1" BSP male
taper connections on the left-hand sides of the modules.
A gas header kit is available to combine the inlet connections
to a 2" manifold.
All gas supply pipework must be independently supported.
A minimum working gas pressure of 15mbar (6" w.g.) must
be available at the boiler inlet with the boiler firing.
Fit a gas supply pipe NOT LESS THAN 2" BSP to the boiler.
17 ELECTRICAL CONNECTIONS
Warning. This appliance MUST be efficiently earthed.
A mains supply of 230V 50Hz is required to be fitted to both the
Master and Slave Modules (see terminals marked 'Mains In'
Frame 19). External controls should NOT be wired in series
with these mains inputs. Controlling the boiler in this way will
prevent the pump over-run sequence and may cause damage
to the modules. The supply wiring MUST be suitable for mains
voltage. Wiring should be 3 core PVC insulated cable NOT
LESS than 0.75mm2(24 x 0.2 mm) and to BS. 6500, Table 16.
The fuse rating should be 7A.
Wiring external to the boiler MUST be in accordance with the
current I.E.E. (BS7671) wiring Regulations and any local
regulations. For Ireland reference should be made to the
current ETCI rules for electrical installations.
Connection should be made in a way that allows complete
isolation of the electrical supply - such as a double pole
switch, having a 3mm (1/8") contact separation in both poles,
or a plug and unswitched socket serving only the boiler and
system controls. The means of isolation must be accessible
to the user after installation.
When making mains electrical connections to the modules it
is important that the wires are prepared in such a way that the
earth conductor is longer than the current carrying conductors,
such that if the cord anchorage should slip the current carrying
conductors become taut before the earthing conductor.
WARNING. Sensor cables must be separated from cables in
the 230V circuit. For this purpose three conduits are
provided. Refer to Frame 19 for terminal strip connections.
15 FROST PROTECTION
The boiler has built into its control system the facility to protect
the boiler only against freezing.
If the boiler flow temperature T1, falls below 7oC the pump will
be activated without the boiler firing.
If the flow temperature falls below 5oC the boiler will fire until
the flow temperature exceeds 10oC. The pump will stay
running for a further 5 minutes.
Central heating systems fitted wholly inside the building do
not normally require frost protection as the building acts as a
'storage heater' and can normally be left at least 24 hours
without frost damage. However, if parts of the pipework run
outside the building or if the boiler will be left off for more than
a day or so, then frost protection for the system is
recommended.
INSTALLATION

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INSTALLATION
19 INSTALLER CONNECTIONS
230V AC
permanent
mains supply
230V AC permanent
mains supply
230V AC
output for CH
system pump.
max 1 amp
Optional 230V AC
output for DHW pump
or divertor valve.
max 1 amp.
* Optional call for CH
Optional call for DHW
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MASTER MODULE
SLAVE MODULE
* Optional connections for
programmable room stat
and modulating sequencer kits
Optional volt free connections for
boiler alarm during lock out condition.
(Closed circuit during lock out)
Optional connections for outside
temperature sensor kit
* Optional connections 0-10V
boiler control
Test point for measuring
flame ionisation current using
0-10V DC meter - see Frame 61
Test point for measuring
flame ionisation current using
0-10V DC meter - see Frame 61
Optional volt free connections for
boiler 'run' inidication
(Closed circuit during burner on operation)
0-10V
Ground
*Note.
BOTH OT CENTERS MUST BE CONFIGURED IN ACCORDANCE WITH BOILER CONTROL INPUT OPTION CHOSEN.
(See Frame 22 for details)
Input terminals are available for connecting a variety of system
controls for central heating demand. Only one method should
be employed on an individual boiler. OT Centers to be
configured in accordance with choice mode (see to Frame 22).
Heating demand can be controlled by:
1. ON/OFF using a 230V switched live to 'CH call' terminal.
(e.g. programmer and/or room thermostat).
A call for heat will cause the boiler to run and maintain a set
flow temperature controlled by parameter 4* (see Frame 31).
Connect switched live to Master Module terminal marked 'CH
CALL'.
2. Programmable Room Thermostat Kit.
The programmable room thermostat kit incorporates a room
temperature sensor and a programmer capable of
controlling the heat output from the boiler to satisfy different
temperature requirements at different time periods. The
addition of an Outside Sensor Kit will enable a weather
compensated flow temperature (see Instructions with kit for
more details).
Connect Programmable Room Thermostat to Master Module
using terminals marked 'CONTROLLER'. Wires have no
polarity and are low voltage control cables.
3. Modulating Sequencer Kit.
A Modulating Sequencer Kit is capable of controlling the
heat demand on up to 5 boilers simultaneously. (See
instructions with kit for more details.)
Connect Modulating Sequencer Kit to Master Module
using terminals marked 'CONTROLLER'. Wires have no
polarity and are low voltage control cables.
4. 0-10V
A call for heat can be generated using a 0-10V input with
the flow temperature setpoint controlled by the voltage
signal. 10V generates a maximum flow temperature top
limited by parameter 4* (see Frame 31).
Connect 0-10V signal to Master Module using terminals
marked '0-10V INPUT'. The ground wire should be
connected to the lower terminal and the 0-10V
modulating signal to the upper terminal.
CH Pump
Output terminals marked 'CH PUMP' are provided for a
circulating pump which must be connected to allow the
pump overrun function to operate. A pump requiring more
than 1 amp supply current must be connected via a relay.
20 CH CONTROL CONNECTIONS
* Changes to parameter 4 must be carried out in common to
both Master and Slave Modules.
INSTALLATION