Intergas XCLUSIVE 24/30/36 INSTALLATION MANUAL

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Xclusive 24

G.C. 47-291-13

Xclusive 30

G.C. 47-291-14

Xclusive 36

G.C. 47-291-15

INSTALLATION MANUAL

High Eiciency Wall-Mounted Gas Boiler

Read this installation manual thoroughly before the installation and use of the boiler. Follow all indicated instructions. This installation manual must remain with the boiler.

Smart Opentherm™

Benchmark places responsibilities on both manufacturers and installers. The purpose is to ensure that customers are provided with the correct equipment for their needs, that it is installed, commissioned and serviced in accordance with the manufacturer’s instructions by competent persons and that it meets the requirements of the appropriate Building Regulations. The Benchmark Checklist can be used to demonstrate compliance with Building Regulations and should be provided to the customer for future reference. Please read the Benchmark Checklist carefully, page 90 , and complete all sections, as required by law, relevant to the appliance and installation. Failure to install and commission according to the manufacturer’s instructions and complete the Benchmark Commissioning Checklist will invalidate the warranty for the Gas Boiler installation. The details within the Checklist will be required in the event of any warranty work. On completion the Checklist must be le with the end user. The relevant sections of the Service Record, pages 91 & 92, must be completed on each subsequent Service visit.

Installers are required to carry out installation, commissioning and servicing work in accordance with the Benchmark Code of Practice which is available from the Heating and Hotwater Industry Council who manage and promote the scheme. Visit www. centralheating.co.uk for more information.

CONTENTS

1 Preface 5

1.1 Regulation ....................................................................................................................5

1.2 Warnings .....................................................................................................................5

1.3 Manual handling ..............................................................................................................5

1.4 Pictograms ...................................................................................................................6

1.5 Warnings on the box ...........................................................................................................6

1.6 Abbreviations .................................................................................................................6

2 Safety regulations 7

2.1 General .......................................................................................................................7

2.2 The installation ...............................................................................................................7

3 General boiler information 8

3.1 General .......................................................................................................................8

3.1.1 ErP label ......................................................................................................................8

3.1.2 Gas category ..................................................................................................................8

3.2 Operation ....................................................................................................................9

3.3 Data plate ....................................................................................................................9

3.4 Control panel ................................................................................................................10

3.5 Operational modes ...........................................................................................................10

4 Main components 11

4.1 Standard scope of delivery ....................................................................................................12

4.2 Accessories ..................................................................................................................13

5 Installer important points 14

6 Installation 15

6.1 Overall dimensions of boiler including the wall bracket .........................................................................15

6.1.1 Mounting the wall bracket ....................................................................................................15

6.2 Installation location ..........................................................................................................16

6.2.1 Installation within a kitchen area or wall cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

6.2.2 Removing/installing the front panel ...........................................................................................17

6.3 Installing the boiler ...........................................................................................................18

7 Connection 19

7.1 Connecting to the central heating system circuit ...............................................................................19

7.1.1 Expansion vessel .............................................................................................................19

7.1.2 Thermostatic radiator valves ..................................................................................................20

7.1.3 Underfloor heating ...........................................................................................................20

7.1.4 X-Plan zone Hydraulic diagram ................................................................................................22

7.1.5 X-Plan wiring diagram (Unvented cylinder option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

7.1.6 S-Plan zone hydraulic diagram ................................................................................................24

7.1.7 S-Plan wiring diagram ........................................................................................................25

7.1.8 S-Plan wiring diagram (With outside weather compensation kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

7.1.9 Y-Plan zone hydraulic diagram ................................................................................................27

7.1.10 Y-Plan wiring diagram ........................................................................................................28

7.2 Connection of domestic hot water ............................................................................................29

7.2.1 DHW circuit resistance graph ..................................................................................................29

7.2.2 Boiler with heat pump boiler ..................................................................................................30

7.2.3 Boiler with Pre-Heated Solar Boiler) ...........................................................................................31

7.3 Electrical connection .........................................................................................................32

7.4 Gas connection ..............................................................................................................32

7.5 Connecting room thermostat .................................................................................................33

7.5.1 Connecting Modulating OpenTherm thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

7.5.2 Connecting on/o volt free TPI room thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

7.5.3 Connecting 230V room thermostat ............................................................................................33

7.5.4 Connecting outdoor sensor ...................................................................................................34

7.5.5 Frost protection ..............................................................................................................34

7.5.6 Connecting boiler sensor/thermostat ..........................................................................................35

7.5.7 PC interface .................................................................................................................35

7.5.8 Comfort Touch ...............................................................................................................35

7.6 Flue and air supply duct ......................................................................................................36

7.6.1 Flue, materials and compounds ...............................................................................................36

7.7 Pipeline lengths ..............................................................................................................37

7.7.1 Replacement lengths .........................................................................................................37

7.7.2 Example calculation ..........................................................................................................37

7.8 General layout of the flue .....................................................................................................38

7.8.1 Horizontal wall terminal 60/100mm C13 .......................................................................................39

7.8.2 Flue terminal positions 60/100mm C13 ........................................................................................40

7.8.3 PMK terminal positions 60mm ................................................................................................41

7.8.2 Vertical roof terminal for twin-pipe 80mm flue system C33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

7.8.3 Vertical roof terminal and air supply duct from the facade C53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

7.8.4 Clamping the flue system (twin and concentric) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

7.8.7 Twin flue terminal positions ..................................................................................................46

8 Operation 47

8.1 Using the control panel .......................................................................................................47

8.2 Boiler preparation ............................................................................................................47

8.2.1 Filling and venting the central heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

8.2.2 Domestic hot water facility ....................................................................................................48

8.2.3 Gas supply ...................................................................................................................48

8.3 Commissioning procedure ....................................................................................................49

8.4 Clock function ...............................................................................................................50

8.5 Shutting down the boiler .....................................................................................................51

9 Settings and adjustments 52

9.1 Navigate the settings .........................................................................................................52

9.1.1 Main menu ..................................................................................................................52

9.1.2 Domestic hot water menu ....................................................................................................53

9.1.3 Central heating menu ........................................................................................................54

9.1.4 RF menu .....................................................................................................................54

9.1.5 Service menu ................................................................................................................56

9.1.6 Info menu ...................................................................................................................58

9.2 Setting and adjusting the clock functions ......................................................................................59

9.2.1 Programming the CH on / o times ............................................................................................59

9.2.2 Programming the DHW pre-heat on / o times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

9.3 Parameters ..................................................................................................................62

9.4 Switching DHW comfort function on and o. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

9.5 Adjusting the maximum central heating output ................................................................................63

9.6 Adjusting pump capacity .....................................................................................................63

9.7 Outside weather compensation ...............................................................................................64

9.8 Conversion to another gas type ...............................................................................................65

9.9 Gas/air control ...............................................................................................................66

9.10 Inspection of the gas air control valve .........................................................................................67

9.10.1 Measuring the flue gas at maximum output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

9.10.2 Measuring the flue gas at minimum output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

9.10.3 Minimum output correction ...................................................................................................70

10 Faults 71

10.1 Fault codes ..................................................................................................................71

10.2 Other faults ..................................................................................................................73

10.2.1 No heat (central heating) .....................................................................................................73

10.2.2 Central heating does not reach the correct temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

10.2.3 Central heating system remains too warm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

10.2.4 No domestic hot water (DHW) .................................................................................................74

10.2.5 Domestic hot tap water does not reach the correct temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74

10.2.6 Burner ignites loudly .........................................................................................................74

10.2.7 Burner resonates .............................................................................................................75

10.3 Notifications .................................................................................................................75

11 Maintenance 76

11.1 Annual service procedure .....................................................................................................76

11.2 Annual service continued (syphon maintenance). ..............................................................................76

11.3 Annual service continued (internal maintenance) ..............................................................................78

11.3.1 Annual service continued (cleaning) ...........................................................................................78

11.4 Annual service (re-assemble) ..................................................................................................79

11.5 Annual service checklist ......................................................................................................80

12 Technical specifications 81

12.1 Electrical schematic ..........................................................................................................82

12.2 Product Fiche according to CELEX-32013R0811, Appendix IV ....................................................................84

12.3 NTC resistances ..............................................................................................................84

13 Spares short list 85

15 Benchmark Commissioning & Warranty Validation Service record 87

To be completed at each annual service, not subsequent.

1 PREFACE

The manufacturer Intergas Heating Ltd accepts no liability whatsoever for damage or injury caused by failure to adhere (strictly) to the safety regulations and instructions, or carelessness during installation of the Intergas wall mounted gas fired boiler and any associated accessories

Intergas Heating Ltd are continuously developing ways to guarantee the quality of its products and to improve them where necessary. In so doing we (Intergas Heating Ltd.) reserve the right to modify at any time the features named within this document.

Read and observe all safety instructions within this instruction manual to prevent unsafe situations, fire, explosion, damage to property or personal injury.

1.1 Regulation

The Intergas combination boiler meets the requirements of Statutory Instrument ‘The Boiler (Eiciency) Regulations’ and is deemed to meet the requirements of:

► Low Voltage Directive (2014/35/EU) ► Gas Appliances Regulation (EU) 2016/426 ► Boiler Eiciency Directive (92/42/EEC) ► EMC Directive (2014/30/EU) ► RED Directive (2014/53/EU) ► Ecodesign (2009/125/EC) ► Energy labelling Regulation (EU) 2017/1369

Intergas declares that the materials used in the manufacturing of this appliance are non hazardous and that no substances harmful to health are contained within the appliance.

1.2 Warnings

Intergas accepts no responsibility for the unsatisfactory performance of the appliance or flue arising from the failure to comply with this installation manual. Incorrect installation could invalidate your guarantee and may lead to prosecution.

The appliance cannot be removed from the original place of installation and transferred to another site or re-sold without prior consent from Intergas. You must re-register the appliance with Intergas in order to maintain any remaining warranty.

The boiler must be installed by a competent Gas Safe registered engineer and in accordance with these instructions, It is the installers responsibility to ensure that the installation conforms to the current legislation and Standard Codes of Practice.

Please read these instructions carefully before installing or using the appliance.

1.3 Manual handling

When moving the boiler always keep your back straight, bend your knees, don’t twist, move your feet. Avoid bending forwards or sideways and keep the load as close to your body as possible. Where possible transport the boiler using a suitable trolley, sack truck or get some assistance. Grip the boiler firmly and before liing establish where the weight is concentrated to determine the centre of gravity, repositioning yourself if necessary.

1.4 Pictograms

The following pictograms are used within this installation manual:

CAREFUL / IMPORTANT

Procedures which, if these are not performed with the required caution, can damage the product, the surrounding or the environment or may result in personal injury.

COMMENT

Procedures and/or instructions which, if they are not followed, can negatively aect the operation of the boiler.

SEE

Reference to other manuals

1.5 Warnings on the box

INSTRUCTION (THIS SIDE UP)

Store the appliance upright as indicated on the box.

INSTRUCTION (FRAGILE)

This is a fragile piece of equipment: Please handle with care do not to drop.

INSTRUCTION (FRAGILE)

This is a fragile piece of equipment: Please provide dry storage for the appliance.

INSTRUCTION (STACK)

MAX 3 MAX2

No more than three boxes should be stacked on top of each other.

1.6 Abbreviations

► DHW: Domestic hot water ► CH: Central heating ► CW: Comfort domestic hot water ► HE: High eiciency

► PHS: Pre Heated Solar water. ► LT: Low temperature (zone). ► HT: High temperature (zone)

► OT: OpenTherm ► RF: Radio frequency ► PC: Personal computer ► NTC: Sensor (Negative temperature coeicient) ► PP: Polypropylene ► CAC: Combination air supply duct and combustible

gas flue system (concentric chimney system)

2 SAFETY REGULATIONS

Safety precautions If you smell gas

A gas leak could potentially cause an explosion. If you smell gas, observe the following rules:

► Prevent flames or sparks:

- Do not smoke, use a lighter or strike matches.

- Do not operate any electrical switches or unplug any equipment.

- Do not use the telephone or ring doorbells.

► Turn o the gas at the meter or regulator. ► Open windows and doors. ► Warn your neighbors and leave the building ► Prevent anyone from entering the building. ► Call the National Gas Emergency Service on

0800 111 999 (From a location away from the gas leak). L.P.G. boilers: Call the supplier’s number on the side of the gas tank or cylinder.

2.1 General

Depending on the year of construction, an Intergas HR boiler may contain part(s) in which ceramic fibers are used. Always use the recommended personal protective equipment when working with ceramic fibers.

It is law that all gas appliances are installed and serviced by a Gas Safe registered competent engineer, if in any doubt please check with Gas Safe (0800 408 5500) and in accordance with the following recommendations:

► Current Gas Safety (Installation and Use) Regulations ► All current building regulations ► Building Standards (Scotland) Consolidated ► I.S.813 Installation of Gas Appliances (Ireland) ► IET Wiring Regulations (BS 7671) ► Health and Safety Document (Electricity at Work Regulations) ► UK Water fittings Regulations and Byelaws ► Health & Safety Regulations

2.2 The installation

The installation must comply with the following British Standards codes of practice:

► BS 5440: Flueing and Ventilation for gas appliances of rated input not exceeding 70kW (Part 1 Flues) ► BS 5440: Flueing and Ventilation for gas appliances of rated input not exceeding 70kW (Part 2 Air Supply) ► BS 5546: 2010 Specification for installation and maintenance of gas-fired water-heating appliances of a

rated input not exceeding 70Kw net. ► BS EN 12828:2012+A1:2014 Heating systems in buildings. Design for water-based heating systems ► BS EN 806-1:2000 Specifications for installations inside buildings conveying water for human consumption.

General (802-2 Design, 806-3 Pipe sizing, 806-4 Installation, 806-5 Operation and maintenance). ► BS 6798: 2014 Specification for selection, installation, inspection, commissioning, servicing and

maintenance of gas-fired boilers of rated input not exceeding 70kW net ► BS 6891: 2015+A1:2019 Specification for the Installation and maintenance of low pressure gas installation

pipework of up to 35mm (R1 1/4) on premises ► BS 7593: 2019 Code of practice for the preparation, commissioning and maintenance of domestic central

heating and cooling water in systems ► BS 7671: 2018 Requirements for electrical installations, IET Wiring regulations ► BS 5955-8:2001 Plastic pipework (thermoplastics materials). Specification for the installation of

thermoplastic pipes and associated fittings for use in domestic hot and cold services and heating systems

in buildings.

Reference should also be made to:

► Guide to condensing boiler installation assessment procedures for dwellings (SBSA) ► The institute of Gas Engineers document & managers IGE/UP/7 Gas installations in timber frame and light

steel framed buildings.

3 GENERAL BOILER INFORMATION

3.1 General

The Intergas Xclusive wall-mounted gas boiler is a room sealed unit. The boiler is intended solely to provide heat for the water in a central heating system and domestic hot water installation and is for domestic use only.

The Intergas Xclusive meets the European directives and additional national regulations that are indicated by CE marking. The associated conformity declaration can be requested from Intergas Heating Ltd (also see §14)

The Intergas Xclusive meets the electrical protection class IPX4D.

3.1.1 ErP label

Based on the European ErP Directive (Energy related Products) all newly produced gas fired boilers have to meet minimum standards regarding energy performance. The Intergas Xclusive carries an European energy label containing specific information regarding energy eiciency class (CH and DHW), noise level and maximum power.

Intergas Heang Ltd Xclusive --

The Intergas Xclusive carries label A for both CH and DHW. In addition the Intergas Xclusive meets the following DHW capacity profile:

► Xclusive 24 : L ► Xclusive 30 : XL ► Xclusive 36 : XL

The extensive product fiche can be found in §12.2.

3.1.2 Gas category

Gas category Gas type Gas inlet pressure

2H3P

The Intergas Xclusive is factory-set for H-gas, G20. The boiler may optionally be converted to another gas type (as in §3.1.2) using a conversion set (see §9.8).

(mbar)

Natural gas (G20) 20

LPG (G31) 37

A A B C D E F

+++

A A B C D

2019 811/2013

3.2 Operation

The Intergas Xclusive is a modulating high eiciency boiler. This means that the output is adjusted according to the desired heating capacity. Two separate copper circuits are infused within the aluminium Bithermic heat exchanger.

The boiler has a printed circuit board with microprocessor control, this allows constant calculations to take place during any demand for either heating or hot water, these calculations are based on many factors and measuring points within the boiler. The microprocessor manages and takes control of the modulating output, ensuring optimum eiciency is maintained at all times during production.

3.3 Data plate

Identification of the product

You will find the unit details on the data plate on the bottom of the boiler. The data plate contains, important information and the boiler specification (boiler type and model name), and the serial number:

******

-yymm

PMS

PWS

Qn HS

Qn Hi

BE, CH, DE, ES,

FR, GB, IE, IT, MT

I2E(s), I2H,

IIELL3P, II2H3P,

II2Esi3P

G20-20 mbar G31-37 mbar

B23, ......C93(x)

Tmax

IPX4D

******

Production code - Serial number YY = year of production, mm = month of production

Product Information Number

Data related to Domestic Hot Water

Data related to Central Heating

Information regarding electrical power supply (Voltage, mains frequency, elmax, IP-class)

Permissible overpressure in CH circuit in bar

Permissible overpressure in DHW circuit in bar

Input related to gross caloric value in kilowatts

Input related to net caloric value in kilowatts

Output in kilowatts

Countries of Destination (EN 437)

Approved unit categories (EN 437)

Gas group and gas connection pressure as set at the factory (EN 437)

Approved flue gas category (EN 15502)

Maximum flow temperature in °C

Electrical protection class

3.4 Control panel

The boiler has a fully integrated touch screen control panel that also displays information about the operational status, temperature settings, demand symbols and fault codes.

The display has multiple functions and options please refer to section §9 for further detail.

COMMENT

► The touch screen is very sensitive only

use a finger tip and not any sharp objects.

3.5 Operational modes

The boiler has a number of operational modes:

The boiler is switched o.

The boiler is switched o but is connected to the mains power. In this mode, the display view is characterised by:

► Displaying the power LED [ ► Displays the pressure within the central heating system on

le hand side [ ].

► Displaying a line on the right display [ ].

Boiler is switched o (mains voltage is present)

The boiler is switched on and is ready for a heat demand.

The boiler is switched on and is ready to answer a request for either domestic hot water or hot central heating water. In this mode, the display view is characterised by:

► Displaying the power LED [

]. All other symbols and values

are not displayed.

The boiler is operating and producing domestic hot water.

The boiler is operating and supplying domestic hot water to a tap or shower etc. The display view is characterised by:

► Displaying the power LED [ ]. ► Displaying the flame i.e. burner is switched on [ ]. ► Displaying the tap symbol [ ].

The boiler is operating and producing central heating water.

The boiler is operating and supplying central heating water. The display view is characterised by:

► Displaying the power LED [ ]. ► Displaying the flame i.e. burner is switched on [ ]. ► Displaying the radiator symbol [ ].

Boiler is switched on (ready for heat demand)

Boiler is in operation (domestic hot water)

Boiler is in operation (central heating water)

4 MAIN COMPONENTS

Flue appliance adapter

Air supply duct (for 80mm twin flue only)

NTC Heat exchanger sensor (S0)

Air supply duct (for 80mm twin flue only)

Ignition module

Ignition electrode

vNTC Flue gas sensor (S5)

Fan assembly

Heat exchanger

Expansion vessel shown as silhouette

3bar Pressure relief valve

NTC Central heating flow sensor (S1)

NTC Domestic hot water sensor (S3)

Central heating low pressure sensor

24V DC Gas valve

Heating Modulating Pump

Flow turbine sensor

Condense syphon Printed circuit board and

housing

Mains lead 230 V AC (bare)

Touch screen fascia panel

4.1 Standard scope of delivery

>>Betrouwbaar in warmte >>Betrouwbaar in warmte >>Betrouwbaar in warmte

Check whether the package is undamaged. Unpack the boiler and check whether all components are present. Also check for any damages to the boiler or accessories and, if present, immediately notify the supplier.

Boiler Wall bracket & fixings Flexible condensate hose

Installation and operation

instruction

Garantiebewijs Intergas HR-ketel Garantiebewijs Intergas HR-ketel

Type/Serienr.

Datum installatie:

Volgens geldende voorschriften geïnstalleerd door:

voor klant

Naam installateur:

Adres:

Postcode:

Woonplaats:

Naam koper:

Adres:

Postcode:

Woonplaats:

12345678910

Type/Serienr. Type/Serienr.

Voor de ‘Garantiebepalingen

Intergas HR-ketels’ verwijzen

Datum installatie:

wij u naar onze website:

Naam koper:

www.intergasverwarming.nl

voor installateur

of naar het bij uw HR-ketel

Adres:

bijgevoegde installatievoorschrift.

Postcode:

Op uw verzoek sturen wij u

graag een exemplaar toe.

Woonplaats:

Het garantiebewijs is slechts geldig, indien de aan het garantiebewijs gehechte

antwoordkaart binnen 8 dagen na de installatie wordt ingezonden. Deze kaart

moet volledig en duidelijk worden

van koper en installateur. Door ondertekening van deze kaart verklaart koper

zich akkoord met de staat van de ketel bij aflevering.

12345678910

ingevuld en voorzien zijn van de handtekening

Garantiebewijs Intergas HR-ketel

Datum installatie:

Naam koper:

Adres:

voor fabrikant

Postcode:

Woonplaats:

Installateur

Het garantiebewijs is slechts geldig, indien de aan het garantiebewijs gehechte

antwoordkaart binnen 8 dagen na de installatie wordt ingezonden. Deze kaart

moet volledig en duidelijk worden ingevuld en voorzien zijn van de handtekening

van koper en installateur. Door ondertekening van deze kaart verklaart koper

1234567891 0

zich akkoord met de staat van de ketel bij aflevering.

Postzegel niet nodig

Intergas Verwarming BV

Antwoordnummer 5

7740 VB COEVORDEN

Guarantee card Connection set

4.2 Accessories

Original Intergas accessories can be ordered separately at your local stockist. Instructions about the correct way to assemble and use these accessories are provided with the product ordered and are therefore not included within this installation manual.

Item no 090347

Post-Heating Solar Boiler

conversion set

Item no 081286

Extension L=1000mm inc.

wall bracket (for plume

management kit)

Item no 087910

60/100 flue weather slate

(pitched roof)

Item no 842177

Thermostatic mixing valve

Item no 084661

Bend 45°

Item no 087372

60/100 flue weather slate

(flat roof)

Item no 203207

Outdoor sensor (For

use with weather

compensation)

Item no 084660

Bend 90°

Item no 082975

60/100 extension

L=1000mm

inc. wall bracket

Item no 081285

Elbow 60° (2 per box) (for

plume management kit)

Item no 081295

Plume terminal bend

Item no 081298

Horizontal telescopic oset

wall terminal

Item no 082980

Horizontal non telescopic

straight wall terminal

Item no 081297

Horizontal telescopic wall

terminal

Vertical roof terminal

(inc. boiler adapter

Item no 081284

Elbow 90° (for plume

management kit)

Only to be used in combination with the base adapter on the boiler

Item no 0821973

60/100)

Item no 081294

Plume management kit

(inc. 2x wall brackets)

5 INSTALLER IMPORTANT POINTS

Please read all instructions before fitting this appliance

► The installer must instruct the user on the operation of the boiler, fault code diagnosis and how to reset

the boiler, location of the filling loop and how to re-pressurise the system if the water pressure drops to

below 0.5 bar. ► The installer must hand over these installation and user instructions ensuring the Benchmark

Commissioning Checklist has been completed correctly. ► The attending engineer must complete the service record on the Benchmark Checklist aer each

service and/or replacing any parts within the boiler. ► It is required under Gas Safe Regulations for the installation to be notified and to register the

installation with Gas Safe, and Building Control (Gas Safe Notification). ► You must register the boiler with Intergas heating ltd within 30 days of the installation to validate any

warranty supplied with the boiler, via post, website or MiReg if you are the installer. ► When commissioning the boiler, check the gas inlet working pressure is 20mbar (NG) or 37mbar for

(LPG) on P1 of the boiler gas valve. (Min 17mB (NG) 30mB (LPG) with all connected appliances operating

at full rate). ► Combustion analysis with a correctly calibrated and certificated electronic analyser is essential for safe

commissioning of the boiler, this must be documented within the Benchmark commissioning checklist. ► A pressure reducing valve set to 3.5 bar must be fitted if the mains water supply pressure is above 5 bar,

this should be located no closer than 3 metres proximity to the boiler for expansion purposes. ► In areas where the water hardness is 200ppm or above, appropriate protection must be taken in

accordance with BS 7593 & in line with building regulations Part L. (See Warranty Provisions on page 88,

point 15).

Intergas recommend Hydroflow HS38a wired into the boiler or HS38b which can be powered

separately. ► The end user / home owner should be advised to keep this installation manual in a safe place,

preferably near the appliance for servicing and future reference, it is a legal requirement that any

attending engineer can check the validity of the Benchmark commissioning checklist (Benchmark

certificate). ► It is important to protect the boiler during the installation. In particular, do not allow any dust or debris

to enter the flue connection at the top of the appliance. ► Before operating the boiler please ensure that the copper pipework you are installing is connected

to the appropriate tappings on the boiler. (Plastic pipework where appropriate must be a minimum

distance of 1000mm away from the boiler connections as per BS 5955-2008). ► It is important to chemically treat and thoroughly flush the heating circuits, prior to commissioning

the boiler, in order to remove any residue fluxes and debris from within them, (please isolate the

appliance). The system flush must be carried out to BS 7593:2019 and an appropriate inhibitor added

to the correct dosage, dependant on the system capacity, as indicated on the product used. ► Intergas recommend water treatment in accordance with the Benchmark Guidance on Water Treatment

in Central Heating Systems, we recommend the use of FERNOX, SENTINEL or ADEY inhibitors. It is most

important that correct concentration of water treatment is maintained for the life of the boiler, a water

sample is required upon installation and to be verified by the aforementioned manufacturers should

we attend a warranty call a water sample may be required to keep the warranty valid. (BS 7593:2019) ► As per BS 7593:2019 Intergas recommend the fitting of an approved magnetic type filter to the

heating return pipe under the boiler (Intergas Nickel plated brass system filter recommended).

► This boiler has been factory set but adjustment may be required to the heating output in order to

match the individual heating demand. This can be done by changing parameter P010 (= max. power

CH) or parameter P070 (= max. power domestic water). See §9.1.5 "To modify a parameter". ► Please do not use the pressure relief valve as a means of flushing, draining the boiler or system. ► Aer domestic hot water production a preset time delay will occur this is designed to prevent the boiler

from cycling thus enhancing the overall eiciency further.

Note: an anti-cycle delay time can be set up to a maximum of 15 minutes by adjusting parameter P036

as described in §8.3. ► When required an external expansion vessels should be inverted with the water side facing downwards

and connected to the heating return (not the flow side) this will allow correct draining of system and

help prolong the life of the vessel diaphragm. (precharge air pressure should be set as per the internal

vessel of the boiler i.e. 0.75bar +/- 0.2bar). ► If you experience any problems please refer to the installation and commissioning guidelines within the

boiler instruction manual. (If necessary, please contact Intergas Heating Ltd).

6 INSTALLATION

6.1 Overall dimensions of boiler including the wall bracket

450

120

100

246

160

120

=320=

Connections

277

98h

Central heating

flow

Central heating

return

Gas flow

Domestic cold

water - Inlet

Domestic hot

water - Outlet

Condense

syphon outlet

Flue / Chimney appliance connection

22mm with isolation valve fitted

15mm with isolation valve fitted

Ødn25

Ø60/100 (concentric, wall terminal )

148

h =

H =

Overall dimensions

618 mm

Xclusive 24

Xclusive 30

678 mm Xclusive 36

766 mm Xclusive 24

A B

D E

6.1.1 Mounting the wall bracket

Due to the size and weight of the appliance it is not recommended to install the boiler on a stud wall as this may also cause noise issues.

766 mm Xclusive 30

826 mm Xclusive 36

6565120 6565 70

E C D

275

Refer to the installation dimensions and clearances on the boiler template supplied with this appliance.

6.2 Installation location

The boiler must be installed on a solid brick wall that has suicient strength to be able to withstand the weight of the boiler when filled with water (see Technical data).

The appliance must be connected to a 3 amp fused spur within one (1) meter of the boiler. The condense discharge from the boiler must be connected to an internal drain or waste system where possible to prevent freezing during any adverse weather conditions. Any unheated area's i.e. a lo space or garage must be treated as external and therefore adequate frost protection measures must be taken for the boiler and any pipework etc. (see §6.3)

Make sure the boiler is easily accessible by ensuring that the adjacent clearances are adhered to.

Further dimensions

*D =

600 mm Xclusive 24,30,36

* 5mm clearance from a closing door

600mm for servicing clearnances

min. 10

min. 50

450

min. 200

H =

766 mm Xclusive 24

766 mm Xclusive 30

826 mm Xclusive 36

6.2.1 Installation within a kitchen area or wall cabinet

The boiler can be installed between two kitchen wall units or inside a cabinet that is of suicient size. There must be suicient ventilation above and below the boiler for cooling purposes (as per the adjacent diagram). Any decor panels or grills used to aid ventilation must be removable for servicing and maintenance purposes.

CAREFUL

► The appliance must not be installed

above any heat source as this will invalidate any warranty supplied with the boiler.

min. 250

Minimum dimension 50cm

277

Minimum dimension 50cm

6.2.2 Removing/installing the front panel

► The front cover of the boiler must be removed to perform

various maintenance activities however you must be a

competent Gas Safe registered engineer before carrying out

the following procedure! ► Loosen both screws (1) under the boiler by using a 5 mm

allen key. (They are captive and therefore will not drop out

of the lower housing). ► Slide the front cover (2) upward and then remove it by

pulling it towards you.

COMMENT

► The front cover has a rubber seal around

the inner edge sometimes making it very sti to slide o so please ensure the boiler is secured to the wall correctly before attempting this procedure!

Replacing the room sealed front cover.

To replace the front panel, proceed as follows:

► Position the front panel (3) against the boiler and slide

it downwards until it is correctly connected to the

lower fascia panel.

► Hand tighten screws under the boiler using a 5 mm

allen key (do not over tighten).

CAREFUL

► This is a room sealed cover and therefore

extremely important that it is fitted correctly, failure to do so could lead to products of combustion entering the room / environment where it is situated.

6.3 Installing the boiler

1. Attach the wall bracket.

2. Li the boiler (2 person li) and slide it down onto the wall bracket.

3. Remove the syphon cup.

4. You must fill the syphon cup just over half full with water.

5. Replace the cup and install the supplied black flexible hose onto boiler outlet union.

6. Connect the flexible hose to a 22 mm O.D solvent weld pipe. To minimize the risk of freezing the condensate pipe should be connected internally and terminate to an internal soil stack, (ref.: TB115 Gas Safe & HHIC).

7. Install the flue system (see §7.6).

8. Install the required pipework as per the following sections.

9. Should the condensate be terminated to an external soil pipe, drain, rainwater system or soakaway we only recommend the Condensate PRO system which is available from our normal stockists or heating supplies. https://condensatepro.co.uk

COMMENT

► The Intergas Xclusivehas a boiler-

specific siphon cup. Ensure that the correct version is ordered upon replacement. (Item no 510054)

1. Mount the wall bracket (ensure its level)

4. Fill the condense syphon cup 5. Replace the condense syphon cup

2. Hang the boiler onto the wall bracket 3. Twist and pull to remove the condense

and attach the supplied flexible hose

syphon cup

Open connection to waste system

6. Connect the flexible hose to the waste system via a tundish or similar.

7 CONNECTION

7.1 Connecting to the central heating system circuit

► Flush the central heating system thoroughly as per

BS7593:2019.

► Fit the flow and return pipes to the isolation valves using the

supplied 3/4" fibre washers, noting that the filling link valve attaches to the return side as per the adjacent drawing.

► The pipework must be correctly supported with full wrap

over type clips / brackets.

► Do not over tighten the connections onto the boiler as

this can cause stress damage and possible internal boiler leakage.

The CH system should include the following:

► As per BS 7593:2019 a magnetic type filter such as the

Intergas system filter, should be fitted onto the return pipework as shown in the adjacent diagram.

► When installing the Intergas system filter, the supplied spigot valve should be fitted to the bottom union to enable combined isolation with the boiler return valve.

► The drain / dosing valve at the bottom of the filter housing facilitates the easy draining of the appliance, with the spigot valve and heating flow valve both closed at the same time.

► A drain tap at the lowest point(s) of the installation.

► A full bore spring loaded single check valve, in the return pipework nextto the boiler whenever the pipework rises above the appliance. This prevents the occurrence of thermosyphoning (radiators getting warm) during DHW production.

Preformed flow pipe

Preformed return pipe

7.1.1 Expansion vessel

The appliance is fitted with a expansion vessel adequate for a typical heating system with 8 radiators installed. For larger volume systems, an additional expansion vessel must be fitted. Refer to the below table or contact Intergas for further advice in these cases.

SAFETY VALVE SETTING (bar)

VESSEL CHARGE PRESSURE (bar)

INITIAL SYSTEM PRESSURE (bar)

TOTAL WATER CONTENT of SYSTEM

LITRES

100

125

150

175

200

For syst. volumes other than those

given above, mult. the syst. volume

by the factor across

Intergas system filter.

3.0

0.75 1.0 1.5

1.0 1.5 2.0 1.5 2.0 2.0

EXPANSION VESSEL VOLUME (litres)

3.5 6.5 13.7 4.7 10.3 8.3

7.0 12.9 27.5 9.5 20.6 16.5

10.5 19.4 41.3 14.2 30.9 24.8

14.0 25.9 55.1 19.0 41.2 33.1

17.5 32.4 68.9 23.7 51.5 41.3

21.0 38.8 82.6 28.5 61.8 49.6

24.5 45.3 96.4 33.2 72.1 57.9

28.0 51.8 110.2 38.0 82.4 66.2

0.140 0.259 0.551 0.190 0.412 0.33

Spigot isolation valve

Drain/Dosing valve.

7.1.2 Thermostatic radiator valves

If the radiators have thermostatic radiator valves or valves that can be closed to isolate the flow completely from the return, a minimum amount of water circulation (6ltrs/min *) must be maintained by installing a manual fixed bypass as this will not interfere with the pump modulation, (* also see §9.5).

7.1.3 Underfloor heating

Underfloor heating with pump

For eective operation of the DHW supply any undesired circulation through the appliance as a result of a second pump in the CH circuit must be avoided. Connect the underfloor heating system in a hydraulically neutral manner to the appliance, or install the CH circuit with an normally open zone valve ( I ) to prevent flow through the appliance heat exchanger when there is no CH demmand.

see §9.5. for minimum permissible water circu lation through the boiler heat exchanger.

Underfloor heating connection diagram

A. Boiler B. Under floor circulation pump C. Thermostatic mixing valve D. Spring-operated non-return valve E. Normally closed 230V~ zone valve (Radiators)

. Normally closed 230V~ zone valve (Under floor)

F. Radiators (Fitted with TRV's except room stat location) G. Programmable room thermostat H. Limit thermostat I. Normally open 230V~ zone valve (powered via X4 terminal 3)

 

Underfloor option wiring diagram

230Vac 3amp

Switched

Fused Spur

L N

Wiring centre

Time control to Heating circuit

HTG on

Orange & Grey wires from underfloor Zone are not required. Isolate and make safe.

(If applicable cables not always supplied with this valve model)

1 2

NEUTRAL

EARTH

GREY (P/LIVE)

Room thermostat

3 4 5 6 7 8 9 10

EARTH

M/V SWITCHED LIVE

Zone Valve

FLOW TO

UNDER FLOOR

V4043B

(normally open)

OpenTherm Heating Control

Zone Valve

Heating

(normally closed)

M/V SWITCHED LIVE

SWITCHED LIVE

Parameter P081 must adjusted to value '1'

Switched Live from

NEUTRAL

underfloor heating

SWITCHED LIVE

controls to X3 Pin 2

S/L FROM BOILER

123

V4043H

X15

(24V=)

X13

X14

(24V =)

X12

(24V =)

X11

(24V =)

N/A

X10

(24V =)

N/A

24V=

(230V ~)

230V

(230V ~)

F1 (3,15 AT)

(230V ~)

FUSE

(230V ~)

7.1.4 X-Plan zone Hydraulic diagram

Key to Hydraulic & Wiring diagrams

A. Honeywell V4043H DHW Zone valve (Normally closed) B. Honeywell V4043B Heating Zone valve (Normally open) C. OpenTherm room thermostat (or programmable OT type if

not using the boiler intergral timer option for the heating D. Cylinder overheat thermostat (manual reset) E. Cylinder NTC sensor (art. no. 065117) F. Pressure relief valve (3 Bar) G. T/P safety (8 Bar) H. Expansion vessel (potable)

Built in 6 ltr expansion vessel

Stainless steel unvented cylinder (≥30 kW coil) (storage capacity to be established by the installer)

ErP modulating pump

Additional expansion vessel option see §7.1.1

7.1.5 X-Plan wiring diagram (Unvented cylinder option)

Comments

► The unvented cylinder must comply with G3 regulations regarding

the safety controls which are normally supplied as a kit with the vessel.

► The over heat protection (with manual reset) is wired through our

OpenTherm circuit to prevent the boiler from creating a hot water demand should this safety control operate.

► For rapid recovery a 30 kW rated coil or greater is recommended

(this should be specified when ordering your vessel). Parameter P001 change to option 1 Parameter P081 change to option 3 Parameter P070 adjust output to cylinder coil rating (% of kW)

230v to Overheat thermostat

L N

230Vac 3amp

Switched

Cylinder O/H Stat

Manual reset

Fused Spur

EARTH

Zone Valve

D H W

V4043H

(normally closed)

Hot Water Timer (option) (Volt free switching)

L N

o

1 2

NTC Cylinder Sensor

S/L to HTG M/V

GREY (LIVE)

Wiring Centre

3 4 5 6 7 8 9 10

EARTH

S/L to M/

Zone Valve C/HEATING

V4043B

(normally open)

BLUE (neutral)

DHW S/L to M/V

Orange & grey wires from heating zone are not required, please isolate & make them safe.

(if applicable cables not always supplied with this valve model)

Note:

BLUE (neutral)

DHW S/L

The zone valve B closes when a demand for DHW is created giving

priority to recover the cylinder.

X15

(24V=)

OpenTherm Heating Control

X13

X14

(24V =)

12 123

X12

(24V =)

X11

(24V =)

N/A

X10

(24V =)

N/A

24V=

(230V ~)

230V

(230V ~)

F1 (3,15 AT)

(230V ~)

FUSE

(230V ~)

7.1.6 S-Plan zone hydraulic diagram

Key to Hydraulic & Wiring diagrams

A. Honeywell V4043H DHW Zone valve (Normally closed) B. Honeywell V4043H Heating Zone valve (Normally closed) C. Twin channel Programmer D. Cylinder overheat thermostat (manual reset) E. Pressure relief valve (3 Bar) F. T/P safety (8 Bar) G. Expansion vessel (potable) H. System By-pass (Should be 3 meters from boiler connections) See §9.5 for minimum permissible water circulation through the

boiler heat exchanger.

► To alter the boiler from a combi to a system boiler please see

section §9.1.5 & §9.3 Parameter P001 change to "option 3" Parameter P010 change to required system output % (example 30kW set P010 to 50(%) = 15kW output)

Built in 6 ltr expansion vessel

Stainless steel unvented cylinder (storage capacity to be established by the installer

ErP modulating pump

Additional expansion vessel option see §7.1.1

CH circuit

7.1.7 S-Plan wiring diagram

230Vac 3amp

Switched

Fused Spur

L N

LIVE SUPPLY

Wiring Centre

Twin channel

Programmer

HTG on DHW on

1 2

NEUTRAL

EARTH

M/V/S/L



Cylinder

thermostat



Room

thermostat

P/LIVE

3 4 5 6 7 8 9 10

M/V/S/L

HTG S/L

DHW S/L

P/LINE

Zone Valve

EARTH

NEUTRAL

C/HEATING

V4043H

(normally closed)

Zone Valve

D H W

V4043H

(normally closed)

S/L TO BOILER (DHW)

S/L TO BOILER (HTG)

S/LIVE (BOILER)

23 1

X15

(24V=)

X14

X13

(24V =)

X12

(24V =)

X11

(24V =)

N/A

X10

(24V =)

N/A

24V=

(230V ~)

230V

(230V ~)

F1 (3,15 AT)

(230V ~)

FUSE

Note:With all wiring diagrams when using a digital type room thermostat the Neutral wire from the wiring centre (2) to room thermostat (2) will not be required.

(230V ~)

7.1.8 S-Plan wiring diagram (With outside weather compensation kit)

230Vac 3amp

Switched

Fused Spur

L N

LIVE SUPPLY

Wiring Centre

Twin channel

Programmer

HTG on

DHW on

1 2

BLUE

NEUTRAL

EARTH

M/V S/L



Cylinder

thermostat



Room

thermostat

P/LIVE

3 4 5 6 7 8 9 10

M/V S/L

HTG S/L

DHW S/L

P/LIVE

Zone Valve

G/YELLOW

C/HEATING

V4043H

Zone Valve

S/LIVE (DHW)

S/LIVE (HTG)

S/LIVE (BOILER)

D H W

V4043H

Relay Coil

N/C COM

50051W

Outdoor Sensor S6

23 1234345 1

X15

(24V=)

X14

X13

(24V =)

X12

(24V =)

X11

(24V =)

N/A

X10

(24V =)

N/A

24V=

(230V ~)

230V

(230V ~)

F1 (3,15 AT)

(230V ~)

FUSE

Note:With all wiring diagrams when using a digital type room thermostat the Neutral wire from the wiring centre (2) to room thermostat (2) will not be required.

(230V ~)

7.1.9 Y-Plan zone hydraulic diagram

Key to Hydraulic & Wiring diagrams

A. Room thermostat B. Twin channel programmer C. Cylinder thermostat D. Boiler pressure reflief valve (3 Bar) E. Hot water draw o (Gravity) F. Mid position zone valve G. Cold feed and expansion tank H. System By-pass (Should be 3 meters from boiler connections)

► To alter the boiler from a combi to a system boiler please see section §9.1.5 & §9.3 Parameter P001 change to "option 3" Parameter P010 change to required system output % See §9.5 for minimum permissible water circulation through the boiler

heat exchanger.

Built in 6 ltr expansion vessel

ErP modulating pump

Open vented cylinder (storage capacity to be established by the installer

CH circuit

7.1.10 Y-Plan wiring diagram

230Vac 3amp

Switched

Fused Spur

L N

NEUTRAL

thermostat

Room

EARTH



M/V S/L

Cylinder

thermostat



S/L to BOILER

LIVE

Mid position

Zone Valve

V4073A

Twin channel

Programmer

HTG on DHW on

DHW o

X15

(24V=)

Wiring Centre

X13

X14

(24V =)

LIVE

SUPPLY

X12

(24V =)

1 2

X11

(24V =)

N/A

3 4 5 6 7 8 9 10

NEUTRAL

X10

(24V =)

N/A

HTG S/L

24V=

DHW S/L

(230V ~)

230V

LIVE

(230V ~)

F1 (3,15 AT)

S/L LIVE to BOILER

23 1

(230V ~)

FUSE

(230V ~)

Note:With all wiring diagrams when using a digital type room thermostat the Neutral wire from the wiring centre (2) to room thermostat (2) will not be required.

7.2 Connection of domestic hot water

B, C

► Flush the pipework thoroughly to clean any debris or

residue remaining from the installation (please refer to current Standard Codes of Practice).

► Using the supplied isolation valve, fibre washer and std

15mm copper tail connect the mains inlet cold water.

► Using the supplied swivel union, fibre washer and Long

15mm copper tail connect the domestic hot water outlet.

► Do not over tighten the connections onto the boiler as

this can cause stress damage and possible internal boiler leakage.

Comments

► The pipework should be kept to the minimum lengths

possible and where possible long radius or formed bends to facilitate reduced frictional losses or high resistance circuits.

► The appliance has built-in frost protection, however this

will not protect the entire system, as that will require an external frost protection kit. (The power & Gas supply must be switched on for the frost protection to operate at approximately 5°C to 15°C).

► The Xtreme 24 is equipped with a flow restrictor with a

nominal value of 8 l/min. The Xtreme 30 and Xtreme 36 do not have this feature.

► The Xtreme 36 & 30 have increased flow rates due to their

increased outputs, so a flow limiter is not normally required.

► Where the mains water is 5 bar or greater then a 3 bar

pressure reducing valve must be fitted no closer in proximity to the boiler than 3 metres (for expansion purposes).

► In hard water areas of 200ppm or above a scale reducer must be installed on the mains cold water inlet, Intergas recommend the Hydroflow HS38 powered via X4 connections 1 & 2.

Domestic hot water oultet pipework (long)

Mains cold water inlet pipework (std)

7.2.1 DHW circuit resistance graph

Flow rate (l/min)

0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1,0 1,1 1,2 1,3 1,4 1,5

Water supply system (bar)

(dependant on fittings used and water circuit lengths)

A. Xclusive 24 B. Xclusive 30 C. Xclusive 36

7.2.2 Boiler with heat pump boiler

The boiler is suitable for use in combination with a heat pump unit. If the outlet temperature of a heat pump boiler is lower than 55°C, then the Intergas Xclusive will create a demand to increase this depending on the boilers target temperature setting.

Operational principle:

The domestic hot water outlet connection of the heat pump unit is connected to the input of the thermostatic mixing valve (see the adjacent diagram). If the DHW temperature of the boiler is higher than the set temperature of the mixing valve, the heat pump boiler will be stopped. (The mixing valve does not fully close, a small amount (approximately 10%) will always pass through the Intergas Xclusive.

As soon as the outlet temperature of the heat pump unit becomes lower than the set temperature of the mixing valve, the flow through the Intergas Xclusive will increase. If the flow becomes suicient > 2.5lts/min then the Intergas Xclusive boiler will start producing domestic hot water.

When the outlet temperature of the heat pump unit has become lower than the set temperature of the mixing valve < 12°C, almost the entire domestic hot water flow diverts through the Intergas Xclusive. This time approximately 10% of the flow is now taken from the heat pump unit. The domestic hot water flow rate will be limited to the maximum possible through the Intergas Xclusive (see §7.2.1).

Connection diagram for Xclusive boiler with heat pump unit

A. Heat pump unit B. Xclusive Boiler C. Mixing valve (Set to 55°C) max 60°C D. Mains cold water inlet (service valve required) E. DHW outlet from heat pump unit F. DHW outlet (mixed supply) for consumer

Installation:

The combination must be configured according to the adjacent connection diagram. The following points are important to guarantee a correct operation of the combination.

Thermostatic mixing valve (switched):

The thermostatic switch valve used is a modified valve that meets the specific requirements to which the combination heat pump boiler and Intergas Xclusiveare subject. For the correct operation of the combination, the switch valve has a fixed maximum temperature setting.

Domestic hot water inlet pressure:

For a flow volume of 15 litres per minute, the initial pressure must be a minimum of 2.3 bar. The maximum static domestic hot water pressure for the Xclusive is 5 bar. A pressure reducing valve (set to 3 bar) must be installed to prevent excessive build up, it must be located no closer in proximity to the boiler than 3 meters (for expension purposes).

Maximum flow volume:

If the domestic hot water flow is greater than 20 litres per minute, the Intergas Xclusive will start a domestic hot water demand, regardless of the outlet temperature of the heat pump unit.

Maximum temperature setting of the heat pump boiler:

The outlet temperature of the heat pump unit must not be set higher than 60°C.

Position of thermostatic mixing valve:

To prevent the thermostatic mixing valve being influenced too much by the surrounding air temperature, the valve must be placed in a position and as close as possible to the domestic hot water connection of the boiler (maximum distance of 500mm). This prevents the boiler from igniting every time an outlet tap or shower is operated.

Influence of water flow:

To prevent the flow by the Intergas Xclusivebeing influenced during operation of the valve, the domestic hot water ‘out’ pipework of the combination must run straight (see connection diagram [F]).

7.2.3 Boiler with Pre-Heated Solar Boiler)

A connection set and a thermostatic mixing valve are available to order for this purpose.

Comment:

The NTC cold water sensor must be wired to Connection X13 4/5. When combined with a solar energy system, a thermostatic mixing valve, set at 55°C (max 60°C), must always be installed aer the boiler for safety reasons.

► Pre-heated Solar boiler conversion set item no 090347 ► Thermostatic mixing valve item no 842177

Connection diagram:

A. Intergas Xclusive boiler B. Solar thermal store C. Mains cold water inlet D. Safety group (pressure reducing &

pressure relief valve) E. Hot out to cold inlet max. 85°C F. Domestic hot water outlet G. Thermostatic mixing valve 35°C-65°C

(set at 55°C) TMV3 H. Domestic hot water mixed outlet I. Inlet water NTC sensor

Thermostatic mixing valve

7.3 Electrical connection

CAREFUL

► A fused spur must be located no more

than 1 metre from the appliance.

► For installation within a moisture bound

area i.e a bathroom or kitchen then please consult the current electrical regulations for safe separation distances.

► When working on the electrical circuit

always isolate the 230v supply.

► Should the mains power cord be

replaced, this must be ordered directly from Intergas.

To gain access to the electrical connections or PCB:

► Remove the front panel (see §6.2.2) and pull the PCB

housing forward; then tilt it downwards.

► Consult the electrical schematic in §12.1 for all boiler

connections.

CAREFUL

► The Xclusive complies with IPX4D water

ingress protection. Any cables routed through the PCB housing must have grommets or glands fitted to ensure this integrity is maintained.

► Aer the desired connections have been made, slide the

PCB housing back into the boiler (until the le and right

safety clips are locked) then replace the front room sealed

cover on the boiler; see §6.2.2.

► Aer making the desired connections re-establish the power

supply to the boiler.

7.4 Gas connection

► Using the supplied gas isolation valve & fibre washer

connect the preformed gas pipe to the installation supply

pipework and fully tighten.

► Ensure that the gas pipework is correctly supported with

wrap over type clips.

► Open the main gas valve and boiler isolation valve then

purge the system of air.

► Carry out a full tightness test checking all connections for

any leakage (any leaks must be rectified before proceeding).

CAREFUL

► Before starting any work on the boiler,

► The boiler is intended exclusively to be

► When pollution in the gas is to be

always close the gas isolation valve.

installed on a domestic gas supply with a meter that includes an ECV and pressure governor.

expected a gas filter must be placed in the gas installation pipework to the boiler.

Gas isolation valve

22 mm preformed gas pipe

7.5 Connecting room thermostat

X13

The boiler is suitable for connection to the following room thermostats:

► OpenTherm (OT) thermostat/Intergas Comfort Touch ► On/o thermostat (TPI) ► RF thermostat; see §9.1.4.

7.5.1 Connecting Modulating OpenTherm thermostat

The boiler is supplied with an OpenTherm connection X13 1/2 . This allows the connection of the Intergas Comfort Touch as well as other modulating OpenTherm thermostats without any additional modifications. The Xclusive is also suitable for OpenTherm Smart Power.

► Position the thermostat in a room that functions as a

reference point (in general, the living room or hall).

► Remove the link and connect the modulating thermostat to

terminals 1/2 X13 (also see §12.1); the polarity of the wires

is not important in this situation.

If you would like to make use of the *domestic hot water on/ o switch function of the OpenTherm thermostat, the DHW comfort function must be set to ‘eco’ or ‘on’ (see §9.1.2) and parameter P074 must be set to 0.

O

Remove the yellow link wire prior to connecting the room thermostat

2 1

*Dependant on model type and availability for further information, consult the manufacturers instructions for the OT room thermostat installed.

7.5.2 Connecting on/o volt free TPI room thermostat

The boiler is suitable for connection to a 2-wire on/o room thermostat.

► Position the thermostat in the room that functions as a

reference point (in general, the living room or hall).

► Remove the link and connect the TPI room thermostat to

Connector 1/2 X13 (also see §12.1); the polarity of the wires

is not important in this situation.

► If both OpenTherm and on/o TPI

thermostats are connected, the on/o TPI thermostat will have priority over the OpenTherm thermostat.

7.5.3 Connecting 230V room thermostat

This should be wired to connector X3 1/2.

Connecting Intergas Comfort Touch, OpenTherm and/or on/o volt free TPI room thermostat

O

► Position the thermostat in the room that functions as a

reference point (in general, the living room or hall).

► Connect the 2-wire room thermostat to terminals 1/2

X3 (also see §12.1); the polarity is not important in this

situation however terminal 1 (L) is the supply from the PCB

90 to 230v ac, terminal 2 (S) is the demand signal from the

room thermostat to the boiler.

IMPORTANT (HIGH VOLTAGE)

► Isolate the appliance from the electrical

supply before connecting the thermostat.

X4 X3 (230V)

Connecting 230V room thermostat

7.5.4 Connecting outdoor sensor

The boiler has the facility to operate with an Intergas outdoor weather sensor, part number 203207. The outdoor sensor must be used in combination with an on/o or OpenTherm room thermostat.

In principle, any on/o or OpenTherm room thermostat can be combined with an Intergas outdoor weather sensor.

With an on/o thermostat, the boiler will adjust the flow temperature according to the room target temperature.

With an OpenTherm thermostat, the flow temperature is controlled via the actual internal & external temperatures, this modulates the burner using load control to give a more precise output from the boiler saving energy.

► Connect the outdoor sensor to Connector X13 terminals 3/4

(also see §12.1). For the heating line graph, see §9.7 Outside weather

compensation.

7.5.5 Frost protection

► To prevent freezing of the condensate pipework and the

boiler, it must be installed in a frost-free area..

► The boiler is equipped with a frost protection system.

Should the temperature of the water within the heat

exchanger drop below 5 °C, the pump will run and if

required it will ignite the burner until the temperature of the

water is up to approximately 15 °C.

Outdoor weather sensor part number. 203207

X13 X12

Connecting outdoor sensor

1212

O

Comment

With the on/o TPI room thermostat fitted as per §7.5.2 you must locate the frost stat in an area that will be subject to the coldest conditions, ideally a radiator fitted within the frost-sensitive area must be open on both lock shield & wheel head valves.

► The ideal place to site a frost thermostat is the coldest area

within the property (for example, a garage or roof space).

► Connect the frost thermostat in parallel with an on/o

room thermostat or RF thermostat onto Connector X13 1/2

(also see §12.1).

CAREFUL

► With the use of an OpenTherm

thermostat, a frost thermostat must not be connected in parallel on Connector X13. In this situation, connect the OpenTherm thermostat to Connector X13 and the frost thermostat to Connector X12.

If the (external) frost thermostat is used for the installation and it is connected to the boiler as shown, it will not be active when the boiler is switched o or the power removed.

X13 X12

Frost thermostat and on/o thermostat parallel connection

X13 X12

Frost thermostat and OpenTherm thermostat connection

X13 X12

X14

7.5.6 Connecting boiler sensor/thermostat

► The DHW NTC cylinder sensor can be wired to connector

X13 4/5 (also see §7.1.4 & §7.1.5).

7.5.7 PC interface

The boiler PCB has an interface for a PC. The PC can communicate with the boiler via an IDS cable, or wirelessly through the Intergas USB dongle, providing the appropriate soware has been installed. This facility allows the attending engineer to monitor complete functionality of the appliance, change parameters and view historic fault codes. Engineers must be fully conversant with this utility, training is available from Intergas Heating Ltd. NOTE: IDS cable and USB dongles are subject to availability (Windows operating system not ISO compliant).

NTC Cylinder sensor connection

http://www.intergasverwarming.nl

► Connect the cable to Connector X14 (also see §12.1).

7.5.8 Comfort Touch

It is possible to combine the appliance with the Intergas OpenTherm Comfort Touch Gateway kit this is available in two options:Part number 032034 R.F Gateway inc white Comfort touch thermostat (wired to boiler X13 1/2) Part number 032044 R.F Gateway inc black Comfort touch thermostat (wired to boiler X13 1/2) This set consists of a Intergas gateway and a connection set.

The Intergas gateway provides a connection between an Internet router and the boiler, so that the boiler can be monitored and managed via a web server using the Comfort Touch service app. The Comfort Touch is available via the regular merchant.

If the end user also wants to make use of the Comfort Touch possibilities of the appliance, the set is also available with a Honeywell Round thermostat, part number 032164 R.F Gateway inc Honeywell round R.F thermostat (paired to boiler RF module) For the end user, a consumer version of the Comfort Touch app is available.

The Comfort Touch service and consumer app can be downloaded from both the Google Play Store and the Apple App Store.

X15

X13

PC connection

Comfort Touch App

7.6 Flue and air supply duct

► For the installation of the flue and

air supply duct material, see the manual included with the materials. Further technical information and specific assembly instructions are available upon request.

► Only plastic PP flue material is allowed.

► Make sure that the socket connections

of the flue and air supply duct materials are correctly sealed. Incorrect connection of the flue and the air supply duct can lead to hazardous situations or result in personal injury. Check all flue components for tightness.

► Do not use screws or nails to mount the

flue system as leakage can occur only use the correct support brackets at the recommended distances.

► Do not use any sort of grease when

connecting the flue system. Use water instead. The sealing rubbers can be adversely aected when grease is applied and can also become disconnected.

► Do not mix any components, materials

or ways of connecting from dierent manufacturers as they must be approved by Intergas Heating Ltd.

7.6.1 Flue, materials and compounds

Flue materials

Execution Diameter Material Remark

Rigid Concentric Ø100/60 mm ► Plastic T120 Plastic; Approved material with lip ring sealing.

Rigid single wall Ø80 mm ► Plastic T120 Plastic; Approved material with lip ring sealing.

Flexible Concentric Ø100/60 mm ► Plastic T120

Air supply materials

Execution Diameter Material Remark

Rigid single wall Ø80 mm ► Plastic T120 Plastic; Approved material with lip ring sealing.

Flexible Ø100/60 mm ► Plastic T120 Plastic; Approved material with lip ring sealing.

7.7 Pipeline lengths

R/D = 1

As the resistance of the flue and air supply duct pipes increases, the capacity of the boiler will decrease. The allowed decrease in capacity is a maximum of 5%.

The resistance of the air supply duct and the flue depends on the length and diameter of the piping system and all associated components. For each boiler category, the total allowed pipeline length of the air supply duct and flue is given.

C33

C33 C13

C13C33

The specification of the pipeline length in metres assumes Ø80 mm piping.

7.7.1 Replacement lengths

Elbow of 90°

Elbow of 45°

Boiler Length

Intergas Xclusive 24 100 m

Intergas Xclusive 30 85 m

Intergas Xclusive 36 80 m

R/D=0.5 4 m

R/D=0.5 2 m

7.7.2 Example calculation

Piping Pipeline length Total pipeline length

Flue L1+L2+L3+(2x4m)

Air supply duct L4+L5+L6+(2x4m) 16 m

Comments

► The total pipeline length is:

The sum of the straight pipeline lengths + the sum of all the bends

which equates to a total of 33 metres as per the adjacent drawing.

► If the equivalent length of the air supply duct and flue gas duct

combined are less than the maximum permissible quoted then the

twin flue system meets the requirements at this point.

16 m

C33C53

R/D = 0,5

C13

C13C33C53

R/D = 0,5

Twin Flue General assembly guide

Flue gas section assembly

► Connect the 80mm vertical adaptor 090767 to the boiler (optional

extra).

► Slide the combustion outlet pipe into the adaptor on the boiler. ► Working from the boiler, slide each extension spigot into the previous

socket and continue with each extension or bend.

► The flue must be bracketed every metre and every change in direction. ► Each bend should have a bracket fitted either side.

L3 = 6,5m

L4 = 6m

► Connect the final section to the chosen terminal outlet. ► The flue gas section must be installed with a fall of 5mm/mtr back

towards the boiler.

Air supply section assembly

► Remove either of the air induction caps by liing the tab and rotating it

anticlockwise by 90 °.

► Slide the first air inlet pipe section into the boiler induction socket.

L6 = 1,5m

► Working from the boiler, lide each extension spigot into the previous

socket and continue with each extension and bend.

L1 = 1m

► The air duct must be bracketed every metre and every change of

direction.

► Each bend should have a bracket fitted either side. ► Connect the final section to the chosen terminal outlet. ► The air supply section must be installed with a fall away from the boiler.

(*Not applicable to vertical flue/air sections)

7.8 General layout of the flue

The following drawing shows possible situations schematically.

COMMENT

► The following schematic drawings serve

as examples and the details may dier from the actual situation.

C53

C13

C33

C13

C33

Note for flue systems

Cat. Note according to CE Materials

C13 The terminal is located in the façade; the inlet for the air supply duct is located in the

Terminal

same pressure area as the terminal. Example: combined façade terminal

Other components

C33 The terminal is located above the roof; the inlet for the air supply duct is located in the

same pressure area as the terminal of the flue piping.

Terminal

Terminal at the prefab chimney

Other components

C53 Closed unit, connected to separate air supply duct and flue channels, terminated in

various pressure zones. See the installation manual for the possibilities.

Intake grille

Other components and exhaust cap

7.8.1 Horizontal wall terminal 60/100mm C13

COMMENT

► PP Pipes for the connection of the air

supply duct and the flue from the boiler to the wall terminal 076355 must have a diameter of Ø80 mm.

► The individual flue pipe (Ø80) and/ or

the internal pipe of the combi-pipe wall terminal / extension pipe must be approved by Intergas heating ltd.

Allowed pipeline length

► Twin-pipe Air supply duct and flue pipe together, excluding the length of the combi-pipe wall terminal.

Boiler Length

Intergas Xclusive 24 100 m

Intergas Xclusive 30 85 m

Intergas Xclusive 36 80 m

► Concentric Air supply duct and combustible gas exhaust pipe together, excluding the length of the combi-pipe wall terminal.

Boiler C13

Intergas Xclusive 24 10 m

Intergas Xclusive 30 10 m

Ø60/100

Intergas Xclusive 36 10 m

Assembly of combi-pipe horizontal terminal

► Create an opening of Ø130 mm at the location of the

terminal. ► Shorten the wall terminal to the required length. ► Assemble the concentric flue system. ► Slide the wall terminal in through the opening and attach to

the concentric flue. ► Seal the flue through the wall with sand & cement and fit

the supplied decorative covers to the opening both inside

& out. ► The terminal should be positioned level however any

further extensions must slope back to the boiler 5mm/mtr.

art. no. 086890

art. no. 082969

100mm

7.8.2 Flue terminal positions 60/100mm C13

Concentric Flue 60/100

The boiler utilises a special concentric flue adapter which can only be used with the elbow that is part of the horizontal flue kits.

The flue is not supplied with the boiler and should be purchased separately from your supplier. This flue may be routed to the rear, le or right of the appliance by means of the 900 degree bend, which is supplied in the flue kit.

Note

Only use a pproved Intergas flue products with this boiler, which can be sourced from your boiler or Intergas stockist, with C33 type applications a vertical flue adapter will be required to connect to the boiler.

Flue Terminal position

Terminal Position

Directly below an open able window or other opening

e.g. air brick

distance

Below gutters, soil pipes or drain pipes can be reduced

Min.

to 25mm, as long as the flue terminal is ectended to clear

any overhang. External flue joints must be sealed with suitable slicon seal.

Below eaves 200mm

Below balconies or car front roofs

From vertical drain pipes and soil pip

From internal or external corners

Above ground, roof or balcony level, Terminal guards must be fitted if less than 2 metres from the ground.

From a surface facing a terminal

From a terminal discharging towards another terminal

From an opening in a carport (e.g. door, window) into a dwelling

Vertically from a terminal on the same wall

Horizontally from a terminal on the same wall 300mm

300mm

25mm

200mm

25mm

300mm

600mm

1200mm

1500mm

Above an opening, air brick, opening windows, etc.

Horizontally to an opening, air brick, opening windows,

300mm

etc.

Above roof level (to base of terminal)

From adjacent wall to flue

From an adjacent opening window

From another roof terminal 600mm

300mm

1000mm

Distance to a boundery, unless it will cause a nuisance. BS 5440:Part1 recommends that care should be taken in

sitting terminal in relation to boundary lines. A PMK or Deflector may be fitted.

Terminals adjacent to windows or openings on pitched and flat roofs: The flue should not penetrate this area.

T T1 T2

600mm

2000mm

600mm

Note

Intergas cannot be held responsible for atmospheric conditions when siting flue terminals it is the installers responsibility to ensure products of combustion cannot enter the building under adverse or normal weather conditions.

CAUTION

Once the flue has been installed and the appliance commissioned, the installer should observe the plume direction. Particular attention should be drawn to plume vapour re-entering the boiler via the air intake. If this occurs, it is highly possible the flue is fitted within a negative pressure area and therefore a plume management kit (PMK) must be fitted.

7.8.3 PMK terminal positions 60mm

All measurements in millimetres

200

150

600

Boundary

100

200

300

Window

To reduce the telescopic flue length further:

Separate the telescopic flue, with the terminal end, mark the length required (min. 130mm) for the term inal and cut square, taking care not to damage the tubes. Remove any burrs and chamfer the outer edge of the tubes to assist ease of connection and prevent seal damage. The aluminum tape is not required when reducing the termi nal to a single section.

Balcony

200

150

200

150

Window

300

Door

150

1,200

300

150

Window

300

200

Drainpipe

Terminal Position

600mm distance to a boundary or surface facing a boundary, unless it will cause a nuisance. BS5440:Part1 recommends that care is taken when siting terminals in relation to boundaries.

Adjacent to a boundary line.

Internal/external corners. The air intake clearance can be reduced to 150 mm providing the flue exhaust outlet has a 300

mm clearance.

The flue cannot be lower than 1,000 mm from the top of the

light well due to the build up of combustion products.

4 1,200 mm between air intake and facing terminal.

5 Clearance no less than 200 mm from the lowest point of the

balcony or overhang.

6 1,200 mm from an opening in a car port on the same

wall i.e. door or window leading into dwelling.

7 Balcony kit option.

Using a Plume Management Kit the air intake measurement can be reduced to 150 mm providing the flue exhaust outlet has a 300 mm clearance. Plume kits r unning horizontally must have a 10° fall back to the boiler for proper disposal of condensate. For details on specific lengths see relevant boiler Technical & Specification information.

300 mm minimum clearances to a opening e.g. window. However the minimum clearance to an opening in direction that the plume management is facing, must be increased to 1,500 mm. Where the flue is less than 150 mm to a drain pipe and plume re direction is used the deflector should not be directe-d towards the drainpipe.

Min. distance

600mm

300mm

(Air) 150mm

(Exhaust) 300mm

1000mm

1200mm

200mm

300mm

(Air) 150mm

(Exhaust) 300mm

Installations in car ports are not recommended

7.8.2 Vertical roof terminal for twin-pipe 80mm flue system C33

IMPORTANT

► PP Pipes for the connection of the air

supply and the flue ducts from the boiler to the vertical Terminal must have a diameter of Ø80 mm.

► All the flue pipe components and any

terminal used must must be approved by Intergas heating ltd.

► Intergas Twin-pipe vertical terminal (086883)

Allowed pipeline length

► Twin-pipe Air supply duct and flue pipe combined, excluding the length of the Twin-pipe wall terminal or the twin-pipe wall terminal.

Boiler Length

Intergas Xclusive 24 100 m

Intergas Xclusive 30 85 m

Intergas Xclusive 36 80 m

► Concentric Air supply duct and combustible gas exhaust pipe, excluding the length of the Twin-pipe wall terminal.

Flat roof

Pitched roof

Boiler C33

Intergas Xclusive 24 10 m

Intergas Xclusive 30 10 m

Ø60/100

Intergas Xclusive 36 10 m

Assembly of twin-pipe vertical terminal

► On a sloping roof, install a pitched weather slate (art no.

087910) then slide the terminal through the slate and adjust to vertical. Seal around the storm collar and adjusting section onto the slate with a suitable clear silicone sealant, that is specifically designed for external conditions (not supplied).

► On a flat roof, install a flat roof weather slate (art no. 087372)

then slide the terminal through the slate and ensure it is vertical. Seal around the storm collar using a suitable clear silicone sealant, that is specifically designed for external conditions (not supplied).

► Install the 80/80 twin pipe manifold onto the bottom of the

vertical terminal and secure everything in place with the supplied bracket.

Pitched roof

min. 300

Flat roof

7.8.3 Vertical roof terminal and air supply duct from the facade C53

IMPORTANT

► The air supply duct in the facade must

have an Intergas intake grille (art. no.

082856).

► All the flue pipe components and any

terminal used must must be approved by Intergas heating ltd.

Permissible equivalent pipeline length

Air supply duct and flue pipe combined, excluding the length of the terminal section.

Boiler Length

Intergas Xclusive 24 100 m

Intergas Xclusive 30 85 m

Intergas Xclusive 36 80 m

Assembly of horizontal air supply duct

► The air supply can be made in an arbitrary location in the

façade. ► At the location of the supply, core an opening of Ø90 mm. ► Shorten the air supply duct pipe to the desired length out of

the wall so the cover plate can sit flush. ► Attach the Intergas air intake terminal to the wall using the

4 x screws and plugs provided ► Slide the air supply onto the terminal and attach the

decorative plate to the internal plaster wall face. ► The air supply duct MUST BE angled away from the

appliance to prevent rain entering the boiler during adverse

weather conditions.

Vertical Roof terminal 086883

Intergas intake grille 082856

min. 500

Air cover terminal 075438

Assembly of vertical flue terminal

► On a sloping roof, install a pitched weather slate (part

number 087909) then slide the terminal through the slate and adjust to vertical. Seal around the storm collar and adjusting section onto the slate with a suitable clear silicone sealant, that is specifically designed for external conditions (not supplied).

► On a flat roof, install a flat roof weather slate (part number

075333) then slide the terminal through the slate and ensure it is vertical. Seal around the storm collar using a suitable clear silicone sealant, that is specifically designed for external conditions (not supplied).

► The terminal must be at least 500 mm above the roof

surface secure everything in place with the supplied bracket.

7.8.4 Clamping the flue system (twin and concentric)

IMPORTANT

► These regulations are typical for both

concentric and twin flue systems.

► The flue system must be secured to a solid

structure.

► The flue system should have a continuous

fall back to the boiler (1.5° to 3°). ► Only use Intergas approved brackets. ► Every bend or change of direction must

be secured by using the approved bracket

(excluding the appliance bend).

If the length of the pipes before and aer

the first elbow, are no more than 250mm,

a support bracket must be used and

positioned on the elbow! (See illustration D) ► Every extension must be secured per metre

with a bracket.

This bracket must be clamped around the

pipe ensuring free movement for expansion

and contraction purposes. ► Make sure bracket is locked correctly

depending on its location i.e.

position "A" = pipe location

position "B" = elbow location.

A = bracket on pipe

B = bracket on elbow

Maximum distance between brackets

Orientation

Flue system

Horizontal/

non-vertical

Vertical

Safe-PP 1000 mm 2000 mm

Concentric 1000 mm 2000 mm

► Distribute the length between brackets evenly. ► Each flue system has to contain at least 1 bracket. ► The distance between the boiler and the first bracket must not be more than 500 mm.

max. 1000 mm

max. 2000 mm

A B C

COMMENT

► These examples are typical for

both twin and concentric flue

bracket positioning.

max. 1000 mm

max. 250 mm

Second element aer first elbow

D E

max. 500 mm

max. 250 mm

Second element aer first elbow

fall back to boiler

7.8.7 Twin flue terminal positions

Terminal positions

Terminal Position

Directly below to an openable window or other opening

e.g. air brick

Directly above an opening

Horizontally to an opening 300mm 50mm

D,E

Flue Min. Distance

Air Min. Distance

300mm 50mm

Below gutters, soil pipes or drain pipes

Below eaves

Below balcony or car port roof, Terminal guards must be

75mm 75mm

200mm 50mm

fitted if less than 2 metres from the ground

Above ground or balcony or roof, Terminal guards must

150mm 25mm

be fitted if less than 2 metres from the ground.

From internal or extrnal corners or to boundary

Above ground or balcony or roof, Terminal guards must

300mm 50mm

be fitted if less than 2 metres from the ground.

From a surface or boundary facing a terminal 600mm 100mm

From a terminal discharging towards another terminal

From an opening in a car port (e.g. door, window) into a dwelling

Vertically from a terminal on the same wall

Horizontally from a terminal on the same wall

1200mm 100mm

1500mm 1500mm

300mm 300mm

8 OPERATION

8.1 Using the control panel

Gently touch and release the white power LED symbol

Power on / power o mode.

Gently touch and hold the white power LED symbol for 2 seconds

2sec

8.2 Boiler preparation

8.2.1 Filling and venting the central heating system

► Connect the power cable to a 3 amp fused spur supplied via

a type "A" RCD.

► Switch on the power supply to the boiler, A 22 may

momentary appear on the right display; this means that the internal sensors are being checked. The firmware version will be momentary shown on the le display. The boiler enters standby power o mode, characterised by a line – on the right display and the central heating system pressure on the le display.

► When the central heating pressure is

lower than 0.5 bar, this will be indicated

by a flashing display (if the boiler is in

central heating demand). ► If the central heating pressure is below

0.2 bar then the demand will no longer

be met.

WARNING

► When an additive is added to the

central heating water, this must be

suitable for the materials used in the

boiler,such as copper, brass, steel,

stainlesssteel, plastic and rubber.

Intergas recommend products

manufactured from :

• Fernox Tel 0330 100 7750

• ADEY Innovations Tel 01242 546 777

• Altecnic Calei Group Tel 01785 218 200

Central heating pressure is too low.

► Connect all the pipework then fill the heating system with

mains water via the filling loop provided to a maximum pressure of 1.5 bar (The pressure can be viewed with the power supply on and the boiler switched o, by touching and holding the power LED for 2 seconds).

► Vent the appliance with the manual air vent screw on the

top le hand side of the boiler.

► Vent the air out the entire system with the manual air vent

screws on the radiators.

► Top up the CH installation pressure as required back to 1.5

bar. ► Check the system for any leaks and repair any found. ► Switch on the boiler by touching the control panel just

above the power LED and holding this for 2 seconds. ► Put the boiler in operation using the room thermostat

or Service mode (see §9.1.5) and check the water is

circulating around the system correctly.

Manual air vent

8.2.2 Domestic hot water facility

► Open the cold water main isolation valve under the boiler. ► Vent the heat exchanger and the pipework by opening all

domestic hot water outlets.

Leave the outlets open until all the air has dispersed from

the system then close each one in turn. ► Check all connections and pipework for any leaks, repair

any found as required. ► With the boiler switched on run a domestic hot water outlet

and check the boiler is operating correctly (Only aer the

Gas supply has been commissioned correctly).

Switch on boiler

2sec

Switch o boiler

2sec

8.2.3 Gas supply

► Purge the gas installation pipework to ensure no air

remains. ► Complete a full tightness test any leaks must be repaired

and retested prior to operating the boiler. ► Check the inlet working pressure via P1 at maximum output

(H) which must be ≥17mB with all other appliances at full

rate and gas-air control at minimum output to ensure the

correct CO levels (see §9.9).

(P1) Inlet pressure measurement test point

8.3 Commissioning procedure

Aer filling the heating and hot water systems correctly, the boiler can be commissioned by following the below procedure for this:

► Switch on the boiler by touching just above the power LED

and holding this for 2 seconds. ► Adjust the pump setting depending on the set maximum

capacity and the heating circuit resistance.

To adjust the pump capacity of the boiler; see §9.6. ► Adjust the temperature on the room thermostat to higher

than the actual room temperature so the boiler creates a

heating demand (Timer must be set to on).

Symbols ► Heat up the system. ► Check whether the set central heating output is suicient

to achieve the room target temperature. If necessary, the

maximum central heating output can be adjusted; see §9.3

(parameter P010) and §9.5. ► Check whether the set minimum and maximum values of

the pump output have been adjusted correctly; see §9.3. ► Switch o the boiler by touching just above the power LED

and holding this for 2 seconds. ► Vent the system again once cool and top-up the pressure if

required (see §8.2.1). ► Now switch on the boiler again by touching just above the

power LED and holding this for 2 seconds. ► Check the heating and the domestic hot water facility for

correct operation. ► Instruct the end user about filling and venting and the

operation of the heating and the domestic hot water. ► Hand the installation instructions and warranty registration

card to the customer / end user. ► The heating system must be chemically flushed and treated

to BS7593:2019 as per our "Terms & conditions" failure to

comply will invalidate the warranty supplied with this

product, a system filter should be installed on the return

pipework.

and light up.

Switch on boiler

Switch o boiler

2sec

Garantiebewijs Intergas HR-ketel

Type/Serienr.

Datum installatie:

Volgens geldende voorschriften geïnstalleerd door:

voor klant

Naam installateur:

Adres:

Postcode:

Woonplaats:

Naam koper:

Adres:

Postcode:

Woonplaats:

12345678910

Voor de ‘Garantiebepalingen

Intergas HR-ketels’ verwijzen

wij u naar onze website:

www.intergasverwarming.nl

of naar het bij uw HR-ketel

bijgevoegde installatievoorschrift.

Op uw verzoek sturen wij u

graag een exemplaar toe.

>>Betrouwbaar in warmte

Comments

► The boiler has microprocessor control technology which

ignites the burner and continuously monitors the flame,

modulates the fan and pump with each demand for central

heating output. ► The modulating pump operates during a demand for

heating, it has an overrun facility preset in parameter P033

and it is advised not to adjust this setting. ► The pump automatically runs once every 24 hours for 10

seconds to prevent it becoming stuck during the summer

months, this operation takes place 24 hours aer the last

heat demand. ► Please note the pump does not operate during domestic

hot water operation.

8.4 Clock function

The boiler is equipped with a digital clock and oers the possibility to program both CH and DHW operations separately.

To activate the clock program the following parameters have to be set: For CH operation parameter P040 = 1 (This is factory set to 1 "active") For DHW operation parameter P087 = 1 (This is factory set to 0 "Inactive")

► In CH operation 6 periods can be programmed to switch from CH

o or CH on. ► In DHW operation 4 periods can be programmed to switch the

pre-heat function of the heat exchanger from on to o.

Additionally the following special modes can be chosen:

In CH operation

► P-on (Program on):

The boiler will respond only on CH demands within the

chosen time slots. If the clock program does not contain

any valid switching points, the boiler will remain in standby.

The actual time is shown on the le display indicating that

the clock program is active. ► T-on (Temporary on):

The clock program will be temporary overruled. The boiler will

respond to every CH demand until the next "o" switching point

(t-ON will be displayed on the le side). ► On (Continuous on):

The boiler will respond to every CH demand without any time

limit. ► O:

The boiler will not respond to any CH demand.

(Heating operation is subject to the room thermostat set

point and boiler flow target temperature, outside weather

compensation, if fitted, can restrict the flow temperature for

energy saving purposes, depending upon curve set-point and

outside temperature at that time ).

In DHW operation

► P-on (Program on):

The appliance's DHW comfort function is switched on

continuously within the chosen time slots. In this mode the

heat exchanger will be kept up to temperature to assure rapid

delivery of DHW. If the clock program does not contain any valid

switching points, the heat exchanger will continuously be kept up

to temperature. ► On (Continuous on):

The appliance's DHW comfort function is switched on

continuously. The heat exchanger will be kept up to temperature. ► Eco:

The appliance's DHW comfort function is self learning within the

chosen time slots. The appliance will adapt to the pattern of DHW

usage. As a result, the temperature of the heat exchanger will

not be maintained during the night or during long absence. If the

clock program does not contain any valid switching points, the

self learning feature is maintained. ► O:

The temperature of the heat exchanger is not maintained, as a

result of the delivery of domestic hot water takes slightly longer.

If you don't require rapid delivery of DHW then the comfort

function can be switched o.

Clock shown (P-on active)

T-on active

Note

For setting and adjusting the clock and timer function see §9.2.

8.5 Shutting down the boiler

CAREFUL

► Only drain the boiler and the system if

the mains voltage has been interrupted and there is a chance of freezing.

► Switch the power o to the boiler. ► Remove the 3 amp fuse from the wall spur. ► Turn o the gas isolation valve under the boiler. ► Drain the boiler completely. ► Drain the heating system at the lowest point. ► Turn o the mains cold water supply isolation valve under

the boiler. ► Drain the boiler by disconnecting the domestic hot water

connections under the boiler and the pipework at the

lowest point.

9 SETTINGS AND ADJUSTMENTS

The operation of the boiler can be influenced by the various (parameter) settings within the PCB. Access of these menus, can be made and modified via the touch screen display. NOTE. Some of the settings are only accessible aer entering the installer’s code (see §9.1.5 and §9.3).

► The boiler has a touch screen display panel.

Symbols will illuminate when they are operable and they will be extinguished when they are no longer available.

► 8.8.8.8 8.8.8.8 : Le display / Desired temperature in °C / Central heating pressure

/ Fault code / Time / Information menu ► : - (Minus) button ► : + (Plus) button

: Boiler operating (burner is switched on)

► ► : Power LED ► : DHW demand / DHW comfort setting / Adjusting domestic hot

water setting ► : Central heating demand / Adjusting maximum central heating

temperature ► : Service button ► : Enter button

► 8.8. : Right display / operational code

Touch screen displaying all options

9.1 Navigate the settings

There are several menus to navigate through that are accessible via the touch screen panel. The following menus are available:

► Main menu

First line menu from which all other menus are accessible.

► Domestic hot water menu

Menu in which the domestic hot water-related settings can be modified or set.

► Central heating menu

Menu in which the central heating-related settings can be modified or set.

► RF menu

Menu in which specific RF room thermostats can be assigned to the boiler.

► Service menu

Menu in which the test programs can be activated and the (installer’s) parameters can be modified (installer’s code required).

► Info menu

Menu in which the current boiler characteristics can be obtained.

9.1.1 Main menu

The main menu is accessible by gently tapping just above the power LED. The main menu can be viewed with the boiler switched on or switched o on the fascia (230v power must be switched on). The main menu will be displayed for 1 minute, without intervention, it will then return to its original status.

Initial setting

The following symbols will light up:

► The domestic hot water symbol ► The central heating symbol

Main menu

► The Service symbol

The clock time will be displayed on the le side if enabled.

9.1.2 Domestic hot water menu

The domestic hot water menu has 2 settings and is accessible by gently tapping on the Domestic Hot Water symbol from the main menu. Within the domestic hot water menu:

► The domestic hot water temperature can be adjusted ► The DHW comfort function can be altered

The following symbols will illuminate:

► The Minus symbol ► The Plus symbol ► The Enter symbol

The Central Heating symbol will be extinguished. The le section will illuminate and will display the current preset domestic hot water temperature. By tapping on the domestic hot water symbol once you enter the temperature adjustment menu, by tapping on the DHW symbol again, you enter the comfort setting menu.

To adjust the domestic hot water temperature setting:

1. Tap the Domestic Hot Water symbol temperature is displayed on the le side of the fascia.

2. Using the Plus and Minus buttons, set the desired temperature (for example, 55°C).

3. Tap the Enter button

PP appears on the right display (all other symbols are

A extinguished), which means the setting has been stored.

4. The display returns to the main menu.

to confirm (or wait 30 seconds).

Main menu

. The target

Domestic hot water Temperature adjustment

For a swier supply of domestic hot water, the boiler has a DHW comfort function with the following options:

► P-On:

The DHW comfort function is activated within the chosen time settings. The heat exchanger will then maintain the preset temperature during these times.

► On:

The DHW comfort function is permanently on. The heat exchanger will continuously maintain the preset temperature.

► Eco:

The DHW comfort function of the boiler will self learn. The boiler will adapt itself to the pattern of usage for domestic hot water. This means that the heat exchanger will not maintain temperature during the night or with long absences.

► O:

The heat exchanger is not preheated, the boiler will now act as a normal combination boiler and only operate when there is a demand for DHW. NOTE: during the winter when the heating is operating the heat exchanger will already be at a suicient temperature to facilitate swi DHW supply.

To adjust the DHW comfort function:

1. Tap the Domestic Hot Water symbols 2x

. The preset

comfort setting is displayed on the le of the fascia.

2. Using the Plus and Minus buttons, set the desired comfort setting (for example, P-On).

3. Tap the Enter button

to confirm (or wait 30 seconds).

A PP appears on the right display (all other symbols are extinguished), this confirms the chosen setting has been stored.

4. The display returns to the main menu.

Confirm

Main menu

Domestic hot water menu Tap comfort

Confirm

9.1.3 Central heating menu

The central heating menu has 3 settings and is accessible by gently tapping on the Central Heating symbol from the main menu.

Within the central heating menu:

► the maximum temperature of the central heating water can

be adjusted

► access to the RF menu ► the timer function can be adjusted

The following symbols will illuminate:

► The Minus symbol ► The Plus symbol ► The Enter symbol

The Domestic Hot Water symbol will be extinguished. The le section will illuminate and the current preset

temperature of the central heating water will be displayed.

To adjust the central heating water temperature setting:

1. Tap the Central Heating symbol is displayed on the le side of the fascia.

2. Using the Plus and Minus symbols, set the desired temperature (for example, 60°C).

3. Tap the Enter button A PP appears on the right display (all other buttons are

extinguished), which means the setting has been stored.

4. The display returns to the main menu.

Main menu

. The target temperature

Central heating menu

to confirm (or wait 30 seconds).

Confirm

9.1.4 RF menu

The Xclusive range of boilers have a built-in Ramses 2 RF transmitting/receiving module, this allows the boiler to wirelessly communicate with Honeywell OpenTherm room thermostats T87RF2025 Round, CMS927 & CMS727. Assignment of the thermostat and additional settings can be made via the RF menu.

The RF menu is accessible by touching and holding the Central Heating symbol for 2 seconds. The following adjustments can then be made:

► Assign RF thermostat ► Remove assignment between boiler and RF thermostat

The following symbols will illuminate:

► The Service symbol ► The Enter symbol

The le display will illuminate and, depending on the assignment of the boiler, will show ‘rF1–’ or ‘rF1’.

rF1–:

Boiler and thermostat are not assigned.

rF1:

Boiler and thermostat are assigned.

Tap the Enter symbol to the main menu. To exit the RF menu without saving your settings tap the fascia display just above the power LED, this will take you back to the original menu or standby mode.

(or wait 1 minute) to save and return

Smart Opentherm™

Central heating menu

RF menu (not assigned)

RF menu (assigned)

2sec

To adjust an RF room thermostat:

1. Touch the Central Heating symbol and hold for 2 seconds.

2. The method of assignment is dependent on the type of room thermostat and is described within the installation manual and operation instructions of the wireless room thermostat. Both the appliance and the thermostat

must be in pairing mode to be able to pair.

https://youlearn.honeywellhome.com

3. Aer a successful assignment, ‘rF1’ appears in the le display. Tap the Enter symbol to save.

To remove an assignment:

1. Touch the Central Heating symbol and hold for 2 seconds.

2. ‘rF1’ appears in the le display.

3. Tap the Service symbol to remove the assignment.

4. ‘rF1–’ appears in the le display.

5. Tap the Enter symbol to confirm the removal and return to the main menu.

6. Make a new assignment if desired as described above.

NOTE: Removing an assigned room thermostat will disable the central heating operation until a new one is assigned or a hard wired control is fitted (see §7.5)

Central heating menu

Confirm

Central heating menu

RF menu

2sec

Delete assignment

Confirm

9.1.5 Service menu

The service menu is accessible by first touching the display just above the power symbol then press and hold the service symbol

for 2 seconds.

Within the service menu:

► the test programs can be activated ► access to the (installer’s) parameters ► access to the info menu

The following symbols will illuminate:

► The Minus symbol ► The Plus symbol ► The Enter symbol

The Domestic Hot Water symbol and the Central Heating symbol will be extinguished.

Test programs

The boiler has a test mode facility within the PCB. By activating a test program, the boiler will operate with a fixed fan speed without any of the control functions intervening however, the safety functions remain active.

The following test programs are available:

Program ‘L’

Burner on at minimum output. Press and together once.

Program ‘h’

Burner on at maximum range rated central heating output. Press

and together once.

Program ‘H’

Burner on at maximum output. Press

and twice.

Switching o test program Press

and together once.

Main menu

2sec

Service menu

To activate the ‘L’ test program:

1. Press the Service symbol

and the Minus button once at the same time. The symbol ‘L’ will appear on the right of the display.

2. Tap the Minus button and the Plus button at the same time to terminate the program.

To activate the ‘h’ test program:

1. Press the Service symbol and the Plus symbol once at the same time. The symbol ‘h’ will appear on the right of the display.

2. Tap the Minus symbol and the Plus symbol at the same time to terminate the program.

To activate the ‘H’ test program:

1. Press the Service symbol and the Plus symbol twice at the same time. The symbol ‘H’ will appear on the right of the display.

2. Tap the Minus symbol and the Plus symbol at the same time to terminate the program.

Test program ‘L’

Service menu

Test program ‘h’

Service menu

Test program ‘H’

(Installer’s) parameters

The (installer’s) parameters within the PCB are factory set as detailed within table in §9.3. These parameters can only be modified using the installer’s access code. The installer’s code is shown on the le display and is preceded

by the letter CC. The parameters are also shown on the le display and are

preceded by the letter PP.

To modify a parameter: (for example, modify parameter P031 from 80 to 90)

1. Tap the Service symbol and the Enter symbol at the same time. The Enter symbol

is extinguished and all

other buttons remain on. ‘C000’ appears in the le display.

2. Using the Plus symbol and the Minus symbol , set the installer’s code (C015) and tap on the Service symbol . Parameter ‘P001’ will now be shown on the le display.

3. Using the Plus button and the Minus button , set the desired parameter (in this example, ‘P031’) and tap on the Service button . The current value of the relevant parameter will be shown on the le display (in this example, ‘80’).

4. Using the Plus symbol and the Minus symbol , set the desired value of the parameter (in this example, ‘90’).

5. Tap the Service symbol . Repeat Steps 3 and 4 to set any additional parameters.

6. Tap the Enter symbol

to confirm. A PP appears on the right display (all other symbols are extinguished), which means the settings have been stored.

7. The display returns to the initial setting and is ready for any heat demand.

Service menu

► By tapping just above the power LED during

any parameter modification will cancel the procedure without saving any modifications made. The display will return to the initial setting and is ready for any heat demand.

9.1.6 Info menu

The info menu is accessible by touching the Service symbol from the service menu and holding it for 2 seconds. (Note if you are not in the service menu you will need to touch the service symbol and hold it for 2 x 2 seconds). Via the info menu certain boiler operational statistics can be viewed.

Info menu Ionisation current

The following symbols will illuminate:

► The minus symbol ► The plus symbol

Respectively the right and le display will display the relevant infocode and its corresponding value.

By tapping the plus symbol and the minus symbol the following characteristics are displayed in succession:

Le display Right display

► Ionisation current in A ► Domestic hot water flow in litres/minute ► Boiler output in kW ► Pump RPM in % ► Last fault code ► Current PCB Firmware version ► Current Firmware version DSP processor ► Temperature sensor S0 (Heat exchanger) ► Temperature sensor S1 (Htg flow) ► Temperature sensor S2 (not present) ► Temperature sensor S3 (DHW) ► Temperature sensor S4 (not present) ► Temperature sensor S5 (Flue gas) ► Temperature sensor S6 (Outdoor sensor option) ► Temperature sensor S7 (Cylinder sensor option)

Info menu DHW flow

Info menu Boiler output

Info menu Pump RPM

Info menu Last fault code

Info menu Current PCB firmware version

Info menu Current Firmware version DSP processor

Info menu Temperature sensor S0 (Heat exchanger)

Info menu Temperature sensor S1 (Htg flow)

Info menu Temperature sensor S3 (DHW)

Info menu Temperature sensor S5 (Flue gas)

9.2 Setting and adjusting the clock functions

Show actual time

► With the boiler in standby or operating, gently tap just above

the power LED to access the main menu (also see §9.1.1). The actual time is shown in the le display. The symbols ,

and will also illuminate.

► If the boiler is switched o when accessing the main menu

the symbols and will also illuminate.

Clock setting and adjusting

► Ensure parameter P087 is set to 1 (clock active) default = 1 ► Ensure the boiler is switched o by touching and holding

just above the power LED and holding this for 2 seconds.

► Tap just above the power LED to access the main menu.

Adjust the clock to the correct time by pressing either the or symbol. Note: Holding the or symbol for more than 1 second will make the clock time adjustment scroll faster.

► Tap the Enter symbol to confirm.

Note: By tapping just above the power LED instead of the Enter symbol the display returns to the main menu without saving any changes.

Clock shown (boiler standby)

Clock shown (boiler switched o)

Main menu

Confirm

9.2.1 Programming the CH on / o times

► With the boiler in standby or operating, gently tap just

above the power LED to access the main menu. The symbols , and illuminate.

► Tap on the Central Heating symbol. ► Tap on the Service symbol. ► The symbols , , and are displayed. Also the first

switching period "t1" illuminates on the le display.

► Tapping the or symbol will scroll between the 6

dierent on/o switching periods.

► Choose a switching period (for instance "t1") and tap on the

Central Heating symbol.

► Tap on the or symbol to set the time and tap the

Central Heating symbol again to set the desired action, use the or symbol to select either On / O or –. The options are as follows:

► On: Start period CH on providing there is a demand

from the room thermostat.

► O: End period CH o. No hearting demand will be

provided (boiler frost protection only).

► – – : No action. The time period set will be ignored

during this section resulting in no On or O period.

► Tap on the Central Heating symbol to select the

next switching period. Set the switching time and the corresponding action and repeat this, if required, for all 6 switching periods.

► Tap the Enter symbol to confirm. The switching times

and actions will be saved in the boiler PCB. (Aer 2 minutes of inactivity changes made will also be saved). A PP appears in the right display before it returns to the Central Heating menu. Note: By tapping just above the power LED instead of the Enter symbol the display returns to the Central Heating menu without saving any changes.

Main menu

Central heating menu

Switch moment 1

Switch point t1

Action moment t1

To apply the clock program

► With the boiler in standby or operating gently tap just above

the power LED to access the main menu (also see §9.1.1).

► Tap on the Central Heating symbol. The current

temperature of the central heating water is illuminated in the le display. Tap the Central Heating symbol again to activate the programmed time settings.

► Using the Plus or Minus symbol, set the desired

program option (P-on, T-on, On or O).

► Tap the Enter symbol to confirm. The chosen program

option will be saved in the boiler PCB. (Aer 2 minutes of inactivity any changes made will automatically be saved. A PP appears in the right display and then returns to the Central Heating menu. Note: By tapping just above the power LED instead of the Enter symbol the display returns to the Central Heating menu without saving any changes.

9.2.2 Programming the DHW pre-heat on / o times

► With the boiler in standby or operating gently tap just above

the power LED to access the main menu. The symbols ,

and illuminate.

► Tap the Domestic Hot Water symbol

is shown on the le display. Tap the Domestic Hot Water symbol

again to switch to the clock program setting ► Tap on the Service symbol. ► The symbols , , and are displayed. Also the first

switching period "t1" illuminates on the le display.

► Tapping the or symbol will scroll between the 4

dierent on/o switching periods.

► Choose a switching period (for instance "t1") and tap on the

Domestic Hot Water symbol

► Tap on the or symbol to set the time and tap the

Domestic Hot Water symbol

again to set the desired action, use the or symbols to select either On / O or –. The actions to be set are as follows:

► On: Start period, DHW pre heat will now keep the heat

exchanger at the preset temperature.

► O: End period, DHW pre heat is now deactivated so

the heat exchanger will not be kept at temperature.

► – – : No action. The time period set will be ignored

during this section resulting in no On or O period.

► Tap on the Domestic Hot Water symbol

next switching period. Set the switching time and the corresponding action and repeat this, if required, for all 4 switching periods.

► Tap the Enter symbol to confirm. The switching times and

actions will be saved in the boiler PCB. (Aer 2 minutes of inactivity changes made will also be saved). A PP illuminates in the right display before it returns to the Central Heating menu. Note: By tapping just above the power LED instead of the Enter symbol the display returns to the Central Heating menu without saving any changes.

. The set temperature

to select the

Main menu

Domestic hot water menu Temperature

Switch moment 1

Switch point t1

Action moment t1

To operate the preheat with the programmed times

► With the boiler in standby or operating gently tap just above

the power LED to access the main menu (also see §9.1.1).

► Tap on the domestic hot water symbol

. The current

temperature is illuminated in the le display. Tap the Domestic Hot Water symbol

again to activate the programmed time settings.

► Using the Plus or Minus buttons, set the desired

program setting (P-on, On, Eco or O).

► Tap the Enter symbol to confirm. The chosen program

setting will be saved in the boiler PCB. (Aer 2 minutes of inactivity changes made will automatically be saved). A PP illuminates in the right display before it returns to the Central Heating menu. Note: By tapping just above the power LED instead of the Enter symbol the display returns to the Domestic Hot Water menu without saving any changes.

9.3 Parameters

Para

metre

P001P001

P010P010

P030P030

P031P031

P032P032

P033P033

P034P034

P035P035

P036P036

p040p040

P057P057

Set

Setting

System type 0

Set maximum central heating output

Central heating pump setting 0

Maximum capacity of modulating central heating pump

Minimum capacity of modulating central heating pump

Central heating pump overrun aer central heating demand

Central heating pump overrun aer boiler operation

Pump modulation

Anti-cycle time central heating

Activate clock program CH operation 1

Response for OpenTherm room thermostat 1

value Description/Setting range

------100

0 = Xclusive Combination 1 = Xclusive System boiler + cylinder 2 = Xclusive Instantaneous water heater 3 = Xclusive System boiler

65 Value displayed as a percentage (%)

35 Set 15% of parameter P031

75 = Xclusive 36 100 = Xclusive 24 / Xclusive 30 25% to 100% (see §9.5)

0 = overrun active 1 = continuous

1 0 to 15 minutes

1 0 to 15 minutes (n/a for Combi boiler)

0 = o

1 = on

Delay time for central heating only 0 to 15 minutes

(this does not delay DHW production)

0 = inactive 1 = active

0 = do not respond to heat demand if requested temperature is lower than 30°C 1 = respond to heat demand with minimum flow temperature limited at 30°C 2 = respond to heat demand with maximum set flow temperature (on/o function)

P059P059

P070P070

P074P074

P075P075

P077P077

P081P081

p087p087

Maximum setting value of flow temperature 80 10°C to 90°C

Set maximum DHW output 100 20% to 100%

Number ECO days (During pre-heat) 7 0 to 10 days

Max flow temp during DHW production 80 60°C to 90°C

Waiting time central heating demand aer DHW operation

Setting of three-way valve or electric shuto valve

Activate clock program DHW operation 0

 0 to 15 minutes

0 = powered during central heating demand

1 = powered during DHW operation

0 = inactive 1 = active

DHW comfort function o.

9.4 Switching DHW comfort function on and o

H/M

L/M

0 8 17 25 33

It is possible to switch on and o the DHW comfort function from an OpenTherm room thermostat (provided the thermostat supports this function). To do this, the boiler must be set at the ‘eco’ setting and the parameter P074 must be set to 0. The self-learning character of the control is therefore switched o. (See section §8.4 for further options).

9.5 Adjusting the maximum central heating output

The maximum central heating output is factory-set. If this needs to be adjusted to suit the requirements of the property, then the output can be modified via parameter P010. See the table below: Setting central heating output.

Desired central heating

output in kW (approx.)

P010P010

24 30 36 24 30 36

100

13.8 19.4 25.7 6.6 9.3 12.3

10.6 14.6 19.3 5.1 6.9 9.2

7.3 9.8 12.8 3.5 4.7 6.1

5.4 7.0 9.0 2.6 3.3 4.3

25 -

Note: The output during combustion will slowly increase or decrease as per the "set" flow target temperature (modulation on T

9.6 Adjusting pump capacity

The Xclusive boiler has an ErP pump that modulates based on the central heating output demand. The minimum and maximum output of the pump can be adjusted with the parameters P031 and P032. See section §9.3. The set value of parameter P031 (max. pump setting) is a percentage of the maximum pump capacity and is linked to parameter P010 maximum central heating system output. The set value of parameter P032 (min. pump setting) is linked to the minimum central heating output. The pump capacity must be set so that the temperature dierencial (t) between the flow and return is correct for the system design criteria. If the central heating load modulates between the minimum and maximum value, the pump capacity will modulate proportionately with it.

5.1 6.4

Xclusive

Minimum flow

quantity (ltrs/min)

2.4 3.1

flow

100%

75%

Pressure loss graph boiler central heating side

A. Xclusive 24 B. Xclusive 30 C. Xclusive 36

50%

25%

9.7 Outside weather compensation

When an optional Intergas outdoor sensor is connected, the heating flow temperature will be automatically controlled according to the set heating curve, depending on the outside temperature at that time.

The weather-dependent control functions solely with an on/o room thermostat. When using an OpenTherm room thermostat, the outside temperature will be relayed, but the heating line of the central heating boiler will not be active.

Taking the graph as an example and using the factory setting A. With an outside temperature of -9°C the boiler will achieve an approximate heating flow temperature of 80°C Adjusting the OTC to example B. will result in an approximate heating flow temperature of 60°C.

Heating line

X: T outside in °C Y: T flow in °C A. Factory setting

CH = 80°C, T

max

B. Example

CH = 60°C, T

max

CH = 25°C, T

min

CH = 25°C, T

min

out = -9°C, T

min

out = -9°C, T

min

out = 25°C)

max

out = 25°C)

max

T flow in °C

-30 -20 -10 0

Tmax.

Tmin.

10 20 30

T outside in °C

9.8 Conversion to another gas type

IMPORTANT

► Only qualified competent gas safe

registered engineers may work on the boiler and Intergas training is recommended before undertaking the following procedure.

If the boiler is connected to a dierent gas type than originally set by the manufacturer, then the gas restriction ring must be replaced. Conversion kits for other gas types are available to order.

Changing / replacing of the gas restriction ring

► Switch o the boiler and isolate the power supply. ► Close the gas isolation valve supplied with the boiler and

test to ensure there is no let-by (the valve must be replaced

if faulty or letting by before continuing with the conversion). ► Remove the room sealed front casing of the boiler. ► Disconnect the union above the gas valve and rotate the gas

mixture pipe clear of the gas valve. ► Replace the O-ring seal and gas restriction ring with the

ones supplied in the new conversion kit (ensuring they are

the correct type for the gas category being supplied to the

boiler). ► Reassemble in reverse order. ► Open the boiler gas isolation valve. ► Check the gas connections prior to the gas valve for

tightness. ► Reestablish the power to the boiler. ► Briefly operate the boiler checking all unions above the

gas valve for tightness with a calibrated electronic gas leak

detector or leak detection fluid . ► Now check the adjustment of the gas/air proportion (see

§9.10 to §9.10.3).

► Place the supplied, fuel category sticker, over the existing

one on the gas valve. ► Place the second supplied, fuel category sticker near the

data plate under the boiler. ► Aer adjusting the mixture correctly and completing all gas

safety checks, as per regulation 26(9), then replace the room

sealed front cover to check the flue integrity at full gas rate

("H" in the display).

Gas mixture pipe

Union connection

O-ring Gas restriction ring

9.9 Gas/air control

IMPORTANT

► Only qualified competent gas safe

The gas/air control valve is factory set to optimise combustion for the gas type used. The gas type (Natural Gas or LPG) is detailed on the data plate situated under the boiler The boiler must only be operated with the gas category specified on the aforementioned data plate. The boiler may optionally be converted to another gas type using a conversion set. See §9.8. For the correct gas restriction ring, see the table below.

Table 1: Gas restriction rings

Boiler type Xclusive

24 528 392 315

registered engineers may perform adjustments to the gas/ air ratio control on the gas valve.

Gas category

Fan

Venturi

Insert

number

Natural gas

G20

20 mbar

Gas restriction ring number

LPG

G31

30 & 50 mbar

30 500 450 370

36 500 450 370

By default, the boiler is set to natural gas G20 unless otherwise stated on the boiler carton and data label.

To ensure correct operation of the gas air control valve a calibrated electronic flue gas analyser must be used, taking the measurement directly from the flue sampling test point with the appliance firstly at high (min 10 minutes) and then minimum output (for this, see §9.10.1 and §9.10.2). Any adjustments to the valve must only be corrected at minimum out (see §9.10.3).

IMPORTANT

► Inspection of the gas/air control valve must

be carried out with room sealed casing opened.

► The measurement must be performed

based on O2 ; in other words, the flue gas analyser must have an O2 sensor.

► The deviation of the flue gas analyser may

be a maximum of ± 0.3% (based on O2 ).

► Any extreme weather conditions i.e. high

winds can influence the results of the test.

► Any readings that are out of tolerance

during maximum output cannot be corrected by adjusting the gas valve. The boiler must be meticulously inspected for gas quality / type, correct components used (especially the gas restriction ring and the fan including venturi).

► When replacing components and/or

converting to another gas type, the operation of the gas air control valve must always be checked.

9.10 Inspection of the gas air control valve

9.10.1 Measuring the flue gas at maximum output

A. Switch o the boiler (see §8.2.1).

A dash

–– will appear on the right display and the central heating

pressure will be visible on the le display.

B. Remove the room sealed cover of the boiler by loosening the 2x

5mm Allen key screws (1) and then sliding it up and forward (2).

C. Remove the cap of the flue gas sampling test point (3) on the

appliance connector on top of the boiler.

D. Place the sampling probe of the calibrated electronic flue gas

analyser into the flue gas sampling point (3).

IMPORTANT

► Make sure that the flue gas analyser is

calibrated. The start-up procedure of the flue gas analyser must be completed before the analyser probe is placed in the flue gas measurement point.

► The analyser probe must completely seal

o the flue gas measurement point to provide a reliable measurement.

► The end of the analyser probe must be

located entirely in the flue gases (middle of the flue gas pipe).

E. Switch on the boiler by touching above the power light for 2

seconds.

F. Switch on the boiler to maximum output. To do this, hold the

Service symbol and at the same time tap the Plus symbol

twice until the capital letter HH appears on the right display.

G. Wait until the readout of the flue gas analyser is stable (at

least 10 minutes).

IMPORTANT

► Make sure that the capital letter HH

appears on the right display. This provides assurance that the boiler is operating as maximum load.

H. Note the measured CO

CO2(H) = measured maximum output CO2 value

I. Check according to Table 2 whether the measured

maximum output CO2(H) % is between the indicated upper

and lower limits.

(H) value.

Cap

Flue gas analyser

Table 2: Allowed CO

(H) limits at maximum output (open casing)

Gas category

Value limits

Natural gas

G20

[%] CO2 [%]

Upper limit 9.6 10.8

Lower limit 8.6 9.8

IMPORTANT

► Any readings that are out of tolerance

J. The flue gas performance measurement must also be

checked at minimum output (see §9.10.2).

9.10.2 Measuring the flue gas at minimum output

Before measuring the flue gases at minimum output, the measurement at maximum output must be completed. See §9.10.1. The measured CO2 (H) % at maximum output is important to determine equilibrium, this must be completed before checking the minimum output %.

LPG

G31

A. Switch on the boiler at minimum output. To do this, tap

simultaneously the Service symbol and the Minus

symbol until the capital letter LL appears on the right

display.

B. Wait until the readout of the flue gas analyser is stable (at

least 10 minutes).

C. Note the measured CO2(L) value.

CO2(L) = measured minimum output CO2 value

D. Check according to Table 3 whether the measured

minimum output CO2(L) value is between the indicated

upper and lower limits.

E. If the minimum output measurement falls outside the limits

given in Table 3a or 3b, continue at §9.10.3 to adjust the

gas valve. If the setting is correct, continue to Step F.

► The CO

upper limit is the CO2(H) value that

was noted during the maximum output measurement. (See §9.10.1, Step H)

Table 3 : Allowed CO2(L) limits at minimum output (open casing)

Gas category

Value limits

Upper limit CO

Natural gas

G20

[%] CO2 [%]

(H) CO2(H) - 0.3

LPG

G31

Lower limit 8.4 9.4

IMPORTANT

► The gas air control is correctly set if the

measured value at minimum output falls within the indicated upper and lower limits. Adjustment of the gas air control is not necessary in this case. The setting at minimum output must be adjusted using the method described in §9.10.3 if the measured value is outside the indicated limits.

Example (Natural gas G20)

► During maximum output a CO2(H) value

of 9.0 % has been measured. In this case the CO2(L) value at minimum output must be 8.7 ± 0.1 % (= 0.5x CO2(H) + 4.2) as stated in the table 4 and 5. When measuring the gas-air ratio at minimum output (L) and the value is out of this range then it must be adjusted, as described in §9.10.3

F. Reattach the room sealed cover and tighten the 2 screws by

hand.

Check the CO value at minimum output. The maximum

allowed CO measurement value is 160ppm.

G. Switch the boiler to maximum output. To do this, hold

the Service symbol and at the same time tap the Plus

symbol twice until the capital letter HH appears on the

right display. Check the CO value at maximum output. The

maximum allowed CO measurement value is 160ppm.

H. Switch o the boiler. I. Remove the probe of the flue gas analyser from the flue gas

sampling point and carefully replace the cap on the adapter

above the boiler.

J. Switch on the boiler again. K. Check the gas integrity of the flue gas sampling point. L. Carry out a flue integrity test via the air sampling point on

the boiler adaptor.

9.10.3 Minimum output correction

Before the minimum output correction is performed, the maximum output and minimum output measurements must be completed. The measured CO2(H) value at maximum output is important for determining the correct value for the setting at minimum output (see §9.10.1 and §9.10.2).

A. Remove the dust cap of the gas valve so that the adjustment

screw is accessible.

B. Switch on the boiler at minimum output. To do this, tap

simultaneously the Service button and the Minus button

until the capital letter LL appears on the right display.

C. Wait until the readout of the flue gas analyser is stable (at

least 3 minutes).

D. Measure the CO2(L) value. E. Using the adjustment screw B, set the correct CO2(L) value.

For the correct CO2(L) setting value, see Tables 4a or 4b.

F. Reattach the cover screw of the gas valve so that the

adjustment screw is sealed.

G. Check the measurements at both maximum output and

minimum output noted in §9.10.1 and §9.10.2 (start with

Step F in §9.10.1) to ensure the correct flue gas emission

levels are obtained.

► Select the correct table depending on the

applicable gas category:

4a: natural gas (G20)

4b: LPG 3P (G31)

► The maximum output measurement

value is important for a correct adjustment. This measurement value was noted during the maximum output measurement CO2(H) (see §9.10.1, Step H).

► Turning the adjustment screw to the right

increases CO2.

Turning to the le decreases CO2.

► Turn the adjustment screw with small

steps and wait aer each turn until the measurement stabilises.

Adjustment screw

Dust cap

Use a T15 Torx drive for the dust cap removal & oset adjustments

Clockwise to increase CO

Anticlockwise to decrease CO

Table 4a: Checking CO2(L) levels for Natural gas (open casing)

Natural Gas G20 (20 mbar)

Measured value at

maximum output

(see §9.10.1, Step H)

(H) [%] CO2(L) [%]

Setting value minimum

output

(= 0.5 x CO

(H) + 4.2)

9.6 9.0 ± 0.1

9.4 8.9 ± 0.1

9.2 8.8 ± 0.1

9.0 8.7 ± 0.1

8.8 8.6 ± 0.1

8.6 8.5 ± 0.1

Table 4b: Checking CO2(L) levels for LPG (open casing)

LPG G31 (37 mbar)

Measured value at

maximum output

(see §9.10.1, Step H)

(H) [%] CO2(L) [%]

Setting value minimum

output

(= CO

(H) - 0.3)

10.8 10.5 ± 0.1

10.6 10.3 ± 0.1

10.4 10.1 ± 0.1

10.2 9.9 ± 0.1

10.0 9.7 ± 0.1

9.8 9.5 ± 0.1

Example (when using natural gas G20)

► During maximum output, a CO2(H) level of

9.0% is measured. In this instance a minimum output CO2 value must be 8.7 ± 0.1%.

10 FAULTS

10.1 Fault codes

Viewing fault codes

If the boilers PCB detects a fault, this is indicated by a flashing service symbol

as F004F004, is illuminated on the le display. The service symbol remains flashing until the boiler has reset or where required the faulty component has been replaced.

Resetting the boiler

The boiler can be reset by touching the flashing Service button and holding it for 2 seconds. If the fault code reoccurs an Intergas trained engineer should be requested.

on the display. A fault code, such

Fault code illuminated

Reset

IMPORTANT

► Using the fault code table below to

establish the cause of the issue before

attempting to reset the boiler. NOTE: A reset is not possible when a component is outside its tolerance values.

The following fault codes can be established:

Fault code Description Possible cause / solution

F000F000

F001F001

F002F002

F003F003

F004F004

F005F005

F006F006

Sensor S0 is defective. ► Replace heat exchanger sensor S0.

► Vent the heating system & boiler heat exchanger (see §8.2.1).

► Pump does not operate (check power, impellor, replace pump. Temperature is too high during central heating demand.

Temperature too high during DHW demand.

Flue gas temperature is too high.

No flame during start-up.

Flame failure during normal operation.

Flame simulation.

► Check wiring to the CH flow sensor S1 (ensure its connected and

not damaged). ► Check the CH flow sensor S1 (is located and installed correctly) ► Check for the correct operation of CH flow sensor S1. ► Replace central heating flow sensor S1.

► Check wiring to the DHW sensor S3 (ensure its connected and not

damaged). ► Check the DHW sensor S3 (is located and installed correctly). ► Check for the correct operation of DHW sensor S3. ► Replace domestic hot water sensor S3.

► Check heat exchanger for contamination or debris. ► Check the flue / chimney for blockages.

► Gas valve is faulty or no power from PCB (24v dc pins 1 & 5). ► Gas inlet working pressure below 17mbar (20mbar

recommended). ► Condensation drain is blocked or frozen. ► Check ignition module, ignition pin, lead or spark gap. ► No power to Ignition unit. ► Poor earth to boiler or ionisation pin.

► Condensation drain is blocked or frozen. ► Gas inlet working pressure below 17mbar (20 mbar

recommended). ► Check ignition module, ignition pin, lead or spark gap. ► Check adjustment of gas valve (See §9.10.1). ► Check the flue integrity for possible re-circulation or blockages ► Poor earth to boiler or ionisation pin.

► Replace faulty gas valve. ► Replace faulty PCB.

2sec

Fault code Description Possible cause / solution

► Check ionisation/ignition pin is clean and correctly located. ► Check ionisation/ignition pin wiring is connected not damaged. ► Replace ionisation/ignition pin.

► Check fan wiring. ► Check and/or replace fan assembly . ► Replace PCB.

F007F007

F008F008

No or insuicient ionisation current.

Incorrect fan speed detected

F009F009

F010, F011F010, F011

F012F012

f014f014

f015f015

f016f016

F018F018

F019F019

F027F027

f028f028

Internal PCB fault. ► Replace PCB.

► Check wiring to heat exchanger sensor S0 (ensure its connected

Heat exchanger Sensor S0 fault.

Flue gas sensor fault S5.

Heat exchanger sensor S0 mounting fault.

Heating sensor S1 mounting fault.

DHW sensor S3 mounting fault.

Flue and/or air supply duct is blocked/restricted.

Boiler memory module fault.

Short circuit of outdoor weather compensation sensor S6.

Reset error.

and not damaged). ► Check heat exchanger sensor S0 resistance values are correct. ► Check for the correct location of heat exchanger sensor S0. ► Replace heat exchanger sensor S0.

► Check wiring to flue gas sensor S5 (ensure its connected). ► Check flue gas sensor S5 resistance values are correct . ► Check for the correct location of flue gas sensor S5. ► Replace flue gas sensor S5.

► Heat exchanger sensor S0 is not mounted correctly. Attach the

sensor correctly.

► Central heating flow sensor is not mounted correctly. Attach the

sensor correctly.

► Domestic hot water sensor S3 is not mounted correctly. Attach

the sensor correctly.

► Check the flue and the air supply duct including seals or gaskets. ► Clean the flue and/or the air supply duct.

► Check BMM wiring or connector for damage. ► Replace BMM.

► Check wiring to outdoor sensor and ensure its connected

correctly and not damaged. ► Check the outdoor sensor resistance values are correct. ► Replace the outdoor sensor.

► Check the reset button for unintentional operation (e.g. cleaning

of control panel). ► Replace the PCB.

f029f029

F031F031

IMPORTANT

► Any replacement components must be

► Using 3rd party components or installing

Gas valve fault.

CH flowsensor fault S1.

original Intergas parts.

them incorrectly can lead to serious consequences, with a risk to health, occupants or buildings.

► Check the gas valve wiring, coil resistances. ► Replace the PCB.

► Check wiring of central heating flow sensor for damage and

ensure its connected correctly. ► Ensure the central heating flow sensor resistance values are

correct. ► Check for the correct operation of central heating flow sensor S1. ► Replace central heating flow sensor S1.

10.2 Other faults

10.2.1 No heat (central heating)

Possible causes Analysis Solution

The power LED is not illuminated.  Yes

The right display shows a line ( The boiler is o.

––).

↓ No

 Yes

↓ No

 Check the power supply.

Check the fuse; see Electrical schematic §12.1.

 Switch on the boiler by touching just above the power LED and

holding this for 2 seconds

Room thermostat / weatherdependent control is not connected or is defective.

 Yes

 Check the wiring.

Check OpenTherm, On/O connection of the boiler, or the connection between the central heating boiler and the OpenTherm room thermostat. Replace the thermostat.

↓ No

Replace the weather-dependent control.

No electricity (24V).  Yes  Replace defective programmer. Check the wiring according to

the schematic. Check Connector X13.

10.2.2 Central heating does not reach the correct temperature

Possible causes Analysis Solution

System water pressure is too low.  Yes

↓ No

Room thermostat is turned down.

 Yes

↓ No

Temperature is set too low.  Yes

↓ No

Poor or no flow in the system.  Yes

↓ No

The boiler output is not correctly set.  Yes

 Top up the system via the filling loop; see §8.2.1.

 Check the setting and adjust it if necessary.

 Increase the central heating temperature; see central heating

demand. If an outdoor sensor is present: check the sensor

 location or for damage, check curve setting (see §9.7)

 Check the t (±20°C) between central heating flow and return.

Ensure no air locks are in system also check pump speed setting parameter P031, P032.

 Adjust the boiler capacity. See §9.5 and §9.6.

↓ No

No heat transfer due to debris within

 Yes

the central heating boiler/system.

↓ No

Flue and/or air supply duct is blocked

 Yes  Check and (if necessary) clean the flue and the air supply duct.

or restricted.

10.2.3 Central heating system remains too warm

Possible causes Analysis Solution

Room thermostat / weatherdependent control is defective or has a short circuit.

There is thermo-syphon in the central heating circuit (Radiators getting warm when DHW operates with combination boilers).

 Yes

↓ No

 Yes

 Flush and clean the heating system via the central heating

circuit to BS 7593 and install a return magnetic filter.

 Check the wiring or batteries if applicable.

Check OpenTherm, On/O connection of the boiler, or the connection between the central heating boiler and the RF room thermostat. Replace the thermostat. Replace the weather-dependent control.

 For thermo-syphon Install a check valve in the CH return

pipework near the boiler. For under floor heating install a "normally open" zone valve into the flow circuit. (see under floor wiring diagram on our website).

10.2.4 No domestic hot water (DHW)

Possible causes Analysis Solution

The power LED is not illuminated.  Yes

 Check the power supply.

Check the fuse; see Electrical schematic §12.1.

↓ No

Flow turbine does not work.

 Yes

↓ No

Domestic hot water flow < 2l/min.  Yes

↓ No

Domestic hot water sensor S3 is

 Yes

 Replace the flow turbine.

 Increase the domestic hot water flow.

 Replace domestic hot water sensor S3.

defective.

↓ No

No electricity on the flow turbine (5V

 Yes  Check the wiring according to the schematic.

DC).

10.2.5 Domestic hot tap water does not reach the correct temperature

Possible causes Analysis Solution

Domestic hot water flow is too high.  Yes

 Reduce the domestic hot water flow.

Setting for domestic hot water temperature is too low.

Insuicient heat transfer due to lime scale or contamination within the DHW water circuit.

The central heating system becomes warm while operating the domestic hot water.

Central heating pressure is too low.  Yes

The flue is blocked.  Yes  Check the flue.

10.2.6 Burner ignites loudly

Possible causes Analysis Solution

Inlet Gas pressure is too high.  Yes

Ignition spark gap is incorrect.

Gas-air control is not correctly adjusted.

The spark is weak.  Yes  Check the ignition cable is connected to the ignition module

↓ No

 Yes

↓ No

 Yes

↓ No

 Yes

↓ No

 Yes

↓ No

 Yes

↓ No

 Increase the domestic hot water temperature; see §9.1.2.

 De-scale or flush the domestic hot water circuit within the

boiler heat exchanger.

 For thermo-syphon Install a check valve in the CH return

pipework near the boiler. For under floor heating install a "normally open" zone valve into the flow circuit. (see under floor wiring diagram on our website).

 Top up the central heating system via the boiler filling loop until

the pressure is between 1 to 1.5bar.

 The Gas meter governor may be defective. In this case, contact

the energy company 0800 111999.

 Replace the ignition pin complete with cable.

 Check the adjustment; see §9.9 and §9.10.

correctly. Replace the ignition module mounted within the top cover. Replace the ignition pin.

Burner is defective  Ye s  Replace the burner.

10.2.7 Burner resonates

Possible causes Analysis Solution

Gas inlet pressure lower than 20mbar or sometimes lower.

There is recirculation of flue gases.

Gas-air control is not correctly adjusted.

Burner seal is defective. → Yes

Burner is defective. → Yes

10.3 Notifications

In addition to error codes, the burner control can also show notifications on the display. Notifications are displayed if an anomaly occurs somewhere in the system that does not aect the vital functioning of the system. Notifications disappear if the system can fix the abnormality. Intergas Heating should be consulted if a notification returns repeatedly.

→ Yes

↓ No

→ Yes

↓ No

→ Yes

↓ No

→ The Gas meter governor may be defective. In this case, contact

the energy company 0800 111999.

→ Check the flue and air supply ducts and seals.

→ Check the adjustment; see §9.9 and §9.10.

→ Replace the burner seal.

→ Replace the burner.

The following notifications are distinguished:

Notification Description Possible cause / solution

► Check if parameter P001 is set correctly. ► Check wiring of domestic hot water sensor S3 for damage and

N030

N152

N202

N245

DHW demand is blocked.

Power reduction due to flue gas sensor faulty.

Burner switched o due to flue gas temperature limitation.

Fan speed adapted to CAC protection.

ensure its connected correctly. ► Ensure the DHW sensor resistance values are correct. ► Check for the correct operation of domestic hot water sensor S3. ► Replace domestic hot water sensor S3.

► Check whether flue gas sensor S5 is present and install it if

necessary. ► Check whether it has been mounted correctly. ► Check the wiring for break / short circuit. ► Replace flue gas sensor S5.

► Flue gas temperature higher as to be expected. Check the fins

of the heat exchanger for wear. Replace the heat exchanger if

necessary.

► Backflow of flue gasses detected. Fan on low speed to prevent

recirculation of flue gasses. Check the flue gas non-return valve.

11 MAINTENANCE

The boiler and the system must be inspected annually by an qualified competent gas safe registered engineer. The boilers heat exchanger should be cleaned and inspected as stated below at each service interval.

CAREFUL

► Aer completion of the Annual service

procedure all 26 (9) safety checks must be performed and the results recorded within the service & interim boiler work pages, at the back of this manual.

► Some components can be very hot during and

just aer operating the appliance.

► For Health & Safety reasons the use of PPE is

recommended during the below procedure.

11.1 Annual service procedure

► Switch o the appliance and isolate the power supply at the fuse

spur, make safe the appliance before continuing (Ref TB118). ► Close the boiler gas isolation valve (test for let-by). ► Remove the room sealed cover of the boiler by loosening the two

Allen screws (A) and then liing the panel up and forward (B) ► Wait until the boiler has cooled down. This can be done by

opening a domestic hot water tap (with the power switched o).

11.2 Annual service continued (syphon maintenance).

► Detach the syphon cup (1) by rotating it a quarter turn to the

le and then pulling it out downwards. ► Remove the flexible hose (2) from the siphon base and the

sewage connection. ► Empty the syphon cup (3). ► Detach the syphon base (3) by pressing the three securing

clips in, while simultaneously pushing the siphon base

downwards (4). ► Remove the circlip and the plastic ball from the syphon base

(5). ► Clean the following components with water:

◉ the inside of syphon base ◉ plastic ball ◉ circlip ◉ syphon cup ◉ opening of the exhaust manifold

► Return the plastic ball to the syphon base and attach the

ca. 6 cm

circlip. ► Check that the ball and circlip have been installed correctly

(6). Make sure that the top of the circlip is about 6 cm below

the edge of the syphon base. ► Replace the O-ring (art. no. 086154) at the bottom of the

exhaust manifold. ► Attach the syphon base to the bottom by pushing it high

enough so that the securing clips click over the lip (7).

IMPORTANT

► Make sure that the syphon base is

returned to its original position, firmly locked into the bottom with no gaps.

Incorrectly attaching the syphon base (or not attaching it at all) will result in products of combustion leaking into the room creating a dangerous situation.

► Make sure that the syphon cup is filled with ¾ water (8) before

placing it back, slide it into the syphon base and rotate it a

quarter turn to the right (clockwise) so that it is correctly

secured (9). ► Slide the ribbed hose onto the syphon base and into the

waste connection.

–

NOTE

► To assist the replacement of the syphon base and syphon cup

silicone lubricant is recommended on the following seals,

◉ Exhaust manifold O-ring seal ◉ Syphon base outer seal ◉ Syphon cup O-ring seal



11.3 Annual service continued (internal maintenance)

► Li and rotate the expansion vessel to the le side. ► Disconnect the electrical connector to the fan assembly. ► Loosen both unions and the electrical connector then remove

the gas valve. ► Unscrew the 6mm Allen key shoulder bolts of the front cover

and remove it forward along with the fan (Being careful not to

damage any components). Lay the removed front cover face

down on to its foot supports, this is best achieved on a flat heat-

proof surface. ► The burner and the integrated insulation panel do not require

cleaning only inspecting. Therefore, never use a brush or

compressed air to clean these components (dust hazard).

COMMENT

► The expansion vessel must be inspected and

tested at each annual service and if required repressurise to 0.75 bar (cold and with no system pressure). Ensure the flexible hose is not kinked, leaking or damaged (Replace if required).

11.3.1 Annual service continued (cleaning)

► Clean the slats of the heat exchanger from top to bottom with a

brush or Intergas comb (use a vacuum cleaner to remove debris). ► Clean the underside of the heat exchanger. ► Only clean the underside of the front panel.

CAREFUL

► The integrated insulation panel and

burner seal contain ceramic fibres use the appropriate P.P.E dust mask & gloves.

11.4 Annual service (re-assemble)

IMPORTANT

► Replace the front plate O-ring at least

every 3 years or if damaged/ discoloured. Art.no: 877927 — Xtreme 24/30

620274 — Xtreme 36

► Check and replace any other worn gaskets.

Also check they are correctly located.

► Check whether there is a thin layer of ceramic grease

between the flange of the shoulder bolts and the front

panel. ► If there is insuicient grease present, extra must be applied

using the foam application tool (A) within the kit (ceramic grease kit available to order).

► Check whether the gasket around the front panel is

correctly located. Place the front panel on the heat

exchanger and attach it with the 6mm Allen key shoulder

bolts. Tighten the shoulder bolts (1 to 11)* by hand, working

diagonally. The order of tightening is shown in the diagram. ► Fully tighten the Allen shoulder bolts with a torque wrench

set at 10-12 Nm when available to ensure uniformity. ► Check and tighten the burner bolts diagonally by hand. ► Replace the gas valve and when necessary replace the seals ► Reinstate the electrical connector to the gas valve and fan. ► Open the gas isolation valve and check both of the gas

unions for tightness. ► Check and repair any water leaks within the boiler. ► Turn the expansion vessel back to its original position. Make

sure the vessel is secured by the lip on the cable cover. ► Check a 3amp fuse is fitted before re-establishing the

power.

► Switch on the boiler. ► Check the front panel, the fan seal, fan connection to the

front panel, also check the flue components for leakage,

repair or replace as required. ► Check the gas/air control (see §9.9 and §9.10) and check

the gas outlet on the gas valve for tightness. ► Refit the room sealed cover and tighten the 5mm Allen bolts

under the boiler. (Do not overtighten) ► Check the domestic hot water facility for correct operation.

* 1 to 9 bolts on 24 & 30Kw models. (Do not overtighten) Clicking noise (expansion) during operation is normally due to overtightening of the front panel bolts or lack of ceramic grease. Please check suicient ceramic grease has been applied and the correct torque setting applied before calling the Intrgas service team.

11.5 Annual service checklist

No. Activity

Isolate the boiler from the fused spur and make safe (ref TB118) check

the correct 3amp fuse has been fitted.

Carry out inspection of boiler for dust and dirt and clean where

necessary.

Visually inspect the front plate and heat exchange for signs of

damage. If damage is evident proceed to column 2.

Check the gas inlet pressure on HIGH rate (DHW mode).

Check combustion by measuring CO, CO

tolerances then proceed to a full service in column 2.

Close the boiler gas isolation valve.

Isolate flow and return valves and drain boiler via the drain o on the return. Check the pressure in the expansion vessel. Recharge if

necessary.

Remove the front plate and clean the inside of the heat exchanger.

Check the front plate seal, replace the seal if damaged, discoloured,

3 years old or later.

Check the burner has not delaminated also check the burner seal.

Check the ignition pin for clearance and debris.

Check the condensate trap, clean and refill.

. If the values are outside the

Inspection at every annual service

Maintenance must be carried out at regularly

Open the isolation valves on flow and return and refill the water in the

boiler between 1.2 to 1.5 bar via the filling loop.

Open the gas isolation valve, reconnect the power to the boiler via

fused spur.

Check visually the ignition and burner performance.

Check the boiler for leaks of any kind (gas, flue gas, water,

condensate) rectify if necessary.

Recheck the CO,CO

Complete the Benchmark Service Record on the back pages of the

Installation manual.

and adjust if necessary, adjust CO2 only LOW fire.

12 TECHNICAL SPECIFICATIONS

Boiler category C13; C33; C53

Gas inlet pressure G20: 20 mbar, G31: 37 mbar

Suitable for gas II

Technical data

2H3P

Xclusive

24 30 36

Domestic hot water

Nom. input rating (lower value) kW

Tap threshold l/min

T 25°C l/min

T 35°C l/min

Domestic hot water temperature (default) °C

Domestic hot water-sided pressure dierence bar

3.6 – 25.1 3.6 – 30.5 3.6 – 32.7

14.1 17.1 18.9

10 12.2 13.5

see §7.2.1

Central heating

Nom. input rating (lower value) kW 3.6 – 18.7 3.6 – 23.7 3.6 – 27.0

Nom. output kW 4.0 – 18.2 4.0 – 23.1 4.0 – 26.6

Max. Central heating water pressure bar

Max. Central heating water temperature °C

2.5

Other data

Gas consumption (G20) m3/h

Gas consumption (G31) m

Appliance pressure loss (CH) mWk

Average flue temperature DHW °C

Flue mass flow (minimum-maximum)

kg/h

Maximum counterpressure Pa

Electric data

Mains voltage V

Safety class IP

Recorded output: full load W

Recorded output: standby W

Overall dimensions and weight

Height mm

Width mm

Depth mm

Weight (Empty) kg

Weight (Full) kg

0.38 – 2.66 0.38 – 3.23 0.38 - 3.46

0.15 – 1.03 0.15 – 1.25 0.15 – 1.34

See §9.6

5.9 – 41.6 5.9 – 50.5 5.9 – 54.1

250

230

IPX4D

115

766 766 826

450

277

30 30 33

33 33 36

12.1 Electrical schematic

Gasvalve

Earth connections

heat exchanger

Power cord

230V~ / 50Hz

Ignition module

Earth connections

burner controller

Central heating pump

1 2

Fan

O

On/o

thermostat

3 4 5

123 123456

LS/L

12 12345 123

(230V ~)

FUSE

(230V ~)

230V ~

F1 (3,15 AT)

Ignition pin

OpenTherm thermostat

N/A

X10

(24V =)

N/A

X11

X12

X13

X15

(24V =)

X14

(24V=)

24V =

http://www.intergasverwarming.nl

ICX PCB

O

OpenTherm thermostat

O

On/o thermostat

Frost thermostat

On/o thermostat

Outdoor sensor S6

Frost thermostat

Cylinder sensor S7

2 1

345

5 4 3 2

12 11 10 9 8 7 13

1415

321

BMM

Heat exchanger sensor S0

Flue sensor S5

Central heating flow sensor S1

Domestic hot water sensor S3

Central heating pressure sensor

Flow ssensor

230V~ component

Connector Connections Designation Description

X2 1 – 2 – 3

X3 1 – 2

1 – 2 – 3 – 4 – 5 – 6

1 – 2 – 3

Fan

Central heating pump

On/o room thermostat 230V

O

Shut-o valve underfloor heating or variable output control (1=N (blue), 2=L (brown), 3=T (black))

1 – 2 – 3

X5 1 – 2

X8 1 – 2 – 3 – 4 – 5

Three-way valve (1=N (blue), 2=L (brown), 3=T (black))

Mains power cord 230V~ 50Hz (1=L (brown), 2=N (blue), = ground (green/yellow))

Ignition unit

24V = component

Connector Connections Designation Description

X12 1 – 2

Optional (OpenTherm thermostat)

Aan

Optional (On/o room thermostat)

Uit

X12 1 – 2

1 – 2

X13

1 – 2

3 – 4

4 – 5

X14

1 – 2

3 – 4 – 5 – 6

7 – 11

7 – 16

X15

7 – 10 – 13

BMM

Optional (Frost thermostat if OT thermostat on X13)

OpenTherm thermostat (primary connection)

Aan

On/o room thermostat

Uit

Frost thermostat

Outdoor sensor S6 (12k  / 25°C)

Hot water cylinder sensor S7

PC Interface

Gas valve

BMM (Boiler Memory Module)

Flue gas sensor S5

Domestic hot water sensor S3

Heat exchanger sensor S0

7 – 15

7 – 9– 17

7 – 8– 17

Central heating flow sensor S1

Flow sensor

Central heating low water pressure sensor

12.2 Product Fiche according to CELEX-32013R0811, Appendix IV

Supplier

Type designation Symbol Unit

Intergas Heating Ltd

Unit 2

Easter Park

Worcester Road

Kidderminster

DY11 7AR

Intergas Xclusive

24 30 36

Seasonal energy eiciency class for room heating

Nominal heat output (capacity) P

Seasonal energy eiciency class for room heating

Annual energy use Q

Noise level L

- - A A A

rated



kW 18 23 27

% 93 93 93

GJ 38 48 58

dB 56 56 58

Domestic hot water capacity profile - - L XL XL

Energy eiciency class for water heating

Domestic hot water eiciency 

Annual electricity use AEC kWh 13

Annual fuel use AFC

- - A A A

% 85 86 87

GJ 11 18 17

IMPORTANT

► Before installation, read the installation manual and the operation instructions. ► This appliance is not intended for use by individuals (included children) with reduced

physical, sensory or mental capabilities, or lack of experience and knowledge, unless supervision of or instruction concerning the use of the appliance is given. Children shall not play with the appliance. Cleaning and user maintenance shall not be undertaken by children.

► The boiler and system must be inspected annually by an qualified Gas Safe registered

engineer and cleaned if necessary. See §11 for the annual servicing procedure.

► The boiler outer casing must only be cleaned with a damp cloth. Do not use aggressive

scrubbing, agents or solvents.

12.3 NTC resistances

NTC 12 kOhm

T [°C] R [Ω] T [°C] R [Ω] T [°C] R [Ω] T [°C] R [Ω]

-15 76020 15 18300 45 5522 75 1994

-10 58880 20 14770 50 4609 80 1717

-5 45950 25 12000 55 3863 85 1467

0 36130 30 9805 60 3253 90 1266

5 28600 35 8055 65 2752 95 1096

10 22800 40 6653 70 2337 100 952

13 SPARES SHORT LIST

Description Part number

PCB complete with housing

230V EBM NRG130 Fan assembly (complete with 877807 seal & 2 x 312027 M5 nuts) 074304

S0 NTC Temperature sensor (heat exchanger) 230034

S1 NTC Temperature sensor (CH Flow) Clip on 18mm 230054

Modulating Yonos Wilo CH pump 074604

Ignition / Ionisation electrode 210024

Pressure sensor (CH) screw in type 230044

24V Gas valve Siemens VGU76S 074514

240V Ignition module ZAG1 210014

S3 Flowswnsor (DHW) clip on 15mm NTC 200177

S5 Flue gas temperature sensor NTC 074704

DHW Flow turbine 074804

DHW HALL sensor (Clip on) 900004

Graphite Seal gas valve (inlet) 21.5/15.5mm 875757

O-ring gas restriction ring 19x2mm 875727

074104

O-ring type front plate seal for 36kW (New type Black Viton replaces 620274) 086474

O-ring type front plate seal for 24 & 30kW (New type Black Viton replaces 877927) 086504

Condensate syphon sediment bowl 510054

Condensate syphon complete 075044

Pressure relief valve (3bar) 600024

Natural Gas G20 restrictor disc kit 392 (24kW) 076924

Natural Gas G20 restrictor disc kit 450 (30 &36kW) 076934

LPG G31 restrictor disc kit 315 (24Kw) 076047

LPG G31 restrictor disc kit 370 (30 & 36kW) 076914

14 WARRANTY PROVISIONS AND CE DECLARATION

1. The installer must be registered with Gas Safe, installer must

complete the Benchmark Commissioning Checklist in full at the time the boiler is installed. The Benchmark must be made available and can be found at the back of the installation instructions. The Benchmark Commissioning Checklist must be retained on site by the owner/occupier for inspection during an engineer's visit.

2. The boiler and Intergas system filter* must both be registered

for warranty with Intergas by either the installer or you the householder, within 30 days of the boiler being installed. For the new build properties, this must be done within 30 days of the sale being completed. if these conditions are not met, the warranty will not be valid. (*Intergas system filter must be installed on the same date as the boiler and registered for warranty at the same time).

The product must be registered via the internet at www.intergasheating.co.uk or on the Intergas MiREG website www.myintergasregistration.co.uk or by returning the warranty card.

3. The boiler must be serviced annually by a registered Gas Safe

Engineer in accordance with manufacturer’s instructions.

4. Service details must be recorded in the Benchmark Checklist

or provide proof of service which must be available for inspection.

5. The cost of the annual service is not included in the warranty.

If the above conditions are not meet this warranty will be limited to 12 months from the date of installation or date of Manufacture, as recorded on the Benchmark commissioning checklist.

IMPORTANT

Warranty terms mentioned above are based on domestic use only. Any non-domestic applications will be covered by a 12 months warranty. Service intervals may need to be increased depending on commercial usage. For additional information please contact Intergas Heating Ltd.

6. Only boiler component failures are covered by the warranty.

The warranty does not cover any connected system or accessories such as time switches, thermostats, motorised valves, external pumps and so on.

7. Any repair carried out under the terms of this warranty does

not extend the warranty beyond its original period.

8. If the boiler breaks down, Intergas may ask you* (Homeowner

or Installer) to pay a deposit before we visit to complete the repair. We will return the deposit in full if we find a fault that is covered by the warranty. We may keep the deposit if we cannot access the property at the time we have arranged with you to visit or we find other conditions of this warranty have not been met.

9. The system must be flushed and cleansed in accordance with

BS7593:2019.

10. If any failure is caused by contaminated water in the system

the engineer visit becomes chargeable.

11. All installation, non boiler or external system faults calls will be

charged to the home owner/occupier.

12. Roof space installation BS6798:2014 Require a permanently

fixed access ladder must service installations in los or attics. Adequate lighting and permanently fixed flooring must also be available.

13. Engineers will not carry out repairs if they think accessing the

boiler would be a risk to Health and Safety. A responsible adult must be at the property to give our engineer access to the boiler.

14. If your boiler is in a cupboard, there must be enough room

for the engineer to work (the minimum area as set out in the installation instructions). We are not responsible for removing cupboards, kitchen units, trims etc to gain access for repairs.

15.

In hard water areas of 200ppm or above, appropriate protection actions must be taken in accordance with BS 7593:2019 in line with building regulations Part L1. (Above 200ppm we recommend Combimate*, Adey Electroscale or Hydroflow HS38 should be installed. 300ppm and above we recommend a Combimate*, Water soener* or HS38 should be installed.) (*serviceable item)

16. The central heating system must be maintained in accordance

with the Benchmark Guidance on water Treatment in Central Heating Systems & BS7593:2019, we recommend the use of Fernox, Sentinel or Adey products, Inhibitors & filters. It is important that the correct concentration of water treatment is maintained for the life of the boiler, should we attend a warranty call Intergas reserve the right to take system water samples and should they fail the aforementioned requirements then the warranty will be void and the call will become chargeable. (Intergas system filter must be installed & registered at the same time as the boiler for enhanced warranty period).

17. If the boiler suers a breakdown you should contact Intergas

on 01527 888000 selecting option 2. Our normal working hours, excluding Bank Holidays are:

8.00am – 5.00pm Monday to Friday and

8.00am – 12.00pm Saturday mornings.

CE DECLARATION

Manufacturer Intergas Heating Limited Address Unit 2 Easter Park Worcester Road Kidderminster DY11 7AR

hereby declares that CH appliance: INTERGAS, Type:

► Xclusive 24 ► Xclusive 30 ► Xclusive 36

Meets the provisions of the following directives:

► Low Voltage Directive (2014/35/EC) ► Gas Appliance Regulation (2016/426/EC) ► Directive regarding eiciency requirements for new oil and gas-

burning central heating boilers (92/42/EC)

► EMC Directive (2014/30/EC) ► RED Directive (2014/53/EC)* ► Ecodesign (2009/125/EG) ► Energy labelling (2010/30/EU)

* The conformity declaration can be requested from Intergas.v

S. Zouch, September 2020

15 BENCHMARK COMMISSIONING & WARRANTY VALIDATION SERVICE RECORD

Benchmark Commissioning &

Warranty Validation Service Record

It is a requirement that the boiler is installed and commissioned to the manufacturers’

To instigate the boiler warranty the boiler needs to be registered with the manufacturer within one month of the installation. The warranty rests with the end-user (consumer), and they should be made aware it is ultimately their responsibility to register with the manufacturer, within the allotted time period.

It is essential that the boiler is serviced in line with the manufacturers’ recommendations, at least annually. This must be carried out by a competent Gas Safe registered engineer. The service details should be recorded on the Benchmark Service and Interim Boiler Work Record and left with the householder. Failure to comply with the manufacturers’ servicing instructions and requirements will invalidate the warranty.

www.hhic.co.uk

This 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 and then handed to the customer to keep for future reference.

Failure to install and commission according to the manufacturers’ instructions and complete this Benchmark Commissioning Checklist will invalidate the warranty. This does not affect the customer’s statutory rights.

www.centralheating.co.uk

GAS BOILER SYSTEM COMMISSIONING CHECKLIST & WARRANTY VALIDATION RECORD

Address:

Boiler make and model:

Boiler serial number:

Commissioned by (PRINT NAME): Gas Safe registration number:

Company name: Telephone number:

Company email: Company address:

Commissioning date:

Heating and hot water system complies with the appropriate Building Regulations? Yes

Time, temperature control and boiler interlock provided for central heating and hot water Yes

Boiler Plus requirements (tick the appropriate box(s))

Boiler Plus option chosen for combination boiler in ENGLAND

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

Zone valves pre-existing Fitted Not required

Thermostatic radiator valves pre-existing Fitted Not required

Automatic bypass to system pre-existing Fitted Not required

pre-existing Fitted Not required

Water quality

What system cleaner was used? Brand: Product:

What inhibitor was used? Brand: Product:

pre-existing Fitted Not required

CENTRAL HEATING MODE measure and record (as appropriate)

Gas rate (for combination boilers complete DHW mode gas rate) m3/hr or ft3/hr

Central heating output left at factory settings? Yes No

If no, what is the maximum central heating output selected? kW

Dynamic gas inlet pressure mbar

Central heating return temperature °C

System correctly balanced/rebalanced? Yes

COMBINATION BOILERS ONLY

Is the installation in a hard water area (above 200ppm)? Yes No

Water scale reducer/softener pre-existing Fitted Not required

Brand: Product:

If yes- DHW expansion vessel pre-existing Fitted Not required

Pressure reducing valve pre-existing Fitted Not required

DOMESTIC HOT WATER MODE Measure and record

Gas rate m3/hr or ft3/hr

Dynamic gas inlet pressure at maximum rate mbar

Cold water inlet temperature °C

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

CONDENSATE DISPOSAL

The condensate drain has been installed in accordance with the manufacturers’ instructions and/or BS5546/BS6798 Yes

Point of termination Internal External (only where internal termination impractical)

Method of disposal Gravity Pumped

ALL INSTALLATIONS

Record the following

At max rate: CO ppm CO

At min rate (where possible) CO ppm CO

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

The manufacturers’ literature, including Benchmark Checklist and Service Record, has been explained and left with the customer Yes

Commissioning Engineer’s signature

Customer’s signature

Weather compensation Smart thermostat with automisation and optimisation

Load compensation Flue Gas Heat Recovery

instructions Yes

Yes No

% CO/CO

instructions, and readings are correct? Yes

Ratio

°C

www.centralheating.co.uk

SERVICE & INTERIM BOILER WORK RECORD

It is recommended that your boiler and heating system are regularly serviced and maintained, in line with manufacturers’ instructions, and that the appropriate service / interim work record is completed.

Service provider

When completing a service record (as below), please ensure you have carried out the service as described in the manufacturers’ instructions. Always use the

SERVICE/INTERIM WORK ON BOILER delete as appropriate

Engineer name: Company name:

Telephone N

Max rate CO ppm CO

Min rate CO ppm CO

undertaken in accordance with manufacturers’ instructions, and readings are correct?”

Gas rate: m

System inhibitor concentration has been checked and appropriate action taken, in accordance with BS 7593 and boiler manufacturers’ instructions. *

: Gas Safe registration No:

/h OR ft3/h

delete as appropriate Yes No

% CO/CO

Date:

yes

yes n/a

Comments:

Signature:

instructions and BS 7593. It is only acceptable to not have undertaken this if the service engineers attendance visit was in between annual services to attend a non-water facing component.

SERVICE/INTERIM WORK ON BOILER delete as appropriate

Engineer name: Company name:

Telephone N

Max rate CO ppm CO

Min rate CO ppm CO

undertaken in accordance with manufacturers’ instructions, and readings are correct?”

Gas rate: m

: Gas Safe registration No:

/h OR ft3/h

delete as appropriate Yes No

% CO/CO

Date:

yes

SERVICE/INTERIM WORK ON BOILER delete as appropriate

Engineer name: Company name:

Telephone N

Max rate CO ppm CO

Min rate CO ppm CO

undertaken in accordance with manufacturers’ instructions, and readings are correct?”

Gas rate: m

System inhibitor concentration has been checked and appropriate action taken, in accordance with BS 7593 and boiler manufacturers’ instructions. *

: Gas Safe registration No:

/h OR ft3/h

delete as appropriate Yes No

% CO/CO

Date:

yes

yes n/a

Comments:

Signature:

instructions and BS 7593. It is only acceptable to not have undertaken this if the service engineers attendance visit was in between annual services to attend a non-water facing component.

SERVICE/INTERIM WORK ON BOILER delete as appropriate

Engineer name: Company name:

Telephone N

Max rate CO ppm CO

Min rate CO ppm CO

undertaken in accordance with manufacturers’ instructions, and readings are correct?”

Gas rate: m

: Gas Safe registration No:

/h OR ft3/h

delete as appropriate Yes No

% CO/CO

Date:

yes

System inhibitor concentration has been checked and appropriate action taken, in accordance with BS 7593 and boiler manufacturers’ instructions. *

yes n/a

Comments:

Signature:

instructions and BS 7593. It is only acceptable to not have undertaken this if the service engineers attendance visit was in between annual services to attend a non-water facing component.

SERVICE/INTERIM WORK ON BOILER delete as appropriate

Engineer name: Company name:

Telephone N

Max rate CO ppm CO

Min rate CO ppm CO

undertaken in accordance with manufacturers’ instructions, and readings are correct?”

Gas rate: m

System inhibitor concentration has been checked and appropriate action taken, in accordance with BS 7593 and boiler manufacturers’ instructions. *

: Gas Safe registration No:

/h OR ft3/h

delete as appropriate Yes No

% CO/CO

Date:

yes

yes n/a

Comments:

Signature:

instructions and BS 7593. It is only acceptable to not have undertaken this if the service engineers attendance visit was in between annual services to attend a non-water facing component.

System inhibitor concentration has been checked and appropriate action taken, in accordance with BS 7593 and boiler manufacturers’ instructions. *

yes n/a

Comments:

Signature:

instructions and BS 7593. It is only acceptable to not have undertaken this if the service engineers attendance visit was in between annual services to attend a non-water facing component.

SERVICE/INTERIM WORK ON BOILER delete as appropriate

Engineer name: Company name:

Telephone N

Max rate CO ppm CO

Min rate CO ppm CO

undertaken in accordance with manufacturers’ instructions, and readings are correct?”

Gas rate: m

System inhibitor concentration has been checked and appropriate action taken, in accordance with BS 7593 and boiler manufacturers’ instructions. *

: Gas Safe registration No:

/h OR ft3/h

delete as appropriate Yes No

% CO/CO

Date:

yes

yes n/a

Comments:

Signature:

instructions and BS 7593. It is only acceptable to not have undertaken this if the service engineers attendance visit was in between annual services to attend a non-water facing component.

www.centralheating.co.uk

SERVICE & INTERIM BOILER WORK RECORD

Service provider

When completing a service record (as below), please ensure you have carried out the service as described in the manufacturers’ instructions. Always use the

SERVICE/INTERIM WORK ON BOILER delete as appropriate

Engineer name: Company name:

Telephone N

Max rate CO ppm CO

Min rate CO ppm CO

undertaken in accordance with manufacturers’ instructions, and readings are correct?”

Gas rate: m

System inhibitor concentration has been checked and appropriate action taken, in accordance with BS 7593 and boiler manufacturers’ instructions. *

: Gas Safe registration No:

/h OR ft3/h

delete as appropriate Yes No

% CO/CO

Date:

yes

yes n/a

Comments:

Signature:

instructions and BS 7593. It is only acceptable to not have undertaken this if the service engineers attendance visit was in between annual services to attend a non-water facing component.

SERVICE/INTERIM WORK ON BOILER delete as appropriate

Engineer name: Company name:

Telephone N

Max rate CO ppm CO

Min rate CO ppm CO

undertaken in accordance with manufacturers’ instructions, and readings are correct?”

Gas rate: m

: Gas Safe registration No:

/h OR ft3/h

delete as appropriate Yes No

% CO/CO

Date:

yes

SERVICE/INTERIM WORK ON BOILER delete as appropriate

Engineer name: Company name:

Telephone N

Max rate CO ppm CO

Min rate CO ppm CO

undertaken in accordance with manufacturers’ instructions, and readings are correct?”

Gas rate: m

System inhibitor concentration has been checked and appropriate action taken, in accordance with BS 7593 and boiler manufacturers’ instructions. *

: Gas Safe registration No:

/h OR ft3/h

delete as appropriate Yes No

% CO/CO

Date:

yes

yes n/a

Comments:

Signature:

instructions and BS 7593. It is only acceptable to not have undertaken this if the service engineers attendance visit was in between annual services to attend a non-water facing component.

SERVICE/INTERIM WORK ON BOILER delete as appropriate

Engineer name: Company name:

Telephone N

Max rate CO ppm CO

Min rate CO ppm CO

undertaken in accordance with manufacturers’ instructions, and readings are correct?”

Gas rate: m

: Gas Safe registration No:

/h OR ft3/h

delete as appropriate Yes No

% CO/CO

Date:

yes

System inhibitor concentration has been checked and appropriate action taken, in accordance with BS 7593 and boiler manufacturers’ instructions. *

yes n/a

Comments:

Signature:

instructions and BS 7593. It is only acceptable to not have undertaken this if the service engineers attendance visit was in between annual services to attend a non-water facing component.

SERVICE/INTERIM WORK ON BOILER delete as appropriate

Engineer name: Company name:

Telephone N

Max rate CO ppm CO

Min rate CO ppm CO

undertaken in accordance with manufacturers’ instructions, and readings are correct?”

Gas rate: m

System inhibitor concentration has been checked and appropriate action taken, in accordance with BS 7593 and boiler manufacturers’ instructions. *

: Gas Safe registration No:

/h OR ft3/h

delete as appropriate Yes No

% CO/CO

Date:

yes

yes n/a

Comments:

Signature:

instructions and BS 7593. It is only acceptable to not have undertaken this if the service engineers attendance visit was in between annual services to attend a non-water facing component.

System inhibitor concentration has been checked and appropriate action taken, in accordance with BS 7593 and boiler manufacturers’ instructions. *

yes n/a

Comments:

Signature:

instructions and BS 7593. It is only acceptable to not have undertaken this if the service engineers attendance visit was in between annual services to attend a non-water facing component.

SERVICE/INTERIM WORK ON BOILER delete as appropriate

Engineer name: Company name:

Telephone N

Max rate CO ppm CO

Min rate CO ppm CO

undertaken in accordance with manufacturers’ instructions, and readings are correct?”

Gas rate: m

System inhibitor concentration has been checked and appropriate action taken, in accordance with BS 7593 and boiler manufacturers’ instructions. *

: Gas Safe registration No:

/h OR ft3/h

delete as appropriate Yes No

% CO/CO

Date:

yes

yes n/a

Comments:

Signature:

instructions and BS 7593. It is only acceptable to not have undertaken this if the service engineers attendance visit was in between annual services to attend a non-water facing component.

www.centralheating.co.uk

Intergas Heating Ltd

Intergas Heating Limited Unit 2 Easter Park Worcester Road Kidderminster DY11 7AR Tel: 01527 888000 Fax: 01384 279480 info@intergasheating.co.uk www.intergasheating.co.uk

2021 Intergas Heating Ltd.

All rights reserved. The information provided applies to the standard version of the product. Intergas Heating Ltd can therefore not be held liable for any damage ensuing from specifications that deviate from the standard version of the product. Although the available information has been composed with all possible care, Intergas Heating Ltd cannot be held liable for any errors in the information or for the consequences of such. Intergas Heating Ltd cannot be held liable for damage ensuing from activities that are performed by third parties.

This document is subject to modifications without prior notice.

Smart Opentherm™

84010403

Intergas XCLUSIVE 24/30/36 INSTALLATION MANUAL

Specifications and Main Features

Frequently Asked Questions

User Manual