Winterwarm XR10 User manual

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THIS DOCUMENT MUST ABSOLUTELY BE READ BEFORE STARTING THE
INSTALLATION.
INSTRUCT USER AND LEAVE THIS DOCUMENT WITH HEATER FOR
REFERENCE.
Instruction manual version GB 82b
date: 12 / 05 / 2005
heaters only for natural gas G20

Instructions premix Air heaters type XR10.. 60 Page 2/15
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This installation and user manual is produced specifically for the gas, electrical and mechanical
installer , it also gives instructions how to use and maintain the heater.
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Page
1INTRODUCTION: 2
2CONTENT: 2
3GENERAL 3
4APPLICATION RESTRICTIONS 3
5TECHNICAL DETAILS: 4
6.1 POSITIONING 5
6.2 GAS CONNECTION 5
6.3 ELECTRICAL CONNECTION 5
6.4 AIR INTAKE /COMBUSTION PRODUCTS DISCHARGE 6
6FUNCTIONING OF THE UNIT 7
6.1 GENERAL 7
6.2 HEAT DEMAND 7
6.3 DELTA-T-REGULATION (TEMPERATURE CONTROLLED DESTRATIFICATION FAN) 8
6.4 HIGH LIMIT PROTECTION 8
6.5 DESCRIPTION SPARE PARTS 8
6.6 FUNCTIONS OF THE DFC : 9
7PUTTING INTO OPERATION AND ADJUSTMENT 9
8.1 GENERAL 9
8.2 START BY USING THE SERVICE-BUTTON 10
8.3 START BY BYPASSING THERMOSTAT 10
8.4 START BY USING THE THERMOSTAT 10
8.5 TO SIMULATE A LOCK OUT CONDITION 10
8ADJUSTING THE GAS-CONTROL 10
9PROBLEM SOLVING 11
9.1 GENERAL 11
10 MAINTENANCE / SPAREPARTS 12
10.1 GENERAL INSPECTION 13
10.2 INSPECTION OF THE HEATER 13
10.3 SPARE PARTS 13
11 EXAMPLES ELECTRICAL INSTALLATION 14
11.1 INSTALLATION WITH OPENTHERM TCW THERMOSTAT 14
11.2 INSTALLATION WITH OPENTHERM CLOCK THERMOSTAT 14
11.3 INSTALLATION WITH EXTRA RESET POSSIBILITY 14
12 ELECTRICAL DIAGRAM 15

Instructions premix Air heaters type XR10.. 60 Page 3/15
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The premix unit air heater is provided with sophisticated control sequence to maintain a
comfortable room temperature and even air distribution.
It is paramount that that the installation and maintenance of this appliance are carried out by
qualified gas engineers, and strictly according to our instructions.
Before unpacking and installation, please check (i.e. on the data badge) if the heater is in
accordance with the order and if it is suitable for the local present provisions (gas type, gas
pressure, electrical supply etc.)
The installation of this appliance must be in accordance with the relevant requirements of the
gas safety regulations building regulations (and the IEE regulations ) and any requirements of
the Local Authority , Fire Officer and Insurers.
The heater must also comply with all applicable local and national standards.
The heater has been tested in detail on safety and correct operating settings before leaving the
factory. It has been adjusted for the type of gas that is stated on the data badge. Should there
be any doubt , please contact the manufacturer.
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The installation of the air heater must be in accordance with the relevant
requirements of the Gas Safety regulations (for example in GB; The Institute of Gas
Engineers IGE UP-1 and 2), building regulations and the IIE regulations also
incorporating the gas safety (installation and use) regulations. Other national and/or
local regulations may apply! The competent installer must make sure the heater operates
correctly and must instruct the user about the safe operation of the heater.
A ventilation gap of 30 cm is required from the top and bottom of the heater to any flammable
materials.
If this heater is drawing its combustion air from within the room in where it is located, the
necessary combustion ventilation requirements must be allowed for as per the gas safety
regulations. The heater should not be directly installed in areas containing any corrosive or
explosive vapours , in high moisture or dust concentrations, at negative pressures or
temperatures higher than 30°C ; please consult Winterwarm or your supplier. The guarantee is
then invalidated. The heater has a protection degree of IP20, this means for use in a dry and
not very dusty environment. This is also the case for the Open-therm room-thermostats.
Make sure that the warm air can be blown out freely. There should absolutely be (no possibility
of) materials within 5m from the front of the heater.

Instructions premix Air heaters type XR10.. 60 Page 4/15
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Type unit 10 20 30 40 50 60
Maximum nominal heat input (Nett) kW 14,0 22,8 32,0 44,0 55,0 66,0
Minimum nominal heat input (Nett) kW 9,0 14,8 20,5 26,4 33,0 39,6
Maximum heat output kW 12,6 20,8 29,2 40,2 50,1 60,5
Minimum heat output kW 8,3 13,8 19,1 24,4 30,8 37,0
Max air output (+ temp increase) m3/h 1150 2070 2600 4700 5150 6300
Throw horizontal (max) m 12 16 23 26 28 30
Throw vertical (max.warm) m 5 5 6 7 7 8
Sound level dB(A) 42 45 45 46 47 49
Electric Connection Vac 230 230 230 230 230 230
Thermostat Open Therm yes yes yes yes yes yes
Power Consumption W 250 250 250 450 450 600
Gas connection G" 1/2" 1/2" 1/2" 3/4" 3/4" 3/4"
Minimum suspension height horizontal throw m 1,7 1,7 1,7 2,7 2,7 2,7
Minimum suspension height vertical throw m 4 4 4 5 6 6
Weight kg 36 37 38 78 80 82
Min supply pressure G20 (H) mbar 20 20 20 20 20 20
Gas category Cat I2H
Class Clas. B23, C13, C33
Max gas consumption G20 (H) m3/h 1,5 2,4 3,4 4,7 5,8 7,0
Offset gasvalve mbar -0,30 -0,30 -0,50 -0,25 -0,25 -0,25
CO2 max G20 (H) % 9,0 9,0 9,0 9,0 9,0 8,9
CO2 min (indication) G20 (H) % (8,1) (8,2) (8,7) (8,1) (8,0) (8,2)
680
575
490
65
490
290
245
110
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80(2X)
65
85
Gas 1/2" inw.
105
M12
650 150
325
395
M12
M10
85625
445
795
670
90
GAS 3/4" uitw.
140150
100
XR 10 - 30
XR 40 - 60
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100(2X)

Instructions premix Air heaters type XR10.. 60 Page 5/15
Installation
6.1 Positioning
•Check that the support is solid enough.
•Keep sufficient distance between the heater and any
obstruction , in connection with safety and access for
service and maintenance. Pay particular attention to
any flammable materials. Please take into account
the possibility to open the door of the heater for the
necessary service and maintenance work . Make
sure the air flow to and from the heater is
unhindered. Any obstacles should be a minimum of
5 metres away from the front of the heater.
•The heater can be installed horizontally or vertically,
the positioning is completely free.
•The heater is provided with 2 off M12 threaded sockets as fixing
points (see the dimension diagram). The types 40, 50 and 60
also have four M10 threaded sockets on the top as fixing points.
Use preferably the Winterwarm suspension kits.
•Make sure that after fitting, there is no mechanical tension on any
connecting gas or electric supplies.
•If the heater is installed with the air stream vertical downwards
the maximum suspension height is 8 meters. Otherwise the warm air will not reach the floor.
Attention:
See the application-restrictions in this manual (Chapter 4) for further installation restrictions.
6.2 Gas connection
The gas supply line has to meet the national valid requirements and possibly the local
requirements of the building inspector, police or fire brigade. (In GB it must comply with Gas
Engineers publication UP-1 and UP-2 together with BS 6891.
A manual isolation valve in the supply line must be placed within reach of the heater, and all gas
lines must not be mounted under mechanical tension.
When testing the supply lines with pressures above 60 mbar, this manual valve at the heater
must be closed.
The working and standing supply pressure must be a minimum of 17 mbar, and a maximum of
30 mbar ,measured at the inlet pressure nipple of the gascontrol in the heater .
6.3 Electrical connection
6.3.1 230Vac supply
The installation must comply with local and national requirements, ( as well as IEE regulations)
The unit heater is delivered completely wired internally, where controls of any type are to be
added (eg. room thermostat) , the relevant wiring diagrams must be adhered to. Never use a
room thermostat to interrupt the electrical supply to the heater!
Make provisions to completely isolate the heater for maintenance purposes. This can be an
isolation switch (min.3mm contact opening gap) , a power plug or a nonswitched fuse spur. The
wiring diagram for the heater can be found towards the end this manual.
The supply is 230Vac. with earth. The control circuit is 24 V.
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Instructions premix Air heaters type XR10.. 60 Page 6/15
20
10
26
6
TCW
IN
OUT
110

80

80
65
65
85
Gas 1/2"
105
6.3.2 Roomthermostat
There are several possibilities to connect the heater.
1. By using the TCW OpenTherm thermostat. This offers the possibility to
modulate the burner and fan, to reset the heater and to enable summer
ventilation.(no time clock). See separate manual !
2. By using an OpenTherm clock thermostat, please ask your supplier.
3. By using an on/off (clock) thermostat.(PCP 5) Attention, when using an on/off thermostat,
the heater will not modulate and summer-ventilation is not possible. Furthermore, the so-
called delta T-regulation will not be operational and remote reset requires additional wires.
In all cases: make sure you use a screened 24Volts cable.
In a disturbance sensitive environment a so-called sealed “twisted pair” cable must
be used. Before connecting, switch off the tension from the heater. Connect the
earth shield of the cable only to the earth terminal in the heater.
6.3.4 Lockout indication
The heater has a potential free contact (max. 230Vac) for lockout indication. (see diagrams
further in this manual)
24V is available on the connection-terminals for possible use with this fault indication. This
contact is closed in a lockout condition.
6.3.5 Reset
The heater can be reset in 3 ways.
•On the TCW thermostat.
•On the DFC printed circuit-board within the heater, push the lower red button.
•On a remote reset button . For the connection, see the diagram towards the end of this
manual.
6.3.6 Fuses
The heater contains 3 fuses:
•F1 to protect the DFC regulation printed board
•F2 to protect the DBC burner control and the pre-mix fan
•F3 to protect the system fan and the transformer .
Replace the different fuses only by ones of the same type. See the wiring diagram for the
different values.
6.4 Air intake / combustion products discharge
Check for compliance with local / national regulations.
The combined Winterwarm combustion-air supply / combustion-
gas outlet device (Roof terminal or wall terminal) has to be used,
only so the installation is CE approved. See installation drawings.
Never connect a roof terminal for condensing appliances, rain can
damage the heater trough the discharge pipes.
Condensation in the discharge system
During heating up, it is possible that condensate is formed in the discharge system. This,
however, will evaporate if the heater is operating for a longer period of time.
Service
Reset
Red
Green

Instructions premix Air heaters type XR10.. 60 Page 7/15
If the straight length of the discharge flue is longer than 4 meters this condensate will not
evaporate again and accumulate in the heater ! Isolation of the discharge pipes or an
condensate trap just at the heater is then absolutely necessary.
The maximum flue length not isolated is 4 meters. (do not count bends)
The maximum flue length isolated is 9 meters. (do count bends, see below).
The maximum pressure drop in either the air supply pipe, or the flue pipe ,must not exceed 9
metres straight pipe , excluding the terminal. Whenever bends are used the pressure drop is
greater and therefore a 90°bend will count as 2 metres and a 45°bend as 1 metre. All flue
pipes must be of the same diameter as the flue spigots on the heater, and all flue joints must be
sealed. For further information regarding the flue system please contact Winterwarm or your
supplier. Make sure the roof terminal is at least 0,5m above roof level..
Do not connect a ‘standard’ flue terminal to this heater ,nor a terminal for a condensing boiler.
Use only pipes and bends for overpressure with profiled sealing-rings.
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6.1 General
The unit can heat as well as ventilate. By using the temperature-sensor on the unit and the one
in the room-thermostat, the temperature-difference between the two in the room is monitored.
Should the difference become higher than a set value, due to the fact that warm air has
accumulated underneath the roof, the system-fan will start and push the warm air down, acting
as a destratification fan.
6.2 Heat demand
If the thermostat indicates heat demand, the following cycle will commence:
The DFC circuit board acknowledges the heat-demand and sends a signal to the burner control
DBC.
The DBC gives power to the premixfan and the latter will start running on the starting speed.
After 30 seconds the electrode will spark for max. 5 seconds and the gas-air mixture will ignite.
When the flame is detected, the unit will modulate to the desired load after ca. 15 seconds.
Depending on the given load, the system fan will start modulating (3 steps) as well.
Attention!
decline towards outside

Instructions premix Air heaters type XR10.. 60 Page 8/15
When the heat demand is satisfied, the burner will switch off and the system fan will continue to
run for ca. 3 minutes in order to cool the unit down.
The unit will try to ignite twice before lockout on flame fault.
In the case of flame failure during operation, the heater will attempt one restart.
6.3 Delta-T-regulation (temperature controlled destratification fan)
In case there is no heatdemand, the delta-T-regulation will be active. (only in case OpenTherm
thermostat is installed).
When the temperature-difference between the sensor on the unit (the NTC) and the sensor in
the OpenTherm thermostat is bigger than the set value (factory setting standard 10°C), the
systemfan will start ,at a regulated speed, depending on the differential temperature difference.
This operation ensures an even temperature distribution throughout the building, thus acting as
a fully automatic variable destratification fan.
Should this delta-T-regulation not be required , the connection between the OpenTherm
thermostat and the unit must be interrupted electrically(by means of a so-called Out-of-service
switch). Alternatively the set point for the delta T regulation to become active, can be set to
15°C (maximum)by turning Potentiometer 2 (P2) fully clockwise. See below.
6.4 High limit protection
The unit contains 2 temperature protections. The NTC thermostat monitors the air temperature
electronically. Should the temperature become too high, the burner will switch off. When the
unit has cooled down , it will automatically restart.
Should the temperature increase to an unacceptable level, , the STB (capillary thermostat) will
interrupt the electric power to the DBC. This thermostat can only be reset manually.
If during operation the power line is disconnected, the STB can switch because of the internal
heat in the appliance. It has to be reset before the heater functions again.
6.5 Description spare parts
List of abbreviations:
DFC: Digital Fan Control. This is the central regulation printed circuit board
that communicates with the room thermostat and modulates the premix
fan, it also determines the system fan speed.
DBC Digital Burner Control, situated on the gascontrol. This monitors the
ignition and burner sequence, whilst supplying power to the premix-fan.
NTC Negative Temperature Sensor. This sensor measures the temperature of
the blown out air.
STB This mechanical maximum thermostat that measures the temperature of
the blown out air by means of a capillary sensor. The set value cannot
be changed.
PWM This is the pulsating 24 Volts signal of the DFC to the pre-mix fan. The
PWM regulates the modulation and the start-up speed.

Instructions premix Air heaters type XR10.. 60 Page 9/15
6.6 Functions of the DFC :
Lock out
(Red ) The alarmled lights up red,
when the DBC 577 is locked and the
alarmcontact is therefore active.
Burnerdemand Led
(Green ) This led lights up green,
when heat demand is present.
Service button
push 1 time = low load
push another time = high load
push 3 times = off (normal operation)
Reset button
push 1 time to reset
Potentiometer 1 (P1)
This one is for the manufacturer
only, it has no function for the end-
user.
Potentiometer 2 (P2)
This alters the set value for the the delta-T regulation to become active. This can be between
4°C (potentiometer completely anti-clockwise) and 15°C (potentiometer completely clockwise).
Factory setting: 10°C.
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8.1 General
Prior to packaging, each unit is checked in detail on safety and well functioning. It is a.o.
adjusted to the right efficiency of combustion. In general, the heater is not needed to be
adjusted after installation, only a check of well functioning is necessary by a competent person.
Also obtain a flue gas analysis and record it for later reference.
Use only a calibrated instrument !
The CO2 value may be adjusted if necessary, only do this in case it turns out that the CO2
value is not correct. Do not ever turn injudiciously the adjusting screws!
Adjustment of the gascontrol without a supporting flue gas analysis will invalidate the warranty.
Once the unit is installed according this manual, the unit can be put into operation. Make sure
the gaspipe is clean, gastight and free from air.
Switch on the electric supply with the maintenance-switch, and open the door in order to be able
to observe the first start-up and so become familiar with the functioning of the heater.
Should the gas line not be purged correctly the heater will attempt to start twice before going
into a lock-out condition. Manual reset is necessary in that case.
Do not forget to instruct the end user about a safe use of the heater (presence of gas, place of
the manual gasvalve !), the operation of the heater (lock-out indication and reset) and about the
necessary maintenance. This manual must be left with the end user.
X4
12345 1 2 3 123 4 5
Service
Reset
Red Green
IC
P1 P2
F1 2AT
3.15AT F2
4
3
2
1
678
X5 X6
1
2
3
4
5
6
7
9
8
10
X2
X1
RE1
RE2 RE3 RE4 RE5 RE6
Fan High
Fan Medium
Fan Low
DBC ON
Alarm
Reset
X3
DFC 100

Instructions premix Air heaters type XR10.. 60 Page 10/15
8.2 Start by using the service-button
Press the service-button (shortly) once , and the unit will commence the ignition-cycle; (30 sec
pre-purge, ignition, 15 sec flame stabilize, modulating operation) The burner will then start in
low fire. By pressing the service-button again, the burner will go to high fire.
Pressing the service-button for a third time will put the unit into normal operation. (depending
on the thermostat)
8.3 Start by bypassing thermostat
When the thermostat connection is jumpered (between terminals 4 and 5), the unit will only
function on high fire. The ignition sequence is always the same as 8.2.
8.4 Start by using the thermostat
Put the thermostat in the highest position.
With the TCW roomthermostat following functions are possible ;
Red LED lights continuously : Flame on.
Red LED lights intermittently : Flame in lock-out.
Green LED lights : Summer ventilation on.
Grey button ; press 1 sec. : Summer ventilation on / off.
Grey button ; press 6 sec. : Flame fault reset
8.5 To simulate a lock out condition
Close the manual gas supply valve. The heater will go to lock-out after a restart attempt. The
lock out indication (in the heater ) must light up. The lock out indication on the TCW room
Thermostat (if installed) will now flash.
Check also the function of the reset button (with gasvalve open again), and observe if heater
starts smoothly.
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In principle, it is not necessary to adjust the gascontrol after putting the unit into operation.
In case it needs to be adjusted, (f.e. after fitting a new one), this must be done only by a
qualified person. Only use calibrated instruments ! A poor adjustment can lead to
overheating and / or production of the poisonous carbon monoxide !.
There are two screws to adjust the
gascontrol, the Offset adjuster and the
Ratio adjuster.
Put the heater into operation at high fire
by pressing the service button twice
quickly.
If the heater does not ignite while
sparking, you can, if necessary, close the
air-openings of the coloured ring on the gas-air mixer with thumb and forefinger during ignition.
The mixture will become richer and will ignite more easily.
Open the pressure-nipple “P offset” and connect a calibrated pressure gauge to it.
If the heater is in operation, the read underpressure must comply with the value from the
technical specifications. You can change this underpressure by turning the Offset adjuster
screw located under the little cover. Turn to the left for more underpressure, turn to the right for
less underpressure. When the underpressure is set correctly, you replace the little cover and
close the pressure-nipple “P offset”.
Offset adj.
Ratio adj.
P out
P offset
P in

Instructions premix Air heaters type XR10.. 60 Page 11/15
Check the CO2 in high load of the heater. In case the CO2 is too high, you turn the Ratio
adjuster to the right (less gas). In case the CO2 is too low, you turn the Ratio adjuster to the left
(more gas).
Never forget to check the CO (carbon monoxide ) production of the heater!!! Too much CO
means mostly that the mixture is too rich. CO value should always be below 100 ppm. Always
check and (adjust eventually ) the CO2 content (see above), and then control the CO value.
After adjusting the high fire, the heater should be checked on low fire. (use servicebutton)
2
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9.1 General
When it turns out that the problem is not caused by the external circumstances (i.e. no electric
supply power or no gas), please take the following instructions into account. Please remember
the built in waiting times of the heater (do not react too soon!) and the signals of the LEDs!
Attention!: The fault-signal will only be indicated when there is heat-demand!
Please check the following items first :
•Check the fuses as well as the wires and plugs in the heater for possible loose contacts.
•In a heat-demand situation, the green LED on the print DFC must light up.
•In a flame failure situation, the red LED on the DFC will illuminate, if so, reset.
•Use first the service-button to put the heater in run mode, try later the room thermostat.
Premix-fan (M2) does not start
a) Check if the heater is not in an over heat condition. On both terminals of the STB must be
230 Volt. This STB must be reset if necessary, or it can be jumpered temporarily.
b) Check if the NTC prevents the DFC from functioning. Measure the resistance of the NTC
(pull plug from DFC). This must be approx. 20 kilo Ohm at 25°C, or 40 kOhm at 10°.
c) Check that a 230V signal is being received at the DBC.
d) Check that a230V signal is being received on the plug of the pre-mix fan (between the
brown and the blue wire).
e) It is possible that there is no (!) PWM-signal to the pre-mix fan for the starting-speed. This
can be checked on the 24V plug of the premix-fan.
f) Depending on e), c) and d) the DFC or the DBC may be faulty.
g) Check if the pre-mix fan is not blocked by pushing the cooling impeller carefully. The cause
of non-starting of the premix-fan could be in the fan itself.
Premix-fan does start, but no further action, no flame failure.
a) Faulty DBC , replace.
Premix-fan does start, no sparks, then flame lock-out.
a) Check if the electrode does spark by unscrewing it and taking it out of the heat exchanger
and holding it against the mass (with an insulated pliers) during the sparking period. In
case you see or hear no spark, the DBC must be replaced.
Sparks in the heatexchanger, then heater goes on lock out.
a) There could be no gas. Check this by measuring the underpressure on the pressure-nipple
on the gascontrol (P out). During the purge cycle there is an underpressure of circa 6 mbar.
When the gascontrol is opened and there is gas during the sparking period, this
underpressure will lower by circa 3 mbar, to circa 3 to 4 mbar. If not, take the DBC off the
gascontrol (unscrew M3 screw between the wires) and check with a multimeter if the coils of
the gascontrol are not interrupted internally. There are two coils, you must find on both some
(k)Ohms resistance, if not they are broken. Also check the screen on the inlet side of the
gascontrol. This can be done by detaching the gasconnection outside the heater and by
looking through the gasconnection into the gascontrol.

Instructions premix Air heaters type XR10.. 60 Page 12/15
It can also be that the DBC does not send a 230 Volt signal to the coils. In this case, try
another DBC.
b) There are sparks and the gascontrol opens, but the mixture does not ignite. Check if the
flame does ignite if the coloured air inlet ring on the pre-mixfan is closed partially between
thumb and forefinger. There will be less air, so the mixture is richer and ignite easyer. If the
flame now ,becomes established, check the CO2-content when the heater is warm at high
fire. Adjust it if necessary with the adjusting-screw on the gascontrol. Only do this with a
good (calibrated) CO2-meter in the outlet of the heater.
The burner ignites briefly, then the heater goes to lock-out
This points to problems with the flame-ionisation. Check first for a sound earth connection in
the heater, by pulling shortly on various earth wires.
The ionisation current itself must be circa 2 microampère. This can be measured, provided
the connections of the multimeter are jumpered during the sparking period in order to prevent
the meter from damage.
Most of the time, problems with the ionisation current, can be solved by replacing the DBC.
Heater does start, but shows other problems.
a) Heater stays on starting speed and does not modulate to a higher work speed : Check if the
pre-mixfan speed does vary if you press the service button of the DFC. Press one time; the
heater will go to low-fire, press one more time; the heater will go to high fire. Pressing a
further time will de-activate the servicemode. After 10 minutes of servicemode this function
will switch off automatically. Check if the heater does function normally if the wires of the
roomthermostat are jumpered (heater must start up and go to full load), and if it switches off
when the wires are opened again. Try first another OpenTherm thermostat. If this does not
work, the DFC must be replaced. It can also be the pre-mixfan itself that does not modulate
inspite of a good input signal. The heat output of the heater will also be insufficient if there is
too much resistance in the inlet- or outlet flue system. In this case the pre-mixfan will be on
full speed, but because of the high resistance too little air is moved and therefore also too
little gas. The pressure in the outlet flue for example, will normally never be above 30 Pascal.
b) Systemfan (M1) does not start or does not vary in speed; Check first the functioning of this
fan by connecting it to 230 Volt. Check with a multimeter if the different lower tensions are
secondary present on the transformator as well. The fuse could have failed. If the motor and
transformer are OK, the cause of the probleem must be in the DFC, as the DFC dictates the
different voltages from the transformer to the fanmotor. In that case, replace the DFC.
c) Delta-T-regulation problems: For this regulation, potentiometer P2 on the DFC is used. This
controls the desired difference in temperature between the room sensor (the OpenTherm)
and the sensor in the heater (NTC). A smaller difference in temperature (potentiometer P2
anti clock wise) will keep the systemfan running on higher speed for longer periods.
Check the functioning of the OpenTherm thermostat by putting it on heathdemand for a
little while. In case this functions well, then check the NTC (measure the Ohm resistance).
The problem may be the DFC. In this case, the DFC must be reprogrammed, or replaced.
Resistance value NTC sensor at 20°C= 25 kOhm.
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The heater must be inspected and cleaned regularly (once a year) by a qualified installer who
understands this appliance.
This is all the more important as the circumstances are heavier, especially in case of dust,
humidity, high frequency of switching on/off etc.

Instructions premix Air heaters type XR10.. 60 Page 13/15
Activities:
10.1 General inspection
•Check the overall condition of the installation. Check the heater, the thermostat, the wires
and the gas line.
10.2 Inspection of the heater
Before starting the inspection, switch off the electric power to the heater with the maintenance-
switch and close the manual gasvalve.
•Take out the burner, complete with flange and pre-mix fan, by unscrewing the 6 off M6
socket screws and you have taken off the ignition and fan wires
•Check the heatexchanger from the inside for dirt and/or damage.
•Check the burner on damage and clean the ignition electrode if necessary . CAUTION: do
not twist the electrode out of shape!
•Check the airsupply and the flue discharge.
•Clean eventual the inside of the heater with a vacuum cleaner.
•In case the heatexchanger is dirty on the outside, clean it with a soft brush. Never use a
steel wire brush!
•Clean the fan-grid with a vacuum cleaner and a brush.
•Put the burner back in (renew the gasket)
After this, check the heater on efficiency of combustion and adjust these if necessary
Check the heater operates correctly.
10.3 Spare parts
Description 10 20 30 40 50 60
Burner XR IX.3206 IX.3206 IX.3208 IX.3208 IX.3210 IX.3212
Ignition/Ionisation electrode IX.3458 IX.3458 IX.3458 IX.3458 IX.3458 IX.3458
Premix fan MVL RG128 (M2) IX.4500 IX.4500 IX.4500 IX.4500 IX.4500 IX.4500
Inspection glass IX.6812 IX.6812 IX.6812 IX.6812 IX.6812 IX.6812
Gas-AirMixer SIT 391 AGM IX.4506 IX.4504 IX.4502 - - -
Gascontrol SIT SIGMA 848 IX.3000 IX.3000 IX.3000 IX.3000 IX.3000 IX.3000
Burner control SIT DBC577 IX.3550 IX.3550 IX.3550 IX.3550 IX.3550 IX.3550
Fan Control DFC 100 GA.5706 GA.5708 GA.5710 GA.5712 GA.5714 GA.5716
Systemfan FMV (M1) IX.4200 IX.4200 IX.4200 IH.4206 IH.4206 IX.4205
NTC Cable sensor IX.3918 IX.3918 IX.3918 IX.3918 IX.3918 IX.3918
STB capillairy thermostat IX.3914 IX.3914 IX.3914 IX.3914 IX.3914 IX.3914
Transformer system fan IX.5100 IX.5100 IX.5100 IX.5098 IX.5098 IX.5098
Gasket ; inlet heatexchanger IX.6702 IX.6702 IX.6702 IX.6742 IX.6742 IX.6742
Gasket ; outlet heatexchanger IX.6708 IX.6708 IX.6708 IX.6744 IX.6744 IX.6744
Gasket ; premix fan IX.6704 IX.6704 IX.6704 IX.6704 IX.6704 IX.6704
Gasket ; ignition / ionisation electr IX.6710 IX.6710 IX.6710 IX.6710 IX.6710 IX.6710
Gasket ; inspection glass IX.6706 IX.6706 IX.6706 IX.6706 IX.6706 IX.6706
Burner isolation plate IX.6720 IX.6720 IX.6720 IX.6724 IX.6724 IX.6724

Instructions premix Air heaters type XR10.. 60 Page 14/15
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11.1 Installation with OpenTherm TCW thermostat
•Connect the heater to 230Vac
•Connect the thermostat to the terminals according to the
diagram. (terminal 4 and 5)
11.2 Installation with OpenTherm clock thermostat
•Connect the heater to 230Vac
•Connect the thermostat to the terminals according to the
diagram. (terminal 4, 5, 6 and 7)
11.3 Installation with extra reset possibility
•Connect the heater to 230VaC
•Connect the thermostat (can be OpenTherm or on/off).
•Reset is possible by mounting a pressbutton between
terminals 6 and 7
230 Vac
Open therm (24 Vdc)
L (230 Vac)
N (neutral)
20°C
Room Thermostat
21 3124 57
6 11 13 14
F3
N (neutral)
L (230 Vac)
21 3 5 467
230 Vac
20°C
Room Thermostat
Open therm (24 Vdc)
1311 12
F3
14
4567
Externe reset
20°C
Room Thermostat
Thermostaat
Ruimte
L (230 Vac)
N (neutral)
230 Vac 24 Vdc
21 3124 57
6 11 13 14
F3

Instructions premix Air heaters type XR10.. 60 Page 15/15
123456 7 89 10 11
12
13 14
J2 J1
X2
Hall sensor
PWM
Gnd
24 Vdc
2
5 4 1
-T
X6 X5 X4
Room Thermostat
Sit DBC 577
DFC 100
1 2 3 4 5
6
1
2
7
3 8 5
10
4
9
2 4
6
7 3 1
5
8
20°C
STB
NTC 20KOhm 25°C
X6-7
1
2
3
7
4
56
41 2 3 5 6 7 11 12
M1 (N)
24V gnd
M1 (L)
L (230 Vac)
X2-9
X2-4
X2-10
X6-2
X6-4
1
X4
2 3 45 1
X5
1 2 32 3 4 5
X6
6 7 8
42P1 P2
49
10 5
7 8
2
3
61
3.15AT
F1
RE2 RE3
X2
IC
X3
31X1
RE5
RE4 RE6
RE1
DFC 100
2AT
F2
Code 0.577.406
1 2 3 4
EV2
EV1
M2
X7
X7
External reset: make contact between connection 6 and 7
EV1/ 2 Gas valve
Transformer for Fanregulation
Fuse
TR1
F
Pre mix fan
Connections for installation purposes
Limmit thermostat (manual reset)
3
Fan motor
STB
M1 M2
n
F3
M1
1~
white red braun
braun
black
black
blue
black
12 13
grey
-T
14
blue
11
TR1
L (230V AC)
1
N (Neutral)
2
X6-5
X6-8
13 14
F3
X6-6
violet
transp.
black
black
blue
orange
black
yellow
grey
yellow
red black
blue
green/yellow
Room thermostat (Open therm or ON / OFF)
black
blue
For installer
Room
Connections
TR1grey
Thermostat
Reset (to gnd 24V)
TR1black
N (neutral)
GB
Reset
Service Red Green
Reset
DBC ON
Alarm
Fan Medium
Fan Low
Fan High
NTC 10 Ohm 25°C
N
(type 50: 160 V)
180 V
230 V
1
2
3
type 10-30: 1.25 AT
type 40-60: 3.15 AT
140 V
or black
Auth.:
Titel: Schema N°:
Get.: Datum:
R-series type 10 - 60 230V R101c
MF 26-01-2005
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