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I even tried making up a quick window family out of door family template which inserted OK. I posted on the Autodesk DG and got a suggestion that this would be a parameter issue. Then after changing the wall type it became obvious what I had overlooked - cumulative parameters in the window family exceeding wall core thickness
If the frame offset plus frame thickness exceed the call core thickness then it will throw the error. So during preliminarily modelling in thin walltypes (eg SIPPS panel, timber framing etc) and using convenient out of the box window types set the offset and frame to something that fits within the wall type core params
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