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Xtrafast 96 E1 - Xtrafast 120 E1 Engineer Support

Welcome to the Engineer Technical Support section. Please use the different sections below to find answers to your technical questions. You can also find a range of useful contact numbers, including Technical support, here.

Fault Finding Information

Wiring Diagram

Component Tests

Pump – 230vac across Pins 1 (Brown) & 2 (Blue) on connection H1 on the Main PCB

Fan – 230vac across Pins 3 (Brown) & 1 (Blue) on connection H3 on the Main PCB

Diverter Valve Motor (Domestic Hot Water Mode) – 230vac across Pins 1 (Blue) & 3 (Black) on connection H5 on the Main PCB (the Motor Spindle should drive out) OR remove the Diverter Valve Motor Plug from the Motor and test voltages shown as below with a Domestic Hot Water Demand:

Diverter Valve Motor (Central Heating Mode) – 230vac across Pins 2 (Brown) & 3 (Black) on connection H5 on the Main PCB (the Motor Spindle should retract) OR remove the Diverter Valve Motor Plug from the Motor and test voltages shown as below with a Central Heating Demand:

Spark Generator Input from Main PCB – 50vac across Pins 3 (Brown) & 1 (Blue) on connection H2 ZIG on the Main PCB, or across the 2 pins on the end of the Spark Generator Plug on demand (with the feed plug removed from the Spark Generator)

Air Pressure Switch (AT REST) – 35vdc on Pin 7 (White) to an Earth on connection J4 on the Main PCB (Common contact 1 on APS) and 0vdc on Pin 9 (White) to Earth on connection J4 on the Main PCB (N/O contact 3 on APS)

Air Pressure Switch (MADE) – 32vdc on Pin 7 (White) to an Earth on connection J4 on the Main PCB (Common contact 1 on APS), and 32vdc on Pin 9 (White) to Earth on connection J4 on the Main PCB (N/O contact 3 on APS) when the Fan is running

Overheat Thermostat – 32vdc on Pin 10 (Black) to Earth and Pin 11 (Black) to Earth on connection J4 on the Main PCB on demand (The Overheat Thermostat will only become live during a demand, and will show 0vdc when the appliance is in standby mode) The Overheat Thermostat can also tested for continuity with the power off.

Gas Valve (Main Solenoid) – 22vdc - 24vdc across Pins 15 (Grey) and 14 (White) on connection J4 (during spark generation) to open the Main Solenoid, then drops to approximately 11vdc – 13vdc to maintain the flame.

Water Pressure Sensor

5vdc to Earth on Pin 13 (Orange) on connection J19 on the Main PCB – Feed from the Main PCB to Water Pressure Sensor

1vdc @ 0bar, 1.5vdc @ 1bar, 3vdc @ 3bar to Earth on Pin 14 (White) on connection J19 on the Main PCB – Feedback from the Water Pressure Sensor

0vdc to Earth on Pin 15 (Grey) on connection J19 on the Main PCB – This is a negative (neutral)

User Interface (Display) PCB Test

All measured to Earth from left to right on connection J16 on the Main PCB (All Grey Wires)

Pin 1 - 0vdc

Pin 2 - 5dc

Pin 3 - 3.7vdc – 4.4vdc (ranging)

Pin 4 – 4.3vdc – 4.8vdc (ranging)

NOTE – All the above voltages are from the Main PCB to the User Interface (Display) PCB

Storage Cylinder Heating Element – 230vac - 1.8Kohms

Domestic Hot Water NTC Thermistor – 12Kohms @ 20 degrees celsius

Central Heating NTC Thermistor – 12Kohms @ 20 degrees celsius

Storage Cylinder NTC Thermistor – 12Kohms @ 20 degrees celsius

Domestic Hot Water Flow Sensor Test (Using Onboard Diagnostic Menu)

Press and Hold the “Display Backlight” button on the left hand side of the display for 5 seconds (Key Number 8 on the diagram above) until the digital display shows ”01” on the RIGHT hand side of the display.

Change the “01” to “07” using the Domestic Hot Water PLUS key

The figure on the LEFT hand side of the display will show the domestic hot water flow rate in litres per minute and will show “00” with the hot tap OFF (which means 0 litres a minute)

With the hot tap ON it should show a figure between 10 and 199. Whatever number is shown, divide it by 10 and this will be the litres per minute being read by the domestic hot water flow sensor (For example: if the number is 96 it will equate to 9.6 ltrs/min.)

If the number still shows “00” with the hot tap open, the domestic hot water flow sensor is not functioning.

Domestic Hot Water Flow Sensor Test (Voltage Test Using A Multimeter)

Tap Off

18vdc to Earth on Pin 1 (White) on connection J19 on the Main PCB – Feed from the Main PCB to the Domestic Hot Water Flow Sensor

12vdc to Earth on Pin 2 (Pink) on connection J19 on the Main PCB – Signal from the Domestic Hot Water Flow Sensor *NOTE - This may read 0vdc on occasion depending on where the Hall Effect Turbine has stopped in the Flow Sensor

0vdc to Earth on Pin 3 (Grey) on connection J19 on the Main PCB – This is a negative (neutral)

Tap On

18vdc to Earth on Pin 1 (White) on connection J19 on the Main PCB – Feed from the Main PCB to the Domestic Hot Water Flow Sensor

5vdc – 7vdc to Earth (ranging up and down when the tap is running) on Pin 2 (Pink) on connection J19 on the Main PCB – Signal from the Domestic Hot Water Flow Sensor

0vdc to Earth on Pin 3 (Grey) on connection J19 on the Main PCB – This is a negative (neutral).

Fault codes and Reasons

Fault Codes

Fault Description

Possible Causes

Fan Symbol

Air Flow Fault/Incompatible Software

Flue Problem
Air Pressure Switch Fault (Stuck In “Made” Position)
Replacement User Interface (Display) PCB not configured correctly by the Service Engineer
Replacement Main PCB not configured correctly by the Service Engineer
Fan Fault

Fault Code FF00

Air Flow Fault/Incompatible Software

Flue Problem
Fan Fault
Air Pressure Switch Fault
Replacement Main PCB not configured correctly by the Service Engineer
Replacement User Interface (Display) PCB not configured correctly by the Service Engineer

Fault Code FF02

Air Flow Fault (After 40 Seconds)

Flue Problem
Fan Fault
Air Pressure Switch Fault
Replacement PCB not configured correctly by the Service Engineer
Main PCB Fault

Fault Code FF04

Ignition Fault or Flame Detection Error

Insufficient Inlet Gas Pressure To The Appliance
Ignition Electrode or Flame Sensing Electrode Fault
Incorrectly Adjusted Gas Valve (Via Parameters 16 & 17 in the Boiler Data Menu)
Blocked Injectors Or Burner Cross Lighting Issue
Gas Valve Fault
Flue Problem

Fault Code FF05

The Appliance Has Overheated (Reached 115 Degrees Celsius)

Pump Not Circulating Correctly
Blocked Domestic Hot Water Heat Exchanger (If Fault Occurs On Domestic Hot Water Mode Only)
Blocked Main Heat Exchanger
Air Lock Within The Appliance
Central Heating Return Filter Blocked (If Fault Occurs On Central Heating Mode Only)
Flow Or Return Isolation Valves Closed
Blockage Or Air Lock In The Central Heating Circuit (If Fault Occurs On Central Heating Mode Only)

Fault Code FF06

Central Heating NTC Thermistor Fault

Faulty Central Heating NTC Thermistor (Should Read Approx 12kohms at 20 Degrees Celsius)
Loose Connection On The Wiring Harness Between The Central Heating NTC Thermistor And The Main PCB

Fault Code FF07

Domestic Hot Water NTC Thermistor Fault

Faulty Domestic Hot Water NTC Thermistor (Should Read Approx 12kohms at 20 Degrees Celsius)
Loose Connection On The Wiring Harness Between The Domestic Hot Water NTC Thermistor And The Main PCB

Fault Code FF08

Storage Vessel NTC Thermistor Fault

Faulty Storage Vessel NTC Thermistor (Should Read Approx 12kohms at 20 Degrees Celsius)
Loose Connection On The Wiring Harness Between The Storage Vessel NTC Thermistor And The Main PCB

Fault Code FF09

System Water Pressure Sensor Fault

System Water Pressure Sensor Fault
Wiring Fault Between System Water Pressure Sensor And The Main PCB

Fault Code FF12

User Interface (Display) PCB Fault Or Other Errors

NOTE: On Certain Versions This Code Will Appear For A Few Seconds When The Mains Power Is Turned On. This Is Normal Operation.

Electrical Error On The User Interface (Display) PCB
Replacement User Interface (Display) PCB Not Configured Correctly By Service Engineer (Incorrect Appliance Code)
Incorrect Dipswitch Adjustment On The Main PCB
External Glow Worm “Xtracom” Room Thermostat Fault (If Fitted)

Fault Code FF13

Main PCB Fault And Other Errors

Main PCB Fault
Bad Earth Connection On The Appliance
Moisture Present On Electrical Components (Check For Leaks)
Loose Connection On NTC Thermistors

Fault Code FF14

The Central Heating NTC Thermistor Has Reached 97 Degrees Celsius

Pump Not Circulating Correctly
Blocked Domestic Hot Water Heat Exchanger (If Fault Occurs On Domestic Hot Water Mode Only)
Blocked Main Heat Exchanger
Air Lock Within The Appliance
Central Heating Return Filter Blocked (If Fault Occurs On Central Heating Mode Only)
Flow Or Return Isolation Valves Closed
Blockage Or Air Lock In The Central Heating Circuit (If Fault Occurs On Central Heating Mode Only)
Central Heating NTC Thermistor Showing Incorrect Resistance (Should Read 12kohms At 20 Degrees Celsius)

Fault Code FF20

Communication Error

Replacement User Interface (Display) PCB Not Configured Correctly By Service Engineer
Replacement Main PCB Not Configured Correctly By Service Engineer
Electromagnetic Interference In The Vicinity (External Influences)
Faulty Main PCB
Faulty User Interface (Display) PCB

Lightning Symbol

Ignition Fault or Flame Detection Error

Insufficient Inlet Gas Pressure To The Appliance
Ignition Electrode Or Flame Sensing Electrode Fault
Incorrectly Adjusted Gas Valve (Via Parameter 16 & 17 in the Boiler Data Menu)
Blocked Injectors Or Burner Cross Lighting Issue
Gas Valve Fault
No Power To The Gas Valve from The Main PCB
Flue Problem

Telephone Symbol

Boiler Has Locked Out – A Fault Code Will Be Shown On The Digital Display

Warning Symbol

This Symbol will flash when a lockout fault occurs, and a Fault Code will be shown on the Digital Display
This Symbol will also flash when the system water pressure is too low, and the low pressure figure will be shown on the Digital Display

Available Literature

Installation and Servicing Manual