Immergas INTEC 30 System External, INTEC 12 System External, INTEC 30 COMBI EXTERNAL Installation Instructions Manual

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Page 1

User Installation

Instruction Manual

INTEC 12-30

SYSTEM

EXTERNAL

Wall mounted

heating only boiler

Page 2

Our compliments for having chosen a top-quality Hunt Heating/Immergas product, able to assure well-being and safety for a long period of time, you can also count on a qualied aer-sales service, prepared and updated to guarantee constant eciency of your boiler. Read the following pages carefully; you will be able to draw useful suggestions regarding the correct use of the appliance, the respect of which, will conrm your satisfaction for our product. For any interventions or routine maintenance contact Hunt Heating for Authorised Service Personal.

Dear Client,

All Immergas products are protected with packaging suitable for transport.

e material must be stored in dry environments and protected from bad weather.

e instruction book is an integral and essential part of the product and must be consigned to the new user also in the case of transfer or succession of ownership.

It must be stored with care and consulted carefully, as all of the warnings provide important safety indications for installation, use and maintenance stages.

is instruction booklet contains technical information on how installing Immergas boilers. For other issues related to installation of boilers (i.e.: safety in work sites, environment protection, injury prevention), comply with the laws in force and technical standards.

In compliance with legislation, the systems must be designed by qualied professionals, within the dimensional limits established by the Law. Installation and maintenance must be performed in compliance with the regulations in force, according to the manufacturer’s instructions and by qualied professionals.

Improper installation or assembly of Immergas appliance and/or components, accessories, kit and devices can cause unexpected problems to persons, animals and objects. Read the provided product instructions carefully in order to install the product correctly.

Maintenance must be carried out by Authorised Service Personal.

e appliance must only be destined for the use for which it has been expressly declared. Any other use will be considered improper and therefore potentially dangerous.

If errors occur during installation, operation and maintenance, due to non compliance with technical laws in force, standards or instructions contained in this book (or however supplied by the manufacturer), the manufacturer is excluded from any contractual and extra-contractual liability for any damages and the appliance warranty is invalidated.

e Immergas range of high eciency boilers are wall mounted, fan assisted, room-sealed boilers. e burner is lit electronically and the heat output is controlled by a modulating gas valve. e INTEC 12-30 SYSTEM EXTERNAL is a heating only boilers used for hydronic heating. Domestic hot water is an available option (Hunt Heating only) used in conjunction with a stainless steel hot water storage tank, diverter valve and probe. e boilers are supplied with a pump, pressure relief valve, expansion vessel and pressure gauge fully assembled and tested. ey are designed for use with a fully sealed and pressurised central heating system using only Natural Gas and Universal LPG.

General recommendations

Introduction

IMPORTANT It is the law that all gas appliances are authorised persons and registered technician in accordance with local laws and AS/NZS 5601 and AS/NZS 3500 A.

is appliance meets the requirements of IPX5D. Failure to install this appliance correctly could lead to prosecution. It is in your own interest and that of safety to ensure that the law is complied with.

Manufacturerís instructions must NOT be taken in anyway as over-riding statutory obligations.

WARNINGS

- Do not spray aerosols in the vicinity of this appliance while it is in operation;

- do not use or store ammable materials in or near this appliance;

- do not place articles on or against this appliance;

- do not modify this appliance.

NOTE

e Boilers MUST only be used with Immergas Condensing ue components. THIS BOILER IS NOT SUITABLE FOR POOL OR SPA HEATER UNLESS CONNECTED TO A SUITABLE APPROVED HEAT EXCHANGER. Hydronic System (Australia) Pty Ltd PO Box 294 Braeside VIC 3195.

On conformity to AS/NZS 5263.1.2 and AS 3498.

e manufacturer declines all liability due to printing or transcription errors, reserving the right to make any modications to its technical and commercial documents without forewarning.

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INDEX

USER pageINSTALLER page MAINTENANCE TECHNICIAN page

1 Boiler installation ...................................... 4

1.1 Installation recommendations. ................4

1.2 Main dimensions. ......................................5

1.3 Anti-freeze protection. .............................5

1.4 connections. ............................................... 5

1.5

Remote control (CARv2) (Optional). .......6

1.6 External probe (Optional). ......................6

1.7 Immergas ue systems. .............................7

1.8 Installation of intake /

exhaust terminals. .....................................8

1.9 System lling. ............................................. 9

1.10 Gas system start-up. ..................................9

1.11 Boiler start up (ignition). ......................... 9

1.12 Circulation pump. .....................................9

1.13 Boiler components. .................................10

2 Instructions for use and maintenance. .11

2.1 Cleaning and maintenance. ...................11

2.2 General warnings. ................................... 11

2.3 Control panel. ..........................................11

2.4 Using the boiler........................................ 11

2.5 Fault and anomaly signals. ..................... 12

2.6 Information menu. .................................. 14

2.7 Boiler shutdown ......................................14

2.8 Restoring central heating system

pressure. .................................................... 14

2.9 Draining the system. ...............................14

2.10 Anti-freeze protection. ...........................14

2.11 Case cleaning. .......................................... 14

2.12 Decommissioning. ..................................14

3 Boiler commissioning (initial check). ..15

3.1 Hydraulic Diagram. ................................15

3.2 Wiring diagram. ......................................16

3.3 Troubleshooting. .....................................17

3.4 Converting the boiler to other types of

gas. .............................................................17

3.5 Calibration of number of fan revs. ........ 17

3.6 Adjustment of the air-gas ratio. .............17

3.7 Checks following conversion to another

type of gas. ................................................17

3.8 Programming the P.C.B. .........................18

3.9 “Chimney sweep” function. ...................20

3.10 Pump anti-block function. .....................20

3.11 Radiators anti-freeze function. ..............20

3.12 P.C.B. periodical self-check. ................... 20

3.13 Automatic vent function. .......................20

3.14 Casing removal. .......................................21

3.15 Variable heat power. ................................ 22

3.16 Appliance check and maintenance. ......23

3.17 Combustion parameters. ........................23

3.18 Technical data. .........................................24

3.19 Exploded boiler diagram INTEC 12

System External. ......................................25

3.20 Spare part list INTEC 12 System

External. ................................................... 26

3.21 Exploded boiler diagram INTEC 30

System External. ......................................27

3.22 Spare part list INTEC 30 System

External. ................................................... 28

3.23 Boiler registration. ..................................29

3.24 Commissioning boiler check list. ..........30

3.25 Service records. ........................................31

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BOILER

INSTALLATION

1.1 INSTALLATION RECOMMENDATIONS.

e INTEC 12-30 SYSTEM EXTERNAL boiler has been designed uniquely for wall-installation, for the heating of rooms for domestic use.

- installation (according to the legislation and

technical standards in force);

- maintenance operations (including those

scheduled, periodical, ordinary and special);

INSTALLERUSER

- removal (to the outdoors in a place suitable

for loading and transporting appliances and components) as well as any replacement with equivalent appliances and/or components.

e wall surface must be smooth, without any protrusions or recesses enabling access to the rear part. ey are not designed to be installed on plinths or oors (Fig. 1-1). By varying the type of installation the classication of the boiler also varies, precisely:

- Type C boiler Uses concentric or Coaxial pipes

systems Hunt Heating supplies the correct ue for this application.

Only professionally heating/plumbing technicians are authorised to install Immergas gas appliances.

Installation must be carried out according to regulation standards AS/NZS 5601 or Local Authority laws.

Installation of the INTEC 12-30 SYSTEM EXTERNAL boiler when powered by Universal LPG must also comply with the rules regarding gases with a greater density and be installed to meet all local and AS/NZS 5601 LAWS. Before installing the appliance, ensure that it is delivered in perfect condition; if in doubt,

contact the supplier immediately. Packing materials (staples, nails, plastic bags, polystyrene foam, etc.) constitute a hazard and must be kept out of the reach of children. Leave adequate space above the boiler for possible water and ue removal connections. Keep all ammable objects away from the appliance (paper, rags, plastic, polystyrene, etc.). Do not place household appliances underneath the boiler as they could be damaged if the safety valve intervenes (if not conveyed away by a draining funnel), or if there are leaks from the connections; on the contrary, the manufacturer cannot be held responsible for any damage caused to the household appliances. In the event of malfunctions, faults or incorrect operation, turn the appliance o immediately and contact a qualied technician (e.g. Hunt Heating Service Dept which has specically trained sta and original spare parts). Do not attempt to modify or repair the appliance alone. Failure to comply with the above implies personal responsibility and invalidates the warranty.

Installation Standards:

- Installations MUST comply with AS/NZS 5601 and Local laws. Use AS/NZS 5601 as a guide for specic locations see below.

- Installation is prohibited on the vertical projection of the cooking surface.

- Installation is also prohibited in places/ environments that constitute common parts of oce condominiums such as stairs, cellars, entrance halls, attics, los, escape routes, etc. if they are not located inside technical compartments under the responsibility of each individual building and only accessible to the user (for the features of the technical compartments, see the technical standards in force).

Attention: wall mounting of the boiler must guarantee stable and ecient support for the boiler.

Use the bracket supplied as standard, xing it with proper plugs according to the wall type. e installer is responsible for the choose of the correct plugs, according to the technical standard. Place the supplied bracket, following the indications reported on drawing 1-3 preferring the holes indicated in the before mentioned draw.

N.B.: to fix the bracket we suggest to use hexagon screw or countersunk screw for plug.

ese boilers are used to heat water to below boiling temperature in atmospheric pressure. ey must be attached to a heating system suitable for their capacity and voltage.

YES NO

1-1

Flue terminal positions

Use as a guide only. Refer to AS/NZS 5601 or gas tting rules for specic location.

MAINTENANCE TECHNICIAN

Flue terminal positions. Shaded area indicates prohibited area

Ref. Item Min. Clearance mm

Below eaves, balconies and other projections (Appliances over 50MJ/h) 300

From the ground, above a balcony or other surface 300

From a return wall or external wall 300

From a gas meter 1000

From an electricity meter or fusebox/breaker panel 500

From a drain pipe or soil pipe 75

Horizontally from any building structure or obstruction facing a ue terminal 500

From any other ue terminal, cowl or combustion air intake 300

Horizontally from any opening window, door, non-mechanical air inlet or other opening into a building with the exception of sub-oor ventilation 300

From a mechanical air inlet including a spa blower 1000

Vertically below an opening window, non-mechanical air inlet or any other opening into a building with the exception of sub-oor ventilation 500

• e location of the ue terminal must comply with the clearances shown on this page.

If you are unsure about clearances not indicated here, in general refer to AS/NZS 5601 or your local autority.

D - Door

I - Mechanical air inlet M - Gas meter T - Flue Terminal W - Window

1-2

• All measurements are the minimum clearances required.

• Terminals must be positioned so to aviod combustion products entering the building.

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1.2 MAIN DIMENSIONS.

Height

(mm)

990 470 310

CONNECTIONS

CORD INLET GAS SYSTEM

C G R F

1/2” 3/4” 3/4” 3/4”

1.3 ANTIFREEZE PROTECTION. Minimum temperature -5°C. e boiler comes

standard with an anti-freeze function that activates the pump and burner when the system water temperature in the boiler falls below 4°C. e anti-freeze function is only guaranteed if:

- the boiler is correctly connected to gas and electricity power supply circuits;

- the boiler is powered constantly;

- the boiler is not in no ignition block (Par. 2.5);

- the boiler essential components are not faulty.

In these conditions the boiler is protected against freezing to an env ironmental temperature of -5°C.

Minimum temperature -15°C. If the boiler is installed in a place where the temperature falls below -5°C and in the event there is no gas, or the boiler goes into ignition block, the appliance may freeze.

To prevent the risk of freezing follow the instructions below:

- Protect the central heating circuit from freezing by introducing a good quality antifreeze liquid (specically for central heating systems), (Fernox), carefully following the manufacturer's instructions regarding the percentage necessary with respect to the

Key: G - Gas supply (not supplied as standard) R - Return - CH F - Flow - CH SC - Condensate drain (supplied as standard)

(minimum internal diameter Ø13 mm)

C - Cold ll

Width

(mm)

Depth (mm)

minimum temperature required for preserving the system.

The boilers is made from materials that are resistant to ethylene and propylene glycol-based anti-freeze liquids.

For life and possible disposal, follow the supplier's instructions.

- Protect the condensate drain trap and circuit board against freezing by using an accessory that is supplied on request (anti-freeze kit) comprising two electric heating elements, the relevant cables and a control thermostat (carefully read the installation instructions contained in the accessory kit pack).

Boiler anti-freeze protection is thus ensured only if:

- the boiler is correctly connected to gas and electricity power supply circuits and powered;

- the anti-freezing kit components are ecient.

In these conditions the boiler is protected against freezing to temperature of -15°C.

e warranty does not cover damage due to interruption of the electrical power supply and failure to comply with that stated on the previous page.

N.B.: if the boiler is installed in places where the temperature falls below 0°C the domestic water and heating attachment pipes must be insulated.

1-3

1.4 CONNECTIONS. Gas connection.

Our boilers are designed to operate with NG and Universal LPG. Supply pipes must be sized correctly to relevant gas codes. Before connecting the gas line, carefully clean inside all the supply pipes to remove any residue that could impair boiler eciency. Also make sure the gas corresponds to that for which the boiler is prepared (see boiler data-plate). If dierent, the appliance must be converted for operation with the other type of gas (see converting appliance for other gas types). e dynamic gas supply (NG or Universal LPG) pressure must also be checked according to the type used in the boiler, which must be in compliance, as insufficient levels can reduce boiler output and cause malfunctions. Ensure correct gas isolation valves connection. e gas supply pipe must be suitably dimensioned according to current regulations in order to guarantee correct gas flow to the burner in conditions of maximum boiler.

N.B.: there is a special adhesive label inside the built-in frame displaying the layout of the boiler connections.

Fuel gas quality. The appliance has been designed to operate with gas free of impurities; otherwise it is advisable to fit special filters upstream from the appliance to restore the purity of the gas.

Cold Water connection. Attention: Filling the system, Hunt Heating

recommends the use of Auto fill valves sold as an optional extra. Once satisfactory system pressure is achieved, Auto ll valve MUST BE TURNED OFF.

Attention: in order not to void the warranty before making the boiler connections, carefully clean the heating system on the primary heat exchanger (pipes, radiators, etc.) with special cleaning products (Fernox) to remove any deposits that could compromise correct boiler operation.

Chemical treatment of the heating system water is required, in compliance with the technical standards in force, in order to protect the system and the appliance from deposits (e.g., lime scale), slurry or other hazardous deposits. Products like Fernox are suitable for this appliacation. Use of backow devices are maditory when using chemicals/water treatments or alternatively, ensure physical air break.

Heating Water connections must be made using approved valves this helps with maintenance and servicing. Hunt Heating can provide valves as optional extras.

e boiler safety valve outlet must be connected to a Tun Dish or Directly to a suitable overow outlet.

INSTALLERUSER

MAINTENANCE TECHNICIAN

Page 6

Condensate drain. To drain the condensate produced by the appliance, it is necessary to connect to the sewer system by means of acid condensate resistant pipes i.e. p.v.c. having an internal diameter of at least 13 mm. e system connecting the appliance to the drainage system must be carried out in such a way as to prevent freezing of the liquid contained. Connections must comply with national and local regulations on discharging to waste waters, condensate must not discharge to storm water. Pipes must be on gradient to drain.

INSTALLERUSER

N.B.: ll the trap with water before operating the boiler.

Electrical connection: The “INTEC 12-30 SYSTEM EXTERNAL” boiler has an IPX5D protection rating for the entire appliance. Electrical safety of the appliance is reached only when it is correctly connected to an ecient earthing system as specied by current safety standards.

Attention: Immergas/Hunt Heating declines any responsibility for damage or physical injury caused by failure to connect the boiler to an ecient earth system or failure to comply with the reference standards.

Also ensure that the electrical installation corresponds to maximum absorbed power specifications as shown on the boiler dataplate. The boilers come complete with a 1.5 metre power cable that includes an Australian electrowelded plug. The plug is of type I, compliant with standard AS 3112. e power cable must be connected to a 240V ±10% / 50Hz mains respecting L-N polarity and the earth connection

. When replacing the power supply cable, contact a qualied technician (e.g. Hunt Heating Service Dept) (Fig. 1-4). In the event of mains fuses replacement on the connection board, use 3.15A fast fuses. For the main power supply to the appliance, never use adapters, multiple sockets or extension leads.

Note: If the condensate cannot be on a gradient and terminate to drain, then a suitable condensate neutraliser must be used (available for purchase from Hunt Heating).

1.5

REMOTE CONTROL CARV2 OPTIONAL.

e boiler is prepared for the application remote control CAR (Fig. 1-5). Immergas remote control CAR

, which is available as optional kit.

is connected with 2 wires only. Carefully read the user and assembly instructions contained in the accessory kit.

• In addition to the functions described in the

previous point, the CAR panel

enables the user to control all the important information regarding operation of the appliance and the heating system with the opportunity of easily intervening on the previously set parameters without having to go to the place where the appliance is installed. e CAR

panel is equipped with self-diagnosis to display any boiler functioning abnormalities. The climate chrono-thermostat incorporated into the remote panel enables the system flow temperature to be adjusted to the actual needs of the room being heated, in order to obtain the desired room temperature with extreme precision and therefore with evident saving in running costs. e chrono-thermostat is fed directly by the boiler by means of the same 2 wires used for the transmission of data between boiler and chrono-thermostat.

CAR

(Optional). e operations described

below must be performed aer having removed the voltage from the appliance. Any CARV2 must be connected by means of terminals IN+ and IN- (on the CAR

terminal plate), respecting polarity at boiler PCB, where IN+ connects to terminal 44 and IN- connects to terminal 41 (See Fig. 1-6).

Attention: if the Comando Amico Remoto

(CARV2) remote control is used, arrange two separate lines in compliance with current regulations regarding electrical systems. No boiler pipes must ever be used to earth the electric system or telephone lines. Ensure elimination of this risk before making the boiler electrical connections (ALL

ELECTRICAL CONNECTION MUST MEET ALL LOCAL REGULATIONS).

1.6 EXTERNAL PROBE OPTIONAL.

e boiler is prepared for the application of the external probe (Fig. 1-7), which is available as an optional kit. Refer to the relative instruction sheet for positioning of the external probe. The probe can be connected directly to the boiler electrical system and allows the max. system ow temperature to be automatically decreased when the external temperature increases, in order to adjust the heat supplied to the system according to the change in external temperature. e external probe always operates when connected, regardless of the presence or type of room chrono-thermostat used and can work in combination with Immergas chronothermostats. e correlation between system flow temperature and external temperature is determined by the position of the selector switch on the boiler control panel according to the curves shown in the diagram (Fig. 1-8). e electric connection of the external probe must be made on clamps 38 and 39 on the boiler P.C.B. (Fig. 3-2).

NB: Thermostat connections if using own after market thermostat, after removing manufacturers link, connect to terminals 40 and 41 (Fig. 3-2).

MAINTENANCE TECHNICIAN

POWER SUPPLY CABLE

1-4

1-7

1-5 1-6

Position of the central heating temperature user adjustment

1-8

Page 7

1.7 IMMERGAS FLUE SYSTEMS.

Immergas supplies various solutions separately from the boilers regarding the installation of air intake terminals and ue extraction, which are fundamental for boiler operation.

Attention: the boiler must be installed exclusively with an original Immergas “Green Range” air intake and fume extraction system in plastic, as envisioned by the Standards in force. is system can be identied by an identification mark and special distinctive marking bearing the note: “only for condensing b oi l er s ”.

• Resistance factors and equivalent lengths. Each ue component has a Resistance Factor based on experimental tests and specified in the table below. e Resistance Factor for individual components is independent from the type of boiler on which it is installed and has a dimensionless size. It is however, conditioned by the temperature of the uids that pass through the pipe and therefore, varies according to applications for air intake or ue exhaust. Each single component has a resistance corresponding to a certain length in metres of pipe of the same diameter; the so-called equivalent length, obtained from the ration between the relative Resistance Factors.

All boilers have an experimentally obtainable maximum Resistance Factor equal to 100.

The maximum Resistance Factor allowed corresponds to the resistance encountered with the maximum allowed pipe length for each type of Terminal Kit. is information allows calculations to be made to verify the possibility of setting up various ue congurations.

Positioning of the gaskets (black) for “green range” ue extraction systems. Position the

gasket correctly (for bends and extensions) :

- gasket with notches, to use for bends;

- gasket without notches, to use for extensions.

N.B.: if component lubrication (already carried out by the manufacturer) is not sucient, remove the residual lubricant using a dry cloth, then to ease tting spread the elements with common or industrial talc.

With ue gaskets installed correctly, gently push ue components together fully.

N.B.: considerations need to be made when sighting/terminating ue extraction system as an element of plumage will occur when boiler is in operation.

N.B.: for safety purposes, do not obstruct the boiler intake-exhaust terminal, even temporarily.

INSTALLERUSER

MAINTENANCE TECHNICIAN

Page 8

1.8 INSTALLATION OF INTAKE /

EXHAUST TERMINALS.

• Type C conguration, sealed chamber and fan assisted.

Horizontal intake - exhaust terminal Ø60/100 (supplied as standard). Assembly (Fig. 1-9):

install the gaskets (1) and (2) in the concentric ange (already installed). Couple the bend (3) with the concentric ange up to the stop aer having checked that the gaskets are tted (4) and (5) in the female end. Mount the casing front referring to Paragr. 3.14.

INSTALLERUSER

Couple the terminal pipe (8) with the male end (smooth) into the female end (with lip seals) of the bend (3) up to the stop, making sure that the external wall sealing plate (7) has been tted and checking it is on the casing front and gasket (6); this will ensure proper sealing and joining of the elements.

N.B.: Flue conguration supplied standard with all INTEC external boilers.

MAINTENANCE TECHNICIAN

Components: Concentric ange intake gasket (1) Concentric ange exhaust gasket (2) 90° concentric bend (3) 90° concentric bend exhaust gasket (4) 90° concentric bend intake gasket (5) Gasket (6) External wall sealing plate (7) Concentric intake/exhaust terminal Ø 60/100 (8)

Flue kit complete 60/100 Australia code: 3.026007

1-9

Page 9

1.9 SYSTEM FILLING.

Once the boiler is connected, proceed with system lling through the arranged lling valve, which can be connected to the return pipe system and as close as possible to the boiler (Fig. 1-11), or ideally via connection ‘C’. Filling is performed at low speed to ensure release of air bubbles in the water via the boiler and heating system vents. e boiler has a built-in automatic venting valve on the circulator. Check if the cap is loose. Open the radiator air vent valves. Close radiator vent valves when only water escapes from them. Close the lling valve when the boiler manometer indicates approx. 1.2 bar.

N.B.: during these operations, turn on the circulating pump at intervals by means of the main selector switch on the control panel. Vent the

circulation pump by loosening the front cap and keeping the motor running. Only open for a few seconds at a time.

In presence of the automatic lling, the auto ll valve must necessarily be isolated aer system is pressurized.

1.10 GAS SYSTEM STARTUP.

To start up the system, make reference to the Standard: is divides the systems and therefore the start-up operations into three categories: new systems, modied systems, re-activated systems. In particular, for new gas systems:

- open windows and doors;

- avoid presence of sparks or naked ames;

- bleed all air from pipelines;

- check that the internal system is properly sealed according to specications.

1.11 BOILER START UP IGNITION.

For first ignition, the following must be performed:

- check that the internal system is properly sealed according to specications;

- ensure that the type of gas used corresponds to boiler settings;

- switch the boiler on and ensure correct ignition;

- make sure that the gas ow rate and relevant pressure values comply with those given in the manual;

- ensure that the safety device is engaged in the event of gas supply failure and check activation time;

- check activation of the master switch located upstream from the boiler and in the boiler;

- check that the intake/exhaust concentric terminal (if tted) is not blocked.

e boiler must not be started up even if only one of the checks should be negative.

N.B.: the boiler preliminary check must be carried out by a qualied technician. e conventional boiler warranty is valid as of the date of testing if not commissioned by a qualied technician.

1.12 CIRCULATION PUMP.

e “INTEC 12-30 SYSTEM EXTERNAL” series boilers are supplied with a built-in circulation pump with 3-position electric speed control. e boiler does not operate correctly with the circulation pump on speed one. To ensure optimal boiler operation, in the case of new system it is recommended to use the pump at maximum speed, position 3.

Pump release. If, aer a prolonged period of inactivity, the circulation pump is blocked, unscrew the front cap and turn the motor sha using a screwdriver. Take great care during this operation to avoid damage to the motor.

INSTALLERUSER

Head available to the system (INTEC 12).

Head (kPa)

Head available to the system (INTEC 30).

Flow rate (l/h)

Head (m H

A = Head available to the system at maxi-

mum speed with by-pass closed.

B = Head available to the system at maxi-

mum speed with by-pass open.

C = Head available to the system at second

speed with by-pass closed.

D = Head available to the system at second

speed with by-pass open.

1-10

MAINTENANCE TECHNICIAN

Head (kPa)

Flow rate (l/h)

Head (m H

Page 10

1.13 BOILER COMPONENTS.

INSTALLERUSER

MAINTENANCE TECHNICIAN

Key: 1 - Storage tank unit delivery return by-pass 2 - Gas valve 3 - Condensate drain trap 4 - System pressure switch 5 - Flow probe 6 - Safety thermostat 7 - Gas nozzle 8 - Venturi 9 - Detection electrode 10 - Condensation module 11 - System expansion vessel 12 - Flue probe 13 - Manual air vent valve 14 - Sample points (air A) - (ue gases F)

G - Gas supply R - Return F - Flow C - Cold ll

15 - Negative signal pressure point 16 - Positive signal pressure point 17 - Heat exchanger safety thermofuse 18 - Burner 19 - Ignition electrode 20 - Air intake pipe 21 - Igniter 22 - Fan 23 - Air vent valve 24 - Return probe 25 - Boiler pump 26 - 3 bar safety valve 27 - 3-way valve (motorised) 28 - By-pass 29 - System draining valve

1-11

Page 11

INSTRUCTIONS FOR USE

AND MAINTENANCE.

2.1 CLEANING AND MAINTENANCE. Attention: the boiler and heating systems must

undergo periodical maintenance, combustion and energy eciency checks in compliance with AS/NZS 5601, by a qualied licensed operative. this insure that optimal safety performance and operation of the boiler remains unchanged over time. We recommend your appliance is serviced every 24 months (see Par. 3.16).

2.2 GENERAL WARNINGS.

Use of the boiler by unskilled persons or children is strictly prohibited. If temporary shutdown of the boiler is required, proceed as follows:

2.3 CONTROL PANEL.

2-1

a) drain the heating system if anti-freeze is not

used;

b) shut-o all electrical, water and gas supplies.

In the case of work or maintenance to structures located in the vicinity of ducting or devices for ue extraction and relative accessories, switch o the appliance and on completion of operations ensure that a qualied licensed operative checks eciency of the ducting or other devices. Never clean the appliance or connected parts with easily ammable substances. Never leave containers or ammable substances in the same environment as the appliance.

• Attention: the use of components involving use

of electrical power requires some fundamental rules to be observed:

- do not touch the appliance with wet or moist parts of the body; do not touch it when barefoot;

- the appliance power cable must not be replaced by the user;

- in the event of damage to the cable, switch off the appliance and contact a qualified technician;

- if the appliance is not to be used for a certain period, disconnect the main power switch.

INSTALLERUSER

Key: 1 - O/Stand-by/On Button 2 - Summer/Winter Button 3 - Reset button 4 - Information buttons 5 - Domestic hot water temperatureselector

switch

6 - Central heating water temperature selector

switch

7 - Boiler manometer

To access the control panel, remove the protection panel (6) from the casing front by unscrewing the bolt (7) and removing it as shown in Fig. 3-4a.

2.4 USING THE BOILER.

Before ignition make sure the heating system is lled with water and that the manometer (7) indicates a pressure of 1 ÷ 1.2 bar (Fig. 2-1).

- Open the gas cock upstream from the boiler.

- Press the button (1) until the display switches on. At this point, the boiler goes to the state previous to switch-o.

- If the boiler is in stand-by, press the button (1) again to activate it. If this is not the case, go to the next point.

- Press button (2) in sequence and take the boiler

to summer (

) or winter ( ) position.

8 - DHW production phase functioning active 9 - Boiler in block does not require release via

“RESET” button

10 - Flame presence symbol and relative power

scale 11 - Functioning in summer mode 12 - Functioning in winter mode 13 - Room central heating active phase functio-

ning

• Summer (

functions only to produce the DHW, the temperature is set via the selector (5) and the relative temperature is shown on the display via the indicator (14).

• Winter (

both for producing domestic hot water and heating the environment. e temperature of the DHW is always regulated via the selector (5), the heating temperature is regulated via selector (6) and the relative temperature is shown on the display via the indicator (14).

From this moment the boiler functions automatically. With no demand for heat (heating or domestic hot water production) the boiler goes to “standby” function, equivalent to the boiler being powered without presence of ame.

): in this mode the boiler

): in this mode the boiler functions

14 - Temperature indicator, boiler info and

error codes 15 - Boiler in Stand-by mode 16 - Presence of external connected devices 17 - Solar function active 18 - Functioning with external temperature

probe active (optional) 19 - Boiler connected to remote control V2

(optional) 20 - Not used on this model

Each time the burner ignites, the relative ame present symbol is displayed (10) with relative power scale.

• Operation with Comando Amico Remoto

remote control

is connected, the ( ) symbol will

CAR appear on the display. e boiler regulation parameters can be set via the CARV2 control panel and the reset button (3) remains active on the boiler control panel, along with the switch-o button (1) (“o ” mode only) and the display where the functioning state is shown

Important: if the boiler is put into “off ”

mode, the “ERR>CM” connection error symbol will appear on the CAR however powered constantly so as not to loose memorised programs.

(CARV2) (Optional). If the

. e CAR V2is

MAINTENANCE TECHNICIAN

Page 12

• Solar functioning mode ( ). is function

is activated automatically if the boiler detects a probe on the DHW inlet (optional) or if the “Solar ignition delay” parameter is more than 0 seconds.

During a withdrawal, if the outlet water is

hot enough, the boiler does not switch on, the DHW withdrawal symbol (

on the display along with the ashing solar

function symbol (

INSTALLERUSER

When the water supplied by the solar system

is at a temperature lower than that at which the boiler is set, the boiler switches on. At this point, the solar function symbol will stay on without ashing.

• Functioning with optional external probe

(

). In the case of a system with optional

external probe, the boiler ow temperature for room central heating is managed by the external probe depending on the external temperature measured (Par. 1.6). The flow temperature can be modied by selecting the functioning curve via the selector switch (6) (or on the CARV2 control panel, if connected to the boiler) selecting a value from “0 to 9”.

) appears

With external probe present, the relative

symbol (18) will appear on the display. In the central heating phase, if the temperature of the water contained in the system is sucient to heat the radiators, the boiler can only function with the activation of the pump.

• “Stand-by” mode. Press button (1) in

succession until the ( e boiler remains inactive from this moment and the anti-freeze function, pump anti-block function and 3-way and signalling of any anomalies is guaranteed.

N.B.: in these conditions the boiler is

considered still powered.

• “O” mode. By holding the button (1) down

for 8 seconds, the display switches-o and the boiler is o completely. e safety functions are not guaranteed in this mode.

N.B.: in these conditions the boiler is considered

still live even if there are no functions active.

• “Automatic vent” mode. Every time power is

supplied to the boiler. the system automatic vent function is activated (duration 8 minutes). This function is displayed via countdown signalled by the indicator (14). During this period the DHW and CH functions are not active.

The “automatic vent” can be annulled by

pressing the “reset” button (3).

) symbol appears.

• Display functioning. e display lights up

during the use of the control panel, aer 15 seconds inactivity, the brightness drops until just the active symbols are displayed. The lighting mode can be varied via parameter t3 in the circuit board customisation menu.

2.5 FAULT AND ANOMALY SIGNALS.

e INTEC 12-30 SYSTEM EXTERNAL boiler signals any anomalies using a code shown on the boiler display (14) according to the following table. On the CAR by means of the same numeric code represented according to the following example (e.g. CARV2 = Exx).

, the error code will be displayed

Error Code

Anomaly signalled Cause Boiler status / Solution

In the event of request of room central heating or domestic hot water

01 No ignition block

Safety thermostat

block (overheating)

Flue safety thermo-

stat block

Contacts resistance

block

05 Flow probe anomaly e board detects an anomaly on the ow NTC probe. e boiler does not start (1).

Domestic hot water

probe anomaly

production, the boiler does not switch on within the preset time. Upon appliance commissioning or aer extended downtime, it may be necessary to eliminate the block.

During normal operation, if a fault causes excessive overheating internally, the boiler goes into overheating block.

During normal operation, if a fault causes excessive ue gas overheating, the boiler blocks

e P.C.B. detects an anomaly on the gas valve supply. Check the connection. (the anomaly is detected and displayed only in the event of a request).

e board detects an anomaly on the domestic hot water NTC probe.

MAINTENANCE TECHNICIAN

Maximum N° of

reset

Insufficient system

pressure

15 Conguration error

16 Fan anomaly is occurs if the fan has a mechanical or electrical fault. Press the Reset button (1).

20 Parasite ame block

Return probe anom-

aly

(1) If the shutdown or fault persists, contact an authorised company (e.g. Authorised Technical Aer-Sales Service).

Number of allowed resets that have already performed.

Water pressure inside the central heating circuit that is sucient to guarantee the correct operation of the boiler is not detected.

If the board detects an anomaly or incongruity on the electric wiring, the boiler will not start.

is occurs in the event of a leak on the detection circuit or anomaly in the ame control unit.

e board detects an anomaly on the return NTC probe e boiler does not start (1).

Press the Reset button (1).

e boiler does not start (1).

In this case the boiler continues to produce domestic hot water but not with optimal performance. Moreover, the antifreeze function (1) is restrained.

Attention: the anomaly can be reset 5 times consecutively, aer which the function in inhibited for at least one hour. One attempt is gained every hour for a maximum of 5 attempts. By switching the appliance on and o the 5 attempts are re-acquired.

Check on the boiler pressure gauge (1) that the system pressure is between 1÷1.2 bar and restore the correct pressure if necessary.

If normal conditions are restored the boiler restarts without having to be reset. Check that the boiler is congured correctly (1).

Press the Reset button (1).

Page 13

Error Code

(1) If the shutdown or fault persists, contact an authorised company (e.g. Authorised Technical Aer-Sales Service).

Anomaly signalled Cause Boiler status / Solution

Push button control

panel anomaly

Block due to ue gas

temperature gradient intervention

Insucient circula-

tion

29 Flue probe anomaly

Loss of remote con-

trol communication

IMG Bus communi-

cation loss

Low power supply

voltage

38 Loss of ame signal

Block due to loss

of continue flame signal

Block for exceeding the maximum accu-

mulated time, close gas valve opening

45 High T

Low temperature

safety thermostat (optional)

Burner power limi-

tation

High temperature

block on return probe

e board detects an anomaly on the pushbutton panel

If the board detects a rapid increase in ue gas temperature probably due to a blocked circulating pump or lack of water in the heat exchanger, the boiler shuts down due to the ue gas temperature gradient trip.

is occurs if there is overheating in the boiler due to insucient water circulating in the primary circuit; the causes can be:

- low system circulation; check that no shut-o devices are closed on the heating circuit and that the system is free of air (deaerated);

- pump blocked; free the pump.

If the board detects an anomaly on the ue gas probe the boiler will not start

is occurs 1 minute aer communication is lost between the boiler and the remote control.

Communication between the various components is interrupted due to an anomaly on the boiler control unit, on the zone control unit or on the IMG Bus.

is occurs when the power supply voltage is lower than the allowed limits for the correct boiler operation.

is occurs when the boiler is ignited correctly and the burner ame switches o unexpectedly; a new ignition attempt is performed and if normal conditions are restored, the boiler does not need to be reset (this fault can be checked in the list of errors in the “Information” menu only).

is occurs if the ''Flame signal loss'' error occurs many times in a row within a preset period (38).

is occurs if the gas valve remains open for longer than required for normal operation, without the boiler switching on.

If the board detects a sudden and unexpected rise in ΔT between the system ow probe and return probe, the boiler limits the burner output to prevent damaging the condensing module; when the correct ΔT has been restored, the boiler returns to normal operation.

During normal operation, if an anomaly causes excessive overheating of the ow temperature in low temperature conditions, the boiler blocks.

Should ue high temperature be detected, the boiler reduces power supplied so as not to damage it.

is occurs when the heat exchanger return circuit reaches too high of a temperature.

If normal conditions are restored the boiler restarts without having to be reset (1).

Press the Reset button (1).

e boiler does not start (1).

Power cycle the boiler. If the Remote Control is still not detected on re-starting the boiler will switch to local operating mode, i.e. using the controls on the control panel (1).

e boiler does not satisfy the room heating requests (1).

If normal conditions are restored the boiler restarts without having to be reset (1).

Press the Reset button, before restarting, the boiler will run a post-ventilation cycle (1).

Press the Reset button (1).

Make sure there is water circulating in the boiler, that the pump is congured according to system requirements and that the return probe works properly (1).

In this case, aer suitable cooling, it is possible to reset the thermostat (see relative instructions sheet) (1).

(1).

Make sure that water circulates properly in the boiler and that the three-way valve works properly. To eliminate it, the Reset button (C) must be pressed (1).

INSTALLERUSER

MAINTENANCE TECHNICIAN

Page 14

2.6 INFORMATION MENU.

By pressing the “Info” button (4), the “Information menu” is activated, which lists boiler functioning information.

Press the “Info” button (4) to scroll the various information.

To exit the menu, press the “Info” button (4) up to the end of the list, or by pressing the “Reset” button (3) or by waiting for 15 minutes.

With the menu active, the indicator (14) will alternately show the indication of the parameter via the letter “d” plus the number of the parameter that is being displayed and the value of the parameter itself.

Parameter

d1 Displays the ame signal (uA x 10 approximate)

INSTALLERUSER

d2 Displays the primary exchanger output instant heating ow temperature d3 Displays the instant output temperature from the DHW exchanger d4 Displays the values set for central heating set d5 Displays the values set for DHW set

Displays the external temperature (if external probe present)

If the temperature is below zero, the value is displayed ashing. d7 Display the temperature of the inlet DHW (with DHW inlet probe present) d8 Display the temperature of the return probe.

Displays the list of the last ve anomalies. d9

(to scroll the list, turn the CH temperature selector (6))

2.7 BOILER SHUTDOWN

Switch the boiler o by pressing the “ disconnect the power supply outside of the boiler and close the gas cock upstream of the appliance. Never leave the boiler switched on if le unused for prolonged periods.

2.8 RESTORING CENTRAL HEATING SYSTEM PRESSURE.

Periodically check the system water pressure. e boiler pressure gauge should read a pressure between 1 and 1.2 bar.

If the pressure falls below 1 bar (with the circuit cold) restore normal pressure via the ll valve.

N.B.: close the cock aer the operation. If pressure values reach around 3 bar the safety valve may be activated.

In the event of frequent pressure drops, contact original installer or qualied licensed operative for assistance to eliminate possible system leakage.

” button,

Description

2.9 DRAINING THE SYSTEM.

To drain the boiler, use the special system draining valve (Fig. 1-11, Part. 29). Before draining, ensure that the system lling valve is closed.

2.10 ANTIFREEZE PROTECTION.

The boiler has an anti-freeze function that switches on automatically when the temperature falls below 4°C (standard protection to minimum temperature of -5°C). All information relative to the anti-freeze protection is stated in Par. 1.3. In order to guarantee the integrity of the appliance and the domestic hot water heating system in zones where the temperature falls below zero, we recommend the central heating system is protected using anti-freeze liquid and installation of the Immergas Anti-freeze Kit in the boiler. In the case of prolonged inactivity (second case), we also recommend that:

- the electric power supply is disconnected;

- the heating circuit and boiler domestic water circuit must be drained. In systems that are drained frequently, filling must be carried out with suitably treated water to eliminate hardness that can cause lime-scale.

2.11 CASE CLEANING.

Use damp cloths and neutral detergent to clean the boiler casing. Never use abrasive or powder detergents.

2.12 DECOMMISSIONING.

In the event of permanent shutdown of the boiler, contact an authorised company for the procedures and ensure that the electrical, water and gas supply lines are shut off and disconnected.

MAINTENANCE TECHNICIAN

Page 15

BOILER COMMISSIONING

INITIAL CHECK.

When commissioning the boiler, ensure the appliance checklist, located at the rear of this instruction booklet is completed.

To commission the boiler:

- ensure that the type of gas used corresponds to boiler settings recorded on the appliance data plate;

- check connection to a 230V-50Hz power mains, correct L-N polarity and the earthing connection;

3.1 HYDRAULIC DIAGRAM.

Key: 1 - Condensate drain trap 2 - 3 bar safety valve 3 - Gas valve 4 - Gas valve outlet pressure point (P3) 5 - Venturi positive sign (P1) 6 - Venturi negative sign (P2) 7 - Air/gas Venturi manifold 8 - Fan 9 - Gas nozzle 10 - Detection electrode 11 - Flue probe 12 - Air intake pipe 13 - Condensation module 14 - Manual air vent valve 15 - Heat exchanger safety thermofuse 16 - Air sample point 17 - ∆p gas pressure point 18 - Flue sample point 19 - Flue hood 20 - Safety thermostat 21 - Flow probe 22 - Ignition electrode 23 - Burner 24 - Condensation module cover 25 - Return probe 26 - System expansion vessel 27 - Air vent valve 28 - Boiler pump 29 - System draining valve 30 - System pressure switch 31 - 3-way valve

32 - By-pass

- switch the boiler on and ensure correct ignition;

- ensure the gas inlet working pressure is correct,

1.1 Kpa (Natural Gas), 2.75 Kpa (LPG);

- check and set expansion vessel air pressure to 1 bar;

- pre ll condense trap with clean water;

- ll and set system pressure to 1.2 bar;

- vent air from boiler and system, also allow automatic vent function to run (Par. 3.13);

- check that the gas maximum and minimum relative pressure values correspond to those given in the handbook, Par. 3.15;

- check activation of the safety device in the event of no gas, as well as the relative activation time;

- check activation of the main switch located upstream from the boiler and in the boiler;

- check that the intake and/or exhaust terminals are not blocked;

- ensure activation of all adjustment devices;

- ensure sealing eciency of hydronic circuits;

- check ventilation and/or aeration of the installation room where provided.

INSTALLERUSER

MAINTENANCE TECHNICIAN

G - Gas supply (not supplied as standard) R - System return (not supplied as standard) F - System delivery (not supplied as standard) SC - Condensate drain (supplied as standard)

(minimum internal diameter Ø13 mm)

C - Cold ll

3-1

Page 16

3.2 WIRING DIAGRAM.

INSTALLERUSER

Key: B1 - Flow probe B2 - Domestic hot water probe (optional) B4 - External probe (optional) B5 - Return probe B10 - Flue probe CARV2 - Comando Amico Remoto Version 2

remote control (optional) E1 - Ignition electrode E2 - Detection electrode E4 - Overheating safety thermostat E13 - Exchanger safety thermofuse G2 - Igniter M1 - Boiler pump M20 - Fan R5 - Trimmer DHW set R6 - Trimmer CH set

R8 - Storage tank inhibition resistor

S2 - Functioning knob S3 - Reset button S5 - System pressure switch S20 - Room thermostat (optional) S31 - On/Stand-by/O button S33 - Info button T2 - Voltage transformer X40 - Room thermostat jumper Y1 - Gas valve

MAINTENANCE TECHNICIAN

Storage tank unit: the boiler is prepared for the connection to a storage tank unit, which must be connected to clamps 36 - 37 of the terminal board, eliminating resistance R8.

CAR

: the boiler is prepared for the application of the CARV2 (which must be connected to clamps 41 and 44 of the terminal board respecting the polarity and eliminating jumper X40.

Room thermostat: the boiler is prepared for the application of the room thermostat (S20), which must be connected to clamps 40 and 41 of the terminal board eliminating jumper X40.

3-2

e connector X5 is used for the connection to the relay P.C.B..

e connector X6 is used for the connection to the personal computer.

e connector X8 is used for soware updating operations.

Page 17

3.3 TROUBLESHOOTING. N.B.: maintenance interventions must be carried

out by a qualied licensed operative. Smell of gas. Caused by leakage from gas circuit pipelines. Check sealing eciency of gas intake circuit.

- Repe ated ignition blocks. is may be caused by:

incorrect electric power supply, check respect of L and N polarity. No gas, check the presence of pressure in the network and that the gas intake pipe is open. Incorrect adjustment of the gas valve, check the correct calibration of the gas valve. Also check that the heat exchanger or trap are not clogged.

- Irregular combustion or noisiness. is may be

caused by: a dirty burner, incorrect combustion parameters, intake-exhaust terminal not correctly installed. Clean the above components and ensure correct installation of the terminal, check correct setting of the gas valve (O-Set setting) and correct percentage of CO gases.

in ue

- Frequent activation of the temperature

overload thermostat. It can depend on the lack of water in the boiler, little water circulation in the system or blocked pump. Check on the manometer that the system pressure is within established limits. Check that the radiator valves are not closed and also the functionality of the pump.

- Siphon blocked. is may be caused by dirt or

combustion products deposited inside. Check, by means of the condensate drain cap, that there are no residues of material blocking the ow of condensate.

- Heat exchanger blocked. is may be caused by

the trap being blocked. Check, by means of the condensate drain cap, that there are no residues of material blocking the ow of condensate.

- Noise due to air in the system. Check opening

of the hood of the special air vent valve (Fig. 1-11). Make sure the system pressure and expansion vessel pre-charge values are within the set limits; e factory-set pressure values of the expansion vessel must be 1.0 bar, the value of system pressure must be between 1 and 1.2 bar.

Boiler conversion must be carried out by a qualied licensed operative. To convert to another type of gas the following operations are required:

- remove the voltage from the appliance;

- replace the nozzle located between the gas pipe and gas/air mixing sleeve (Part. 7 Fig. 1-11), taking care to remove the voltage from the appliance during this operation;

- apply voltage to the appliance;

- calibrate the number of fan revs. (Par. 3.5):

- adjust the correct air/gas ratio (Par. 3.6);

- seal the gas ow rate devices (if adjusted);

- aer completing conversion, apply the sticker, present in the conversion kit, near the dataplate. Using an indelible marker pen, cancel the data relative to the old type of gas.

ese adjustments must be made with reference to the type of gas used, following that given in the table (Par. 3.15).

3.5 CALIBRATION OF NUMBER OF FAN

REVS.

Important: verification and calibration is

necessary, in the case of transformation to other types of gas, in the extraordinary maintenance phase with replacement of the circuit board, air/gas circuit components or in the case of installations with ue gas extraction systems, with horizontal concentric pipe measuring more than 1 metre.

The boiler heat output is correlated to the length of the air intake and ue exhaust pipes. is decreases with the increase of pipe length. The boiler leaves the factory adjusted for minimum pipe length (1m). It is therefore necessary, especially in the case of maximum pipe extension, to check the ∆p gas values aer at least 5 minutes of burner functioning at nominal heat output, when the temperatures of the intake air and exhaust ue gases have stabilised. Adjust the nominal and minimum heat output in the domestic hot water and central heating modes according to the values in the table (Par. 3.15) using the dierential manometers connected to the ∆p gas pressure point (15 and 16 Fig. 1-11).

Enter the congurations menu and regulate the

3.4 CONVERTING THE BOILER TO OTHER TYPES OF GAS.

If the boiler has to be converted to a dierent gas type to that specied on the data plate, request the relative conversion kit for quick and easy conversion.

following parameters (Par. 3.8):

- DHW minimum power output;

- DHW maximum power output;

- minimum heating output;

- maximum central heating output;

- ignition power.

Gas Valve 848 Key:

1 - Gas valve inlet pressure

point

2 - Gas valve outlet pressure

point 3 - O/Set adjustment screw 12 - Outlet gas ow rate

adjuster

3.6 ADJUSTMENT OF THE AIRGAS RAT IO.

Important: the verication operations of the CO

must be carried out with the casing mounted, while the gas valve calibration operations must be carried out with the casing open and removing the voltage from the boiler.

Calibration of the minimum CO heating power).

(minimum

Enter the chimney sweep phase without withdrawing domestic hot water and take the selector switches to minimum (turn them in an anti-clockwise direction until “0” is seen on the display). to have an exact value of CO gases the technician must insert the sampling

in the ue

probe to the bottom of the sample point, then check that the CO2 value is that specied in the table, otherwise adjust the screw (3 Fig. 3-3) (OSet adjuster). To increase the CO2 value, turn the adjustment screw (3) in a clockwise direction and vice versa to decrease it.

Calibration of the maximum CO central heating power).

(nominal

On completion of the adjustment of the minimum CO2 keeping the chimney sweep function active, take the heating selector switch to maximum (turn it in a clockwise direction until “99” is seen on the display). To have an exact value of CO2 in the ue gases the technician must insert the sampling probe to the bottom of the sample point, then check that the CO2 value is that specied in the table, otherwise adjust the screw (12 Fig. 3-3) (Gas ow adjuster). To increase the CO2 value, turn the adjustment screw (12) in a anticlockwise and vice versa to decrease it. At every adjustment variation on the screw 12 it is necessary to wait for the boiler to stabilise itself at the value set (about 30 sec.).

INTEC 12 SYSTEM EXTERNAL

(G20)

LPG

(G31)

at nominal

output

(central heating)

9,60% ± 0,2 8,90% ± 0,2

11,00% ± 0,2 10,30% ± 0,2

CO2 at minimum

output

(central heating)

INTEC 30 SYSTEM EXTERNAL

(G20)

LPG

(G31)

at nominal

output

(central heating)

9,45% ± 0,2 8,90% ± 0,2

10,60% ± 0,2 9,70% ± 0,2

CO2 at minimum

output

(central heating)

3.7 CHECKS FOLLOWING CONVERSION TO ANOTHER TYPE OF GAS.

Aer making sure that conversion was carried out with a nozzle of suitable diameter for the type of gas used and the settings are made at the correct pressure, check that the burner ame is not too high or low and is stable (does not detach from burner);

N.B.:All boiler adjustment operations must be carried out by a qualied licensed operative.

INSTALLERUSER

MAINTENANCE TECHNICIAN

3-3

Page 18

3.8 PROGRAMMING THE P.C.B.

e boiler is prepared for possible programming of several operation parameters. By modifying these parameters as described below, the boiler can be adapted according to specic needs.

To access the programming phase, position the DHW selector (5) (Fig. 2-1) on position “6”, the CH selector (6) on position “9” and press the “Reset” (3) and “Summer/Winter” buttons for about 8 seconds (2).

Once the menu has been accessed, it is possible

INSTALLERUSER

to scroll through the three sub-menus present (s, p, t) by pressing the “Summer/Winter” (2) button for 1 second.

Use the “DHW regulator” selector (5), to select the parameter (inside the same sub-menu) and rotate the “CH regulator” selector (6) to modify the value according to the range available.

Press the “Reset” button (3) for 1 second to memorise the variation of the parameters. Memorisation is represented via “88” on the indicator (14) for 2 seconds.

Exit the programming mode by waiting for 15 minutes or by pressing the, “Reset” (3) and “Summer/Winter” (2) buttons simultaneously.

MAINTENANCE TECHNICIAN

Parameter

Parameter Description Range Default

Minimum DHW

output

Maximum DHW

output

Minimum CH

output

Maximum CH

output

Power

block

Central heating

set point mini-

mum temperature

Central heating set point maxi-

mum temperature

External probe

correction

Boiler power

e boiler also has electronic modulation that adapts the boiler potentiality to the ef fective heating demand of the house. erefore the boiler works normally in a variable gas pressure eld between minimum and maximum power depending on the system heat load, setting fan speed (in rpm, hundreds of revs are represented on the display).

N.B.:the boiler is produced and calibrated in the central heating phase at nominal output. Approximately 10 minutes are needed to reach the nominal heat output, which can be changed using the parameter (S3).

N.B.: selection of parameters in the presence of requests, allows boiler functioning with current equal to the respective value.

Denes the minimum ow temperature.

Denes the maximum ow temperature.

If the reading of the external probe is not correct it is possible to correct it in order to compensate any environmental factors. (Over the value of +9 the display shows “CE”, which enables an external control function of the boiler for coupling of the same with a system supervisor)

Identies the boiler’s power (only useful with a coupled storage tank and parameter P0=1).

900 ÷ 1500

3500 ÷ 6100

S0 ÷ S3

S2 ÷ S1

1500 ÷ 3500

20 ÷ 50 °C 25

(S5+5) ÷

85 °C

-9 ÷ 9 K 0

0 = 12 kW 1 = 26 kW 2 = 28 kW 3 = 32 kW

12 =1300 (NG/LPG) 30 =1300 (NG/LPG)

12 =4750 (NG/LPG) 30 =5100 (NG/LPG)

12 =1300 (NG/LPG) 30 =1300 (NG/LPG)

12 =4750 (NG/LPG) 30 =5100 (NG/LPG)

12 =2900 (NG/LPG) 30 =2900 (NG/LPG)

Page 19

Parameter

P0 DHW thermostat

Parameter

t3 Display lighting

t4 Display

Parameter Description Range Default

Solar delay

timing

Pump function-

ing

Relay 1

(optional)

Relay 2

(optional)

Relay 3

(optional)

Parameter Description Range Default

Central heating

ignitions timer

Central heating

ramp timer

CH ignition de-

lay from TA and

CR request

Establishes the boiler ignition and switch-o mode in DHW mode.

0 - Ignition occurs when the water contained in the storage tank drops by 7°C with

respect to the temperature set and switches o when the temperature is at -4°C with respect to the value set (solar deactivated)

1 - Ignition occurs when the water contained in the storage tank drops by 2°C with

respect to the temperature set and switches o when the temperature is at +1°C with respect to the value set (solar deactivated)

2 - Ignition occurs when the water contained in the storage tank drops by 10°C with

respect to the temperature set and switches o when the temperature is at the value set (solar deactivated)

e boiler is set to switch-on immediately aer a request for DHW. In the case of coupling with a solar storage tank positioned upstream from the boiler, it is possible to compensate the distance between the storage tank and the boiler in order to allow the water to reach the boiler. Set the time necessary to verify that the water is hot enough (see par. Solar panels coupling)

e pump can function in two ways. 0 intermittent: In winter "mode" the pump is managed by the room thermostat or by the

remote control

1 continuous: In "winter" mode the pump is always powered and so functions continu-

ously

e boiler is set-up for functioning with the relay board (optional), which can be congured

0 = O 1 = Main zone control 2 =General alarm 3 = CH phase active 4 = External gas valve power supply 5 = (Do not use on this boiler model)

e boiler is set-up for functioning with the relay board (optional), which can be congured

0 = O 1 =General alarm 2 = CH phase active 3 = External gas valve power supply 4 = Secondary zone control (from TA on relay board contact 5 = Heat pump

e boiler is set-up for functioning with the relay board (optional), which can be congured

0 = O 1 = Chiller remote activation 2 =General alarm 3 = CH phase active 4 = External gas valve power supply 5 = heat pump 6 = activation of storage tank pump

e boiler has electronic timing, which prevents the burner from igniting too oen in central heating mode (with step of 10)

In the ignition phase, the boiler performs an ignition ramp in order to arrive at the maximum power set (with step of 10)

e boiler is set to switch-on immediately aer a request. In the case of particular systems (e.g. area systems with motorised thermostatic valves etc.) it could be necessary to delay switch-on (with 10 step)

Establishes the display lighting mode. 0 Automatic: the display lights up during use and lowers aer 15 seconds of inactivity.

In the case of anomaly the display ashes.

1 Low: the display is always lit with low intensity

2 High: the display is always lit with high intensity.

Establishes what the indicator displays 14 (Fig. 2-1). "Summer" mode: 0: the indicator is always o 1: pump active displays the ow temperature, pump o the indicator is o

"Winter" mode: 0: always displays the value set on the CH selector 1: pump active displays the ow temperature, pump o always displays the value set on the CH selector

0 On = -7°C O = -4°C

1 On = -2°C

O = +1°C

On = -10°C

O = +0°C

0 - 30 seconds 0

0 - 1 0

0 - 5 1

0 - 5 0

0 - 6 0

0 - 600 sec-

onds

0 - 840

seconds

0 - 600 sec-

onds

0 - 2 0

0 - 1 1

INSTALLERUSER

MAINTENANCE TECHNICIAN

Page 20

3.9 “CHIMNEY SWEEP” FUNCTION.

When activated, this function forces the boiler to variable output for 15 minutes. In this state all adjustments are excluded and only the safety thermostat and the limit thermostat remain active. To activate the chimney sweep function, press the “Reset” button (3) until activation of the function in the absence of DHW requests.

Its activation is signalled by simultaneous ashing of the indicators (11 and 12 Fig. 2-1).

INSTALLERUSER

is function allows the technician to check the combustion parameters. Once the function is activated, it is possible to select whether to make the check in CH status or DHW status by opening any hot water cock and regulating the power by turning the “CH regulation” selector (6). Functioning in CH or DHW mode is visualised

by the relative symbols

After the checks, deactivate the function switching the boiler o and then on again.

3.10 PUMP ANTIBLOCK FUNCTION.

e boiler has a function that starts the pump at least once every 24 hours for the duration of 30 seconds in order to reduce the risk of the pump becoming blocked due to prolonged inactivity.

3.11 RADIATORS ANTIFREEZE FUNCTION.

If the system return water is below 4°C, the boiler starts up until reaching 42°C.

or .

3.12 P.C.B. PERIODICAL SELFCHECK.

During functioning in heating mode or with boiler in standby, the function activates every 18 hours aer the last boiler check/power supply. In case of functioning in domestic hot water mode the self-check starts within 10 minutes aer the end of the withdrawing in progress, for duration of approx. 10 seconds.

N.B.:during self-check, the boiler remains o.

3.13 AUTOMATIC VENT FUNCTION.

In the case of new heating systems and in particular mode for floor systems, it is very important that dearation is performed correctly. e function consists in the cyclic activation of the pump (100 s ON, 20 s OFF) and the 3-way valve (120 s domestic hot water, 120 s central heating). e function is activated in two dierent ways:

- at every new power supply of the boiler;

- by pressing buttons at the same time (2 and 4 Fig. 2-1) for 5 seconds with boiler in stand-by.

N.B.: if the boiler is connected to the CAR

the “stand-by” function is only obtained via the remote control panel.

In the rst case, the function has duration of 8 minutes and it can be interrupted by pressing the “reset” button (4). In the second case it has duration of 18 hours and it can be interrupted by simply switching the boiler on.

Activation of the function is signalled by the countdown shown on the indicator (14).

MAINTENANCE TECHNICIAN

Page 21

3.14 CASING REMOVAL.

To facilitate boiler maintenance the casing can be completely removed as follows:

• Front panel (Fig. 3-4a).

1) Remove the intake / exhaust terminal (1).

2) Unscrew the screws (2) and extract the front panel (3).

3) Unscrew the screws (4) and remove the lower protection plate (5).

• Front (Fig. 3-4b).

4) Extract the cover plugs (8) and unscrew the screws (9).

5) Make the control panel (10) turn over towards you.

• Casing (Fig. 3-4c).

6) Unscrew the screws (11) xing the casing front (12) and the two sides (16).

7) Slightly pull the casing front (12) in its lower part towards you and at the same time push upwards.

8) Unscrew the screws (13) and extract the upper protection (14).

9) Unscrew the screws (15) on the sides (16).

10) Remove the sides pulling them towards you, in order to extract them from the 2 rear seats (Ref. X).

INSTALLERUSER

3-4b3-4a

Ref. X

Rif. X

MAINTENANCE TECHNICIAN

3-4c

Page 22

3.15 VARIABLE HEAT POWER. N.B.: the pressures indicated in the table repre-

sent the dierences of pressures at the ends of the Venturi mixer and can be measured from the pressure point in the upper part of the sealed chamber (see pressure test 15 and 16 Fig. 1-11).

INTEC 12 SYSTEM EXTERNAL.

INSTALLERUSER

HEAT

OUTPUT

(kW) (MJ/h) (m

GAS

CONS.

12,0 49,2 1,30 0,52 0,96 0,57 11,0 45,0 1,19 0,44 0,87 0,48 10,0 40,8 1,08 0,37 0,79 0,41

9,0 36,8 0,97 0,30 0,71 0,34 8,0 32,7 0,87 0,24 0,64 0,28 7,0 28,7 0,76 0,19 0,56 0,22 6,0 24,8 0,66 0,15 0,48 0,17 5,0 20,8 0,55 0,11 0,40 0,12 4,0 16,8 0,44 0,07 0,33 0,08 3,0 12,7 0,34 0,05 0,25 0,05 2,3 9,8 0,26 0,03 0,19 0,03

e adjustments must be performed using a digital dierential manometer with a scale in tenths of mm or Pascal. e power data in the table has been obtained with intake-exhaust pipe measuring 0.5 m in length. Gas ow rates refer

NG (G20) Universal LPG (G31)

BURNER

GAS

FLOW RATE

/h) (kPa) (kg/h) (kPa)

BURNER

NOZZLES

PRESSURE

BURNER

GAS

FLOW RATE

BURNER

NOZZLES

PRESSURE

to heating values below a temperature of 15°C and at a pressure of 1013 mbar. Burner pressure values refer to use of gas at 15°C.

INTEC 30 SYSTEM EXTERNAL.

HEAT

OUTPUT

(kW) (MJ/h) (m

30,0 121,6 3,22 0,41 2,36 0,49 29,0 117,5 3,11 0,39 2,28 0,46 28,0 113,4 3,00 0,36 2,20 0,43 27,0 109,3 2,89 0,34 2,12 0,40 26,0 105,2 2,79 0,32 2,05 0,37 25,0 101,1 2,68 0,30 1,97 0,35 24,0 97,1 2,57 0,28 1,89 0,32 23,0 93,1 2,46 0,26 1,81 0,30 22,0 89,0 2,36 0,24 1,73 0,28

21,0 85,0 2,25 0,22 1,65 0,25 20,0 81,0 2,15 0,20 1,58 0,23

MAINTENANCE TECHNICIAN

19,0 77,0 2,04 0,19 1,50 0,21 18,0 73,0 1,93 0,17 1,42 0,19 17,0 69,0 1,83 0,16 1,34 0,17 16,0 65,0 1,72 0,14 1,26 0,16 15,0 61,0 1,62 0,13 1,19 0,14 14,0 57,0 1,51 0,11 1,11 0,12 13,0 53,0 1,40 0,10 1,03 0,11 12,0 49,0 1,30 0,09 0,95 0,09 11,0 45,0 1,19 0,08 0,87 0,08 10,0 41,0 1,09 0,06 0,80 0,07

9,0 36,9 0,98 0,05 0,72 0,06 8,0 32,9 0,87 0,04 0,64 0,05 7,0 28,8 0,76 0,03 0,56 0,04 6,0 24,8 0,66 0,03 0,48 0,03 5,7 23,6 0,62 0,02 0,46 0,03

GAS

CONS.

NG (G20) Universal LPG (G31)

BURNER

GAS

FLOW RATE

/h) (kPa) (kg/h) (kPa)

BURNER

NOZZLES

PRESSURE

BURNER

GAS

FLOW RATE

BURNER

NOZZLES

PRESSURE

Page 23

3.16 APPLIANCE CHECK AND MAINTENANCE.

e following checks and maintenance should be performed every 24 months.

- Clean the ue side of the heat exchanger.

- Clean the main burner.

- If deposits are detected in the combustion

chamber one must remove them and clean the heat exchanger coils using nylon or sorghum brushes; it is forbidden to use brushes made of metal or other materials that may damage the combustion chamber itself.

- Check the integrity of the insulating panels

inside the combustion chamber and if damaged replace them.

- Visually check for water leaks or oxidation

from/on fittings and traces of condensate residues inside the sealed chamber.

- Check contents of the condensate drain trap.

- Via the condensate drain cap check that there

are no residues of material that clog condensate passage; also check that the entire condensate drain circuit is clear and ecient.

In the event of obstructions (dirt, sediment,

etc.) with consequent leakage of condensate in the combustion chamber, one must replace the insulating panels.

- Check that the burner seal gaskets and the lid

are intact and perfectly ecient, otherwise replace them. In any case the gaskets must be replaced at least every two years, regardless of their state of wear.

- Check that the burner is intact, that it has no deformations or cuts and that it is properly xed to the combustion chamber lid; otherwise it must be replaced.

- Visually check that the water safety drain valve is not clogged.

- Check that, aer discharging system pressure and bringing it to zero (read on boiler pressure gauge), the expansion vessel pressure is at 1.0 bar.

- Check that the system static pressure (with system cold and aer relling the system by means of the lling valve) is between 1 and 1.2 bar.

- Visually check that the safety and control devices have not been tampered with and/or shorted, in particular:

- temperature safety thermostat;

- Check the condition and integrity of the electrical system and in particular:

- supply voltage cables must be inside the

fairleads;

- there must be no traces of blackening or

burning.

- Check ignition and operation.

- Check correct calibration of the burner in domestic hot water and central heating phases.

- Check the operation of the appliance control and adjustment devices and in particular:

- system regulation probes intervention;

- domestic hot water control thermostat inter-

vention.

- Check sealing eciency of the gas circuit and the internal system.

- Check the intervention of the device against no gas ionisation ame control. e relative intervention time must be less than 10 seconds.

N.B.: in addition to maintenance, one must also check the thermal system, with frequency and procedures that comply with the indications of the technical regulations in force.

INSTALLERUSER

3.17 COMBUSTION PARAMETERS.

INTEC 12 SYSTEM EXTERNAL NG (G20) Universal LPG (G31)

Gas nozzle diameter mm 3,80 2,80

Supply pressure kPa 1,13 2,75

Flue ow rate at nominal heat output kg/h 19 19

Flue ow rate at min heat output kg/h 4 4

at Nom Q./Min. % 9,60 / 8,90 11,00 / 10,30

CO with 0% O

with 0% O2 at Nom Q /Min. mg/kWh 30 / 13 35 / 17

at Nom Q /Min. - 0,00125 / 0,00003 0,00173 / 0,00003

Flue temperature at nominal output °C 63 64

Flue temperature at minimum output °C 60 62

INTEC 30 SYSTEM EXTERNAL NG (G20) Universal LPG (G31)

Gas nozzle diameter mm 6,90 4,80

Supply pressure kPa 1,13 2,75

Flue ow rate at nominal heat output kg/h 48 49

Flue ow rate at min heat output kg/h 10 10

at Nom Q./Min. % 9,45 / 8,90 10,60 / 9,70

CO with 0% O

with 0% O2 at Nom Q /Min. mg/kWh 51 / 17 61 / 25

at Nom Q /Min. - 0,00153 / 0,00001 0,00160 / 0,00003

Flue temperature at nominal output °C 40 40

Flue temperature at minimum output °C 64 63

MAINTENANCE TECHNICIAN

Page 24

3.18 TECHNICAL DATA.

Intec 12 Systeme External Intec 30 System External

Nominal heat input (NG / Universal LPG) MJ/h (kW) 49,2 (12,3) 121,6 (30,4)

Minimum heat input (NG / Universal LPG) MJ/h (kW) 9,8 (2,5) 23,6 (5,9)

Nominal heat output (useful) (NG / Universal LPG) kW 12,0 30,0

Minimum heat output (useful) (NG / Universal LPG) kW 2,3 5,7

* Eciency 80/60 Nom./Min. % 97,4 / 93,5 98,6 / 96,7

* Eciency 50/30 Nom./Min. % 107,0 / 102,7 108,0 / 105,9

* Eciency 40/30 Nom./Min. % 107,1 / 107,1 109,0 / 106,0

INSTALLERUSER

Heat loss at casing with burner On/O % 0,3 / 0,88 0,2 / 0,48

Heat loss at ue with burner On/O % 2,3 / 0,02 1,2 / 0,01

Central heating circuit max. operating pressure kPa 300 300

Central heating circuit max. operating temperature °C 90 90

Adjustable central heating temperature °C 20 - 85 20 - 85

System expansion vessel volume l 8,0 8,0

Expansion vessel factory-set pressure bar 1 1

Water content in generator l 2,65 2,30

Head available with 1000 l/h ow rate kPa (m H

O) 17,1 (1,7) 26,4 (2,7)

Weight of full boiler kg 35,65 41,1

Weight of empty boiler kg 33,0 38,8

Electrical connection V/Hz 230/50 230/50

Power input A 0,54 0,66

Installed electric power W 120 140

Pump consumption W 89 92

Fan power consumption W 17 27

Equipment electrical system protection - IPX5D IPX5D

class - 5 5

Weighted NO

mg/kWh 29,0 36,0

Weighted CO mg/kWh 20,4 27,0

Type of appliance C13 /C33 / C43 / C53 / C63

- Flue temperature values refer to an air inlet temperature of 15°C and ow temperature of 50°C.

- The data relevant to domestic hot water performance refer to a dynamic inlet pressure of 2 bar and an inlet temperature of 15°C; the values are measured directly at the boiler outlet considering that to obtain the data declared mixing with cold water is necessary.

MAINTENANCE TECHNICIAN

- * Yields refer to the lower heating value.

Page 25

3.19 EXPLODED BOILER DIAGRAM INTEC 12 SYSTEM EXTERNAL.

INSTALLERUSER

198AE

INTEC 12 SYSTEM EXTERNAL

26/05/15

3.025963

OF SERIES

SERIAL NUMBER START

MAINTENANCE TECHNICIAN

Page 26

(

)

(

)

(

)

y (

)

(

)

(

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(

)

(

)

(

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(

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(

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(

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(

)

(

)

(

)

(

)

(

)

(

)

(

)

(

)

(

)

(

)

(

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Flue probe with O-ring

(

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(

)

(

)

(

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(

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(

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(

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(

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3.20 SPARE PART LIST INTEC 12 SYSTEM EXTERNAL.

INSTALLERUSER

28x21x1

3,5x6,4

djustment-hole plug

screw

137 1.031572

138 1.1656 Nickel-plated crosshead self-tapping

139 1.038393 Gasket

d.6,5

68 2.015633 Lx-Rx wall, casing

69 1.019751 Silicone fairlead

70 1.031289 Knob

71 1.2268 3.68x1.78 O-ring, nitrile, 70 sh

34x27x1

housing

140 1.024996 Brass pressure point

141 1.031009 5-way terminal block with fuse

142 1.021762 NTC fast immersion probe

143 2.014706 Spark generator bracket

144 1.038394 Gasket

145 1.023554 Door hinge mount

146 nfs Front casing insulating panel

146 3.026423 Front casing, assembl

147 1.025360 Spark generator

72 1.036640 Nut

73 nfs Front casing, seal

M5x16

73 3.026423 Front casing, assembl

74 1.030666 Gasket for flange with sample points

75 nfs Clip

75 3.021696 Clip kit

76 1.010289 Tropicalized hex socket screw

77 1.038389 PCB

78 3.026268 Bezel,control panel with nameplate

44,12x2,62

valve

utomatic vent valve

dhesive for displa

148 1.038395 1/2" M - 3/8" M nipple

149 1.038349 Casing insulating panel

150 1.027016 Seal, sealed safet

151 1.027110

152 2.014014 Bracket for expansion vessel

153 1.031288 Control panel push-button

154 3.020380 Complete cartridge

155 1.034442

156 1.026460 Peroxide edpm O-Ring

d.20

assembl

3x10

79 1.030300 Control panel back cover

80 1.026482 Manometer

81 1.037094 3/4'' M - 3/4'' M nipple

82 1.030301 Connection group cover

83 1.035248 Crossheaded self-tapping screw

84 1.034606 Ceramic glass

85 1.029694 Energy metering coupler fitting 3/4"

M4x8

2,9x9,5

terminal block

screw

157 1.2170 Crossheaded screw

158 1.029697 Siphon tank

159 3.017477 Ignition electrode group

160 1.021892 Siphon plug

161 1.6984 Crossheaded flat pointed self-tapping

162 1.030916 Grommet

163 1.038022 Screen-printed plate

164 1.031293 Screw fixing terminal block

165 1.6804 6-wa

166 1.8532 Crossheaded self-tapping screw

stem

3 bar

valve

M-F

86 1.7908 Black cable clamp

87 1.038185 Sealed chamber gasket

88 1.028650 Return manifold

89 1.028643 Safet

2,57x1,78, 70 sh

hole

90 1.030667 Condensate drain s

91 1.025884 Stud M4

92 1.024898 Gasket for module inspection hole

93 2.013322 Flange for module cover inspection

94 nfs Epdm O-Ring

10x5,2x1

3,5x9,5

63x3 sh

4x8

d.8

nnealed copper washer

3,9x16

167 1.025986 Silicone pipe

168 1.032007 Detection electrode

169 1.011131 Fairlead

M4x8

94 3.021695 Kit of O-rings multi-functions

95 1.016246 Crossheaded self-forming screw

dhesive nameplate

170 1.034610

171 1.4246 Lock washer

172 1.026530 Nitrile O-Ring

173 1.6221 Hose union for silicone pipe

174 1.038478 Plug

175 1.037356

176 1.4066 Self-tapping screw

177 2.015634 Casing cover

178 2.015635 Lx panel fixing plate

d.18

4,2x6,5

tapping screw

96 1.030219 Cone pointed crossheaded self-

97 1.023334 Gas manifold

98 1.024543 Front ceramic fibre panel

99 1.025689 Gas manifold gasket

100 1.028548 Housing, outlet manifold

101 1.038187 Storage tank flow pipe

102 1.024204 Rubber buffer

103 1.6011 Crossheaded flat pointed self-tapping

d.60

little cover

d.100

ir intake-drain terminal

179 2.015636 Rx panel fixing plate

180 2.015638 Bracket bottom

181 3.026006 Painted cabinet assembl

182 1.011745 D.100 flue sealing collar

183 1.020366 Black peroxide epdm gasket

184 1.020370 Gasket

185 1.025710 Peroxide epdm gasket

186 3.020896 D.100-60 elbow assembl

187 3.024101

188 3.026008 Front exterior casing, assembl

1/2''F

d.18

13,94x2,62, 70 sh

3,5x9,5

3,9x25

screw

104 1.031823 SIT 848 gas valve

105 3.020367 Plastic siphon

106 1.2337 Crossheaded self-tapping screw

107 1.038188 Boiler return pipe

108 nfs Epdm O-Ring

108 3.021695 Kit of O-rings multi-functions

109 1.038336 Lowered brass nut

110 1.031446 Condensation module

M4x12

dapter d.60-100 assembl

189 1.020369 D.60-100 shaped seal

190 1.2369 Crossheaded screw

191 3.025397

192 3.026237 Subframe assembl

9,25x1,78

3,2x7x0,5

7,6x2,62, 70 sh

4,3x12

14,8x8x2

-pass complete cartridge

111 nfs 19.8x3.6 O-ring

111 3.021695 Kit of O-rings multi-functions

112 3.021689 B

113 1.8599 Washer

114 1.024680 Burner gasket

115 1.022362 Peroxide epdm O-Ring

116 1.011163 Tropicalized washer

117 1.023993 Gasket

118 nfs Epdm O-Ring

118 3.021695 Kit of O-rings multi-functions

3/4''F

d.10x50

l.200

119 1.038337 Lowered brass nut

120 1.019654 Flexible hose for siphon

121 1.038018 Screen-printed plate 6 wa

122 1.5899 Wall plug package

123 1.025898 Flexible hose

124 1.028444 Nut for flexible hose

125 1.021452 Gasket for flexible hose

126 1.016967 Spring pipe clamp for silicone pipe

M5x14

d.22

127 1.024387 "Y" hose union

128 1.024084 Crossheaded screw

129 1.010500 Spring pipe clamp for silicone pipe

130 1.025797 Klixon thermostat 100°C

131 2.014456 Frame

132 1.028554 Pump body133 1.032431 Pump motor

134 2.015642 Valve supporting plate

135 1.027710 Venturi

3,5x19

136 1.7967 Crossheaded self-tapping screw

SERIES

SERIAL NUMBER START OF

MAINTENANCE TECHNICIAN

8 litres

draulic group

expansion tank

- 3.025937 H

- 3.026049 Control panel - complete

1 1.038189 D.8 pipe, hydraulic assembly -

2 1.030996 Expansion vessel

3 3.022550 Pump group

4 1.015258 1/2" F plug

5 1.028394 NTC probe

N. CODE DESCRIPTION

6 nfs Heat exchanger gasket

M5,3x10

d.18

6 3.021695 Kit of O-rings multi-functions

7 nfs Outlet manifold clip

7 3.021696 Clip kit

8 nfs Pipe clip

8 3.021696 Clip kit

9 1.030176 Stainless stell washer

10 1.025910 Graphite gasket for burner

d.14

9,19x2,62

draulic group

ir intake pipe

bsolute pressure switch

d.18

11 1.023442 Gas manifold cover

12 1.029156 D.18 pipe, water gas module -

13 1.029157 Condensation module - pump pipe

14 1.038529 Gas valve - manifold pipe

15 1.033901

16 1.027277

17 1.020211 Cord packing

18 1.026455 Red silicone O-ring

19 1.025357 Gas manifold cover gasket

M4x6

M5x65

18,00x2,8, 83sh

20 1.033854 Epdm O-Ring

21 1.0153 Crossheaded screw

22 1.027178 Fan

23 1.024483 Burner

24 1.025690 Pressure point cap

25 1.038304 Hex socket screw

26 1.027108 Drain fitting

M5x25

d.8

24x16x2

d.80

27 1.031531 D.14,2 plug

28 1.023992 Gasket

29 1.023578 Crossheaded screw

30 1.023676 Gasket

31 1.032851 Filling pipe

32 nfs Pressure switch locking clip

M5x8

M4x20

d.9

3x16

32 3.021696 Clip kit

33 1.035250 Crossheaded self-tapping screw

34 1.1176 Crossheaded screw

35 nfs Metal-sheet clip

kit

35 3.021696 Clip kit

36 1.023581 Rubber adapter

37 1.034459 Crossheaded screw

38 nfs Pump coupler fitting

38 3.021694 Two pump coupler fittings with o-ring

39 1.034173 Cap

40 1.025911 Nut

's hole

17,86x2,62

3,9x13

41 3.026423 Front casing, assembl

42 1.4139 Crossheaded self-tapping screw

43 1.012468 Stainless steel elastic washer

44 1.033429 M5x10 hex screw

45 1.034324 Seal painted cabinet assembl

kit

46 2.014725 Pipes clamping plate

47 1.4072 Clip with clamp screw hole

48 1.038380 Brass pressure point

49 nfs Peroxide epdm O-Ring

49 3.021694 Two pump coupler fittings with o-ring

M4x10

M6x12

8x12

pass

linder manifold

18,5x11,5x2

49 3.021695 Kit of O-rings multi-functions

50 1.034405 Gasket

51 1.036539 D.18 pipe b

52 1.037089 Outlet c

53 1.7349 Crossheaded screw

d.3,80

54 1.016187 Silicone tube

55 1.0017 Crossheaded screw

56 1.024296

57 1.030251 Ignition electrode gasket

58 2.014523 Module mount bracket

59 1.022050 Gas nozzle

60 1.021483 Silicone hood gasket

d.10x3

d.15x3

d.2

dhesive foam strip

61 1.033902 Fan flange for pipe fixing

62 1.025278 Plug for flange with sample points

63 nfs

63 3.026423 Front casing, assembl

64 nfs

64 3.026423 Front casing, assembl

65 1.027009 Silicone fairlead

66 nfs Front casing

66 3.026423 Front casing, assembl

67 1.037804 Flange with sample points

Page 27

3.21 EXPLODED BOILER DIAGRAM INTEC 30 SYSTEM EXTERNAL.

INSTALLERUSER

194AE

INTEC 30 SYSTEM EXTERNAL

12/03/16

3.0259616275236

OF SERIES

SERIAL NUMBER START

MAINTENANCE TECHNICIAN

Page 28

3.22 SPARE PART LIST INTEC 30 SYSTEM EXTERNAL.

3.025937

3.026049

1.038189

1.030996

(

)

3.022550

1.015258

1.028394

3.021695

3.021696

(

)

3.021696

1.039282

(

)

1.025910

1.023442

1.029156

1.029159

)

1.038529

(

)

1.033901

1.027277

1.020211

1.026455

(

)

1.025357

1.033854

(

)

(

)

1.027178

1.026281

1.025690

3.026237

1.027108

1.031531

1.023992

(

)

1.023578

(

)

1.023676

(

)

1.032851

(

)

3.021696

1.035250

)

(

)

(

)

3.021696

1.023581

1.034459

(

)

3.021694

1.034173

1.025911

(

)

3.026423

)

1.012468

(

)

1.033429

1.034324

2.015657

1.038380

(

)

3.021694

3.021695

1.034405

(

)

1.036539

1.037089

(

)

1.034614

(

)

(

)

1.024296 Flue probe with O-ring

1.030251

2.014524

1.038379

(

)

1.021483

1.033902

1.025278

(

)

3.026423

y (

)

3.026423

1.027009

(

)

3.026423

1.037994

(

)

(

)

y )

(

)

(

)

(

)

(

)

(

)

(

)

(

)

(

)

(

)

(

)

(

)

(

)

(

)

(

)

(

)

(

)

(

)

(

)

) (

)

(

)

(

)

(

)

(

)

(

)

(

)

(

)

(

)

(

) (

)

(

) y

(

)

(

)

(

)

(

) y

INSTALLERUSER

28x21x1

3,5x6,4

djustment-hole plug

screw

137 1.031572

138 1.1656 Nickel-plated crosshead self-tapping

139 1.038393 Gasket

d.6,5

68 2.015633 Lx-Rx wall, casing

69 1.019751 Silicone fairlead

70 1.031289 Knob

71 1.2268 3.68x1.78 O-ring, nitrile, 70 sh

34x27x1

housing

140 1.024996 Brass pressure point

141 1.031009 5-way terminal block with fuse

142 1.021762 NTC fast immersion probe

143 2.014706 Spark generator bracket

144 1.038394 Gasket

145 1.023554 Door hinge mount

146 nfs Front casing insulating panel

146 3.026423 Front casing, assembl

147 1.025360 Spark generator

72 1.036640 Nut

73 nfs Front casing, seal

M5x16

73 3.026423 Front casing, assembl

74 1.030666 Gasket for flange with sample points

75 nfs Clip

75 3.021696 Clip kit

76 1.010289 Tropicalized hex socket screw

77 1.038389 PCB

78 3.026268 Bezel,control panel with nameplate

44,12x2,62

valve

utomatic vent valve

dhesive for displa

148 1.038395 1/2" M - 3/8" M nipple

149 1.038349 Casing insulating panel

150 1.027016 Seal, sealed safet

151 1.027110

152 2.014014 Bracket for expansion vessel

153 1.031288 Control panel push-button

154 3.020380 Complete cartridge

155 1.034442

156 1.026460 Peroxide edpm O-Ring

d.20

assembl

3x10

79 1.030300 Control panel back cover

80 1.026482 Manometer

81 1.037094 3/4'' M - 3/4'' M nipple

82 1.030301 Connection group cover

83 1.035248 Crossheaded self-tapping screw

84 1.034606 Ceramic glass

85 1.029694 Energy metering coupler fitting 3/4"

M4x8

2.9x9.5 terminal block

screw

157 1.2170 Crossheaded screw

158 1.029697 Siphon tank

159 3.017477 Ignition electrode group

160 1.021892 Siphon plug

161 1.6984 Crossheaded flat pointed self-tapping

162 1.030916 Grommet

163 1.038022 Screen-printed plate

164 1.031293 Screw fixing terminal block

165 1.6804 6-wa

166 1.8532 Crossheaded self-tapping screw

stem

3 bar

valve

M-F

86 1.7908 Black cable clamp

87 1.038185 Sealed chamber gasket

88 1.028650 Return manifold

89 1.028643 Safet

2,57x1,78, 70 sh

hole

90 1.030667 Condensate drain s

91 1.025884 Stud M4

92 1.024898 Gasket for module inspection hole

93 2.013322 Flange for module cover inspection

94 nfs Epdm O-Ring

10x5,2x1

4x8

d.8

nnealed copper washer

3,9x16

167 1.034615 Black silicone pipe

168 1.032007 Detection electrode

169 1.011131 Fairlead

170 1.034610

M4x8

94 3.021695 Kit of O-rings multi-functions

95 1.016246 Crossheaded self-forming screw

96 1.030219 Cone pointed crossheaded self-

3,5x9,5

63x3 sh

dhesive nameplate

171 1.4246 Lock washer

172 1.026530 Nitrile O-Ring

173 1.6221 Hose union for silicone pipe

174 1.038478 Plug

175 1.037356

176 1.4066 Self-tapping screw

177 2.015634 Casing cover

d.18

4,2x6,5

tapping screw

97 1.023334 Gas manifold

98 1.024543 Front ceramic fibre panel

99 1.025689 Gas manifold gasket

100 1.028548 Housing, outlet manifold

101 1.038187 Storage tank flow pipe

102 1.024204 Rubber buffer

103 1.6011 Crossheaded flat pointed self-tapping

d.60

little cover

d.100

ir intake-drain terminal

178 2.015635 Lx panel fixing plate

179 2.015636 Rx panel fixing plate

180 2.015638 Bracket bottom

181 3.026006 Painted cabinet assembl

182 1.011745 D.100 flue sealing collar

183 1.020366 Black peroxide epdm gasket

184 1.020370 Gasket

185 1.025710 Peroxide epdm gasket

186 3.020896 D.100-60 elbow assembl

187 3.024101

1/2''F

d.18

13,94x2,62, 70 sh

3,5x9,5

3,9x25

screw

104 1.031823 SIT 848 gas valve

105 3.020367 Plastic siphon

106 1.2337 Crossheaded self-tapping screw

107 1.038188 Boiler return pipe

108 nfs Epdm O-Ring

108 3.021695 Kit of O-rings multi-functions

109 1.038336 Lowered brass nut

M4x12

dapter d.60-100 assembl

188 3.026008 Front exterior casing, assembl

189 1.020369 D.60-100 shaped seal

190 1.2369 Crossheaded screw

191 3.025397

9,25x1,78

3,2x7x0,5

3/4''F

7,6x2,62, 70 sh

4,3x12

14.8x8x2

-pass complete cartridge

110 1.031448 Condensation module

111 nfs 19.8x3.6 O-ring

111 3.021695 Kit of O-rings multi-functions

112 3.021689 B

113 1.8599 Washer

114 1.024680 Burner gasket

115 1.022362 Peroxide epdm O-Ring

116 1.011163 Tropicalized washer

117 1.023993 Gasket

118 nfs Epdm O-Ring

118 3.021695 Kit of O-rings multi-functions

119 1.038337 Lowered brass nut

d.10x50

l.200

d.22

120 1.019654 Flexible hose for siphon

121 1.038018 Screen-printed plate 6 wa

122 1.5899 Wall plug package

123 1.025898 Flexible hose

124 1.028444 Nut for flexible hose

125 1.021452 Gasket for flexible hose

126 1.016967 Spring pipe clamp for silicone pipe

127 1.024387 "Y" hose union

M5x14

d.22

128 1.024084 Crossheaded screw

129 1.010500 Spring pipe clamp for silicone pipe

130 1.025797 Klixon thermostat 100°C

131 2.014456 Frame

3.5x19

132 1.028554 Pump body133 1.032431 Pump motor

134 2.015642 Valve supporting plate

135 1.038378 Venturi

136 1.7967 Crossheaded self-tapping screw

MAINTENANCE TECHNICIAN

SERIES

SERIAL NUMBER START OF

8 litres

draulic group H

Control panel - complete

D.8 pipe, hydraulic assembly -

expansion tank

Expansion vessel

Pump group

1/2" F plug

N. CODE DESCRIPTION

M5x65

d.18

NTC probe

Kit of O-rings multi-functions

Clip kit

Hex socket screw

Graphite gasket for burner

6 nfs Heat exchanger gasket

7 nfs Outlet manifold clip

8 nfs Pipe clip

d.14

9,19x2,62

18,00x2,8, 83sh

draulic group

ir intake pipe

bsolute pressure switch

d.18

Gas manifold cover

D.18 pipe, water gas module -

Condensation module - pump pipe

Gas valve - manifold pipe

Cord packing

Red silicone O-ring

Gas manifold cover gasket

Epdm O-Ring

M4x6

Fan

Burner

Pressure point cap

Subframe assembl

Drain fitting

21 1.0153 Crossheaded screw

M5x25

d.8

24x16x2

d.80

D.14,2 plug

Gasket

Crossheaded screw

Gasket

Filling pipe

32 nfs Pressure switch locking clip

M5x8

M4x20

d.9

3x16

Clip kit

Crossheaded self-tapping screw

Clip kit

Rubber adapter

Crossheaded screw

Two pump coupler fittings with o-ring

kit

Cap

34 1.1176 Crossheaded screw

35 nfs Metal-sheet clip

38 nfs Pump coupler fitting

's hole

17,86x2,62

3.9x13

Nut

Front casing, assembl

Stainless steel elastic washer

M5x10 hex screw

Seal painted cabinet assembl

Pipes clamping plate

Brass pressure point

42 1.4139 Crossheaded self-tapping screw

47 1.4072 Clip with clamp screw hole

49 nfs Peroxide epdm O-Ring

M4x10

M6x12

8x12

pass

linder manifold

18.5x11.5x2

Two pump coupler fittings with o-ring

kit

Kit of O-rings multi-functions

Gasket

D.18 pipe b

Outlet c

53 1.7349 Crossheaded screw

d.6,90

Black silicone pipe

Ignition electrode gasket

Module mount bracket

Gas nozzle

Silicone hood gasket

Fan flange for pipe fixing

55 1.0017 Crossheaded screw

d.10x3

d.15x3

d.2

dhesive foam strip

Plug for flange with sample points

Front casing, assembl

Silicone fairlead

Front casing, assembl

Flange with sample points

63 nfs

64 nfs

66 nfs Front casing

Page 29

3.23 BOILER REGISTRATION. is Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations.

Failure to install and commission according to the manufacturer’s instructions and complete this Commissioning Checklist may invalidate the warranty.

Customer name: Telephone number:

Address:

Boiler make and model:

Boiler serial number:

Commissioned by (PRINT NAME): Plumbing license number:

Company name: Telephone number:

Company address:

Commissioning date: Commissioning date:

Certicate of compliance number:

CONTROLS (tick the appropriate boxes)

Time and temperature control to heating

Time and temperature control to hot water Cylinder thermostat and programmer/timer Combination boiler

Heating zone valves Fitted Not required

Hot water zone valves Fitted Not required

ermostatic radiator Fitted Not required

Automatic bypass to system Fitted Not required

Boiler interlock Provided

ALL SYSTEMS

e system has been adequately ushed and cleaned? Yes

What system cleaner was used?

What inhibitor was used? Quantity Litres

Has a system lter been installed? Yes No

Room thermostat and programmer/timer Programmable room thermostat

Weather compensation Optimum start control

INSTALLERUSER

HEATING MODE measure and record:

Burner inlet gas working pressure (at maximum rate) Kpa OR gas inlet pressure Kpa

Central heating ow temperature °C

Central heating return temperature °C

COMBINATION BOILER  DOMESTIC HOT WATER MODE measure and record:

Burner inlet gas working pressure (at maximum rate) Kpa OR gas inlet pressure at maximum rate Kpa

Cold water inlet temperature °C

Hot water has been checked at all outlets Yes Temperature °C

Has a DHW tempering valve been tted to sanitary ttings? Yes Temperature °C

Water ow rate I/min

CONDENSING BOILERS ONLY

e condensate drain has been installed in accordance local laws in force? Yes

ALL INSTALLATIONS

Record the following:

e heating and hot water system complies with the appropriate Building Regulations Yes

e boiler and associated products have been installed and commissioned in accordance with the manufacturer’s instruc tions Ye s

e operation of the boiler and system controls have been demonstrated to and understood by the customer Yes

e manufacturer’s literature, including Commissioning Checklist and Service Record, has been explained and le with the customer Ye s

Commissioning Engineer’s Signature

Customer’s Signature

(To conrm satisfactory demonstration and receipt of manufacturer’s literature)

At max. Rate: Co Ppm Co

At min. Rate: (where possible) Co Ppm Co

% Ratio CO/CO Ratio

MAINTENANCE TECHNICIAN

Page 30

3.24 COMMISSIONING BOILER CHECK LIST.

A suggested method of commissioning the boiler, actual method can very according to the boiler make type and the installation. e boiler must always be installed, and commissioned by an qualied gas technician. e installer certies that this Boiler has been installed to the manufacturer’s instructions, has been lled, commissioned and is ready for use.

INSTALLERUSER

No. Description

1 Read carefully the instruction manuals supplied with this boiler.

2 BEFORE INSTALLING THIS BOILER FLUSH OUT THE PIPES UNTIL CLEAN WATER IS ACHIEVED. IF REPLAC-

ING AN OLD BOILER, HUNT HEATING RECOMMENDS A POWER FLUSH

3 Turn o all service to this boiler - water, gas and power. Install the boiler as shown in the instructions following and con-

nect all services.

4 Turn on water to ll system, check for leaks regularly and bleed air from all points.

Bleed the air from all the pumps in the system, and rotate the impeller sha.

5 Check that all radiators valves are open, all lock shields remove the thermostatic valve heads, fully open.

6 Turn ON gas, bleed air out at the isolation valve union. Reseal and check for gas leaks.

7 Turn electricity on at the power point. At the boiler front panel set the temperature setting to the lowest setting, switch

boiler to ON position. e “Power on” Indicator should light. Turn the boiler o at the front panel.

8 Turn the room thermostat to the manual ON position set the temperature to a high level so that it does not switch o

during the commissioning phase. e thermostat will unusually click and shows an Indicator in the window.

9 Boiler should start fan, pump and ignite gas. If it fails rst few times this may be just residual air in the gas line. A noisy

water pump indicates there is air in the water pipes.

10 Boiler lights and heats the water. Check gas ame is the correct colour and for gas and water leaks as the system heats up.

11 Check that heat is circulating to all radiators through the manual or thermostatic radiator valve located on the ow pipe

(unless reverse ow thermostatic valves).

12 Allow the boiler to heat up to the set temperature and switch o. Re-adjust the boiler temperature to a mid temperature point.

CAUTION, if this is connected to a oor heating system. e boiler should re light and increase the water temperature to the new setting.

13 Check that all radiators are hot all the way up. If the radiator is cold at the top, then there is usually air in the radiator

Bleed the radiator. Balance the system so that all radiators are hot as according to the radiator installation manual. Adjust the boiler water temperature.

14 Set the room thermostat to the correct times and temperatures according to the manufacturer’s instructions.

15 On completion of the commissioning phase, complete the information sheet at the front of this manual.

Hand over the installation to the owner and demonstrate how the system works plus basic fault resolution and safety procedures. Make sure that this important document is kept in a safe accessible place.



when done

IF IN DOUBT ASK

MAINTENANCE TECHNICIAN

No. Description

Handover Instructions

1 Fill in all the details on this Boiler manual.

2 Instruct the owner/users on the correct operation of this heating system, this includes how to turn the system on and o,

adjust the time and temperature settings.

3 How to turn the heating system o in summer and on for winter.

4 Where all the major items are, their functions and how to check and turn them on or o. Simple fault resolution i.e. power on.

5 How to check and remove air in the radiators. Give them a bleed key.

6 e importance of this SERVICE RECORDS, keeping safe & accessible when required.

7 Recommend that the boiler should be serviced anually and that the service is recorded withing the allocated area of the

boiler installation manual.



when done

Page 31

3.25 SERVICE RECORDS.

SERVICE 01

Engineer name:

Company name:

Telephone No:

Plumbing Licence No:

Record:

At max. rate: CO ppm CO

At mim. rate: CO ppm CO

Comments:

Signature

SERVICE 03

Engineer name:

Company name:

Telephone No:

Plumbing Licence No:

Record:

Comments:

At max. rate: CO ppm CO

At mim. rate: CO ppm CO

Date:

% CO/CO²Ratio

Date:

% CO/CO²Ratio

SERVICE 02

Engineer name:

Company name:

Telephone No:

Plumbing Licence No:

Record:

At max. rate: CO ppm CO

At mim. rate: CO ppm CO

Comments:

Signature

SERVICE 04

Engineer name:

Company name:

Telephone No:

Plumbing Licence No:

Record:

Comments:

At max. rate: CO ppm CO

At mim. rate: CO ppm CO

Date:

% CO/CO²Ratio

Date:

% CO/CO²Ratio

INSTALLERUSER

Signature

SERVICE 05

Engineer name:

Company name:

Telephone No:

Plumbing Licence No:

Record:

At max. rate: CO ppm CO

At mim. rate: CO ppm CO

Comments:

Signature

SERVICE 07

Engineer name:

Company name:

Telephone No:

Plumbing Licence No:

Record:

Comments:

At max. rate: CO ppm CO

At mim. rate: CO ppm CO

Date:

% CO/CO²Ratio

Date:

% CO/CO²Ratio

Signature

SERVICE 06

Engineer name:

Company name:

Telephone No:

Plumbing Licence No:

Record:

At max. rate: CO ppm CO

At mim. rate: CO ppm CO

Comments:

Signature

SERVICE 08

Engineer name:

Company name:

Telephone No:

Plumbing Licence No:

Record:

Comments:

At max. rate: CO ppm CO

At mim. rate: CO ppm CO

Date:

% CO/CO²Ratio

Date:

% CO/CO²Ratio

MAINTENANCE TECHNICIAN

Signature

Page 32

SERVICE 09

Engineer name:

Company name:

Telephone No:

Plumbing Licence No:

Record:

Comments:

INSTALLERUSER

At max. rate: CO ppm CO

At mim. rate: CO ppm CO

Date:

% CO/CO²Ratio

SERVICE 10

Engineer name:

Company name:

Telephone No:

Plumbing Licence No:

Record:

Comments:

At max. rate: CO ppm CO

At mim. rate: CO ppm CO

Date:

% CO/CO²Ratio

Signature

MAINTENANCE TECHNICIAN

Page 33

Page 34

Page 35

Page 36

AS/NZS 5263.1.2

Cert. SAI-400175

SAI Global

is instruction booklet is made of ecological paper Cod. 1.038483 - rev. ST.001636/005 - 02/18

Immergas INTEC 30 System External, INTEC 12 System External, INTEC 30 COMBI EXTERNAL Installation Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual