Intergas XTREME 24, XTREME 30, XTREME 36 Installation Manual
INSTALLATION MANUAL
High Eiciency 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.
XTREME 24
XTREME 30
XTREME 36
G.C. 47-291-10
G.C. 47-291-11
G.C. 47-291-12
2
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
3.3 Data plate ....................................................................................................................9
3.2 Operation ....................................................................................................................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
4 Installer important points 14
5 Installation 15
5.1 Overall dimensions of boiler + assembly bracket ...............................................................................15
5.1.1 Installing the wall bracket and assembly bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
5.2 Installation location ..........................................................................................................16
5.2.1 Installation in a kitchen cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5.2.2 Removing/installing the front panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5.3 Installing the boiler ...........................................................................................................18
6 Connection 19
6.1 Connecting the central heating system ........................................................................................19
6.1.1 Expansion vessel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
6.1.2 Thermostatic radiator valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.1.3 Floor heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
6.1.4 LT/HT zone system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
6.1.5 Division of central heating system in groups with extra heat source 21
CONTENTS
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 , 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, page , 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.
3
6.2 Connection of domestic hot water ............................................................................................22
6.2.1 DHW circuit resistance graph . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
6.2.2 Boiler with heat pump boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
6.2.3 Boiler with Pre-Heated Solar Boiler) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
6.3 Electrical connection .........................................................................................................25
6.4 Gas connection ..............................................................................................................25
6.5 Connecting room thermostat .................................................................................................26
6.5.1 Connecting Modulating OpenTherm thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
6.5.2 Connecting on/o room thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
6.5.3 Connecting 230V room thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
6.5.4 Connecting outdoor sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
6.5.5 Frost protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.5.6 Connecting boiler sensor/thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
6.5.7 PC interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.5.8 Comfort Touch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
6.6 Flue and air supply duct ......................................................................................................29
6.6.1 Dra, materials and insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
6.7 Pipeline lengths ..............................................................................................................30
6.7.1 Replacement lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
6.7.2 Example calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.8 General layout of the flue .....................................................................................................31
6.8.1 Wall terminal with twin-pipe horizontal terminal C13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
6.8.2 Façade combi-pipe horizontal terminal C13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
6.8.3 Roof terminal with combi-pipe vertical terminal and twin-pipe vertical terminal C33 34
6.8.4 Roof terminal and air supply duct from the façade C53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
6.8.5 Clamping the flue system (parallel and concentric) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
7 Operation 38
7.1 Using the control panel .......................................................................................................38
7.2 Preparation activities .........................................................................................................38
7.2.1 Filling and venting central heating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
7.2.2 Domestic hot tap water facility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
7.2.3 Gas supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.3 Commissioning procedure ....................................................................................................40
7.4 Clock function ...............................................................................................................41
7.5 Shutting down the boiler .....................................................................................................42
8 Settings and adjustments 43
8.1 Structure of the settings ......................................................................................................43
8.1.1 Main menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
8.1.2 Domestic hot water menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
8.1.3 Central heating menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
8.1.4 RF menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
8.1.5 Service menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
8.2 Setting and adjusting the clock functions ......................................................................................49
8.2.1 Setting the clock program on CH operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
8.2.2 Setting the clock program on DHW operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
8.3 Parameters ..................................................................................................................52
8.4 Switching DHW comfort function on and o. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
8.5 Adjusting maximum central heating output ....................................................................................53
8.6 Adjusting pump capacity .....................................................................................................53
8.7 Weather-dependent control ..................................................................................................54
8.8 Conversion to another gas type ...............................................................................................55
8.9 Gas/air control ...............................................................................................................56
8.10 Inspection of gas air control ...................................................................................................57
8.10.1 Measuring flue gas at maximum output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
8.10.2 Measuring flue gas at minimum output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
8.10.3 Minimum output correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
9 Faults 63
9.1 Fault codes ..................................................................................................................63
9.2 Other faults ..................................................................................................................65
9.2.1 No heat (central heating) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
9.2.2 Central heating does not reach the correct temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
9.2.3 Central heating system remains too warm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
9.2.4 No domestic hot water (DHW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
9.2.5 Domestic hot tap water does not reach the correct temperature 66
9.2.6 Burner ignites loudly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
9.2.7 Burner resonates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
4
10 Maintenance 68
10.1 Disassembly .................................................................................................................68
10.2 Cleaning .....................................................................................................................68
10.3 Installation ..................................................................................................................69
10.4 Checklist ....................................................................................................................70
11 Technical specifications 71
11.1 Electrical schematic ..........................................................................................................72
11.2 Product card according to CELEX-32013R0811, Appendix IV .....................................................................74
11.3 NTC resistances ..............................................................................................................74
12 Guarantee provisions and CE declaration 75
13 Gas boiler system commissioning checklist 76
14 Service record 77
To be completed at each annual service, not subsequent.
To be completed at each annual service, not subsequent.
5
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 Boiler wall
mounted gas fired boiler and any associated accessories
Intergas Heating Ltd continuously developing ways to
guarantee the quality of its products and to improve them
where necessary. In so doing it reserves the right to modify at
any time the features named in this document.
Read and observe all safety instructions in this instruction
manual to prevent unsafe situations, fire, explosion, damage to
property or personal injury.
1.1 Regulation
1.2 Warnings
1.3 Manual handling
The Intergas combination boiler meets the requirements of Statutory Instrument 'The
Boiler (Eiciency) Regulations' and is deemed to meet the requirements of:
► Low Voltage Directive (2014/35/EC)
► Gas Appliances Regulation (2016/426/EC)
► Boiler Eiciency Directive for new oil- and gas-fired central heating boilers (92/42/EC)
► EMC Directive (2014/30/EC)
► RED Directive (2014/53/EU)
► Ecodesign (2009/125/EG)
► Energy labelling 2010/30/EU
Intergas declares that the materials used in the manufacturing of this appliance are
nonhazardous and that no substances harmful to health are contained within the
appliance.
Intergas accepts no responsibility for the unsatisfactory
performance of the appliance or flue arising from the failure
to comply with the installation and user instructions. Incorrect
installation could invalidate your guarantee and may lead to
prosecution.
The appliance cannot be removed from the orginal place of
installation and transferred to another site or re-sold without prior
consent from Intergas to re-register the appliance with Intergas in
order to maintain the warranty.
The boiler must be installed in accordance with these instructions
and the regulations currently in force. Read these instructions
carefully before installing or using the appliance. It is the installers
responsibility that the installation conforms to the current
legislation and Standard Codes of Practice.
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 liing establish where the weight is concentrated to
determine the centre of gravity, repositioning yourself if necessary.
6
1.6 Abbreviations
► DHW: Domestic hot water
► CH: Central heating
► CW: Comfort domestic hot water
► HE: High eiciency
► 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 coeicient)
► PP: Polypropylene
► CAC: Combination air supply duct and combustible
gas flue system (chimney system)
1.4 Pictograms
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 aect the
operation of the boiler.
The following pictograms are used in this installation manual:
1.5 Warnings on the box
SEE
Reference to other manuals
INSTRUCTION (THIS SIDE UP)
Store the appliance upright as indicated on the
box.
INSTRUCTION (FRAGILE)
This is a fragile piece of equipment: Please be
very careful not to drop.
MAX 3 MAX2
INSTRUCTION (FRAGILE)
This is a fragile piece of equipment: Please
provide a dry storage for the appliance.
INSTRUCTIE (STACK)
No more than three boxes should be stacked on
top of each other.
7
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.
L.P.G. boilers: Call the supplier’s number
on the side of the gas tank
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
► This appliance must be installed in accordance with the Gas (Safety and Use)
Regulations, current Building Regulations, Building Standards (Scotland),
I.S.813 Installation of Gas Appliances (Ireland), IEE Wiring Regulations (BS
7671), Health and Safety Document No. 635 (Electricity at Work Regulations)
and Local Water Authority Bye Laws
► UK Water Regulations and Bye Laws
► Health & Safety
2.1 General
2.2 The installation
The installation must comply with the following British Standards codes of practice:
► BS 5440: Flues and Ventilation for gas appliances of rated input not exceeding 70kW
(Part 1 Flues)
► BS 5440: Flues and Ventilation for gas appliances of rated input not exceeding 70kW
(Part 2 Air Supply)
► BS 5546: 2000 Installation of gas hot water supplies for domestic purposes.
► BS 5549: 1990 Forced circulation hot water systems
► BS 6700: 1997 Design, Installation, testing and maintenance of services supplying hot
water
► BS 6798: 2000 Specification for installation of gas fired hot water boilers of rated input
not exceeding 70kW
► BS 6891: 1998 Installation of low pressure gas pipe-work installations up to 35mm (RI)
► BS 7593: 1992 Code of practice for treatment of water in heating systems
► BS 7671: 2001 Requirements for electrical installations, IEE Wiring regulations
Reference should also be made to:
► Guide to condensing boiler installation assessment procedures for dwellings
► The institute of Gas Engineers document IGE/UP/7 for timber frame dwellings
2 SAFETY REGULATIONS
Safety precautions If you smell gas
8
3 GENERAL BOILER INFORMATION
The Intergas Xtreme wall-mounted gas boiler is a closed unit. The boiler is
intended solely to provide heat for the water in a central heating system
and domestic hot water installation for household use.
The Intergas Xtreme 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 §12)
The Intergas Xtreme meets the electrical protection class IPX4D.
The boiler can be connected to stainless steel or plastic (PPT120)
combination throughputs that have a CE label.
3.1 General
3.1.1 ErP label
3.1.2 Gas category
Gas category Gas type Gas inlet pressure
(mbar)
II
2H3P
Natural gas (G20) 20
LPG (G31) 37
The Intergas Xtreme is factory-set for H-gas, G20. The boiler
may optionally be converted to another gas type using a
conversion set (see §8.8).
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 Xtreme carries an European energy label containing specific
information regarding energy eiciency class (CH and DHW), noise level
en maximum power.
The Intergas Xtreme carries label A for both CH and DHW.
In addition the Intergas Xtreme meets the following DWH capacity profile:
► Xtreme 24 : L
► Xtreme 30 : XL
► Xtreme 36 : XXL
The extensive product fiche can be found in §11.2.
Xtreme -Intergas Heating Ltd
dB
--
--
kW
2015 811/2013
9
Identification of the product
You will find the unit details on the data plate on the bottom
of the unit. The data plate contains, beside the supplier
information and the boiler specification (boiler type and model
name), the following information:
3.3 Data plate
3.2 Operation
The Intergas Xtreme is a modulating high eiciency boiler. This means
that the capacity is adjusted according to the desired heating capacity.
Two separate copper circuits are integrated in the aluminium heat
exchanger.
In addition, the Intergas Xtremehas a second heat exchanger (heat
recovery unit). This second heat exchanger is integrated in the flue of the
boiler so that the eiciency of domestic hot water is increased further.
The residual heat of the flue gases of the central heating use is also used
to preheat the domestic hot water.
By applying this technology, less energy is required to bring the water to
the correct temperature and an extremely high eiciency is achieved.
The boiler has a burner controller which, with each heat demand of the
heater or the domestic hot water facility, controls the pump (only during
heat demand of the heater) and the fan, opens the gas valve, ignites the
burner and continuously monitors and regulates the flame, depending
on the requested capacity.
****
-yymm
****
Production code-Serial no.
YY = year of production,
mm = month of production
PIN
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)
PMS
Permissible overpressure in CH circuit in bar
PWS
Permissible overpressure in DHW circuit in bar
Qn HS
Input related to gross caloric value in kilowatts
Qn Hi
Input related to net caloric value in kilowatts
Pn
Output in kilowatts
BE, CH, DE, ES,
FR, GB, IE, IT, MT
Countries of Destination (EN 437)
I2E(s), I2H,
IIELL3P, II2H3P,
II2Esi3P
Approved unit categories (EN 437)
G20-20 mbar
G25-25 mbar
Gas group and gas connection pressure as set
at the factory (EN 437)
B23, ......C93(x)
Approved flue gas category (EN 15502)
Tmax
Maximum flow temperature in °C
IPX4D
Electrical protection class
10
The boiler has a number of operational modes:
The boiler is switched o.
The boiler is out of order but is connected to the mains voltage.
In this mode, the display view is characterized by:
► Showing the power LED [ ].
► Showing the pressure in the central heating system (in bar)
on the le display [ ].
► Showing a line on the right display [ ].
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 characterized by:
► Showing the power LED [ ]. All other symbols and values
are not displayed.
3.4 Control panel
The boiler has a fully integrated touch screen control panel
that displays information about the operational mode of the
boiler. Symbols (buttons), numbers, points and/or letters are
displayed.
The buttons light up so that they can be operated.
For extensive control options, see §8.
3.5 Operational modes
Boiler is switched o
(mains voltage is present, however)
Boiler is switched on
(ready for heat demand)
The boiler is in operation and is supplying domestic hot
water.
The boiler is in operation and is supplying domestic hot water
to one of the tap points. The display view is characterized by:
► Showing the power LED [ ].
► Showing the flame. The burner is switched on [ ].
► Showing the tap symbol [ ].
The boiler is in operation and is supplying central heating
water.
The boiler is in operation and is supplying central heating
water. The display view is characterized by:
► Showing the power LED [ ].
► Showing the flame. The burner is switched on [ ].
► Showing the radiator symbol [ ].
Boiler is in operation (domestic hot water)
Boiler is in operation (central heating water)
COMMENT
► Only use your fingers to operate the
touch screen
11
4 MAIN COMPONENTS
Flue adapter
Air supply duct
(not to be removed)
Ignition pin
Ignition unit
Air supply duct
(not to be removed)
Flue sensor
Fan
Gas valve
Pump
Flow sensor
Siphon base
Burner controller
with control panel
Control panel and
readout
Heat exchanger sensor
Heat exchanger
Expansion vessel
shown in broken lines
Domestic hot water sensor
Pressure relief valve
Central heating
flow sensor
Central heating
pressure sensor
Mains lead 230 V
AC without plug
(stripped)
12
4.1 Standard scope of delivery
Boiler Wall bracket Flexible condensate hose
Garantiebewijs Intergas HR-ketel
Garantiebewijs Intergas HR-ketel Garantiebewijs Intergas HR-ketel
Datum installatie:
Volgens geldende voorschriften
geïnstalleerd door:
Naam installateur:
Adres:
Postcode:
Woonplaats:
Naam koper:
Adres:
Postcode:
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 ingevuld en voorzien zijn van de handtekening
van koper en installateur. Door ondertekening van deze kaart verklaart koper
zich akkoord met de staat van de ketel bij aflevering.
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
zich akkoord met de staat van de ketel bij aflevering.
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.
Datum installatie:
Naam koper:
Adres:
Postcode:
Woonplaats:
Installateur
>>Betrouwbaar in warmte >>Betrouwbaar in warmte >>Betrouwbaar in warmte
Type/Serienr.
Intergas Verwarming BV
Antwoordnummer 5
7740 VB COEVORDEN
Datum installatie:
Naam koper:
Adres:
Postcode:
Woonplaats:
Type/Serienr. Type/Serienr.
Postzegel
niet nodig
voor klant
voor fabrikant
12345678910
12345678910
12345678910
voor installateur
Installation and operation
instruction
Guarantee card
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.
13
Item no 090347
Post-Heating Solar Boiler
conversion set
Item no 842177
Thermostatic mixing valve
Item no 203207
Outdoor sensor
Item no 093697
LT/HT two-way valve set
Item no 093707
LT/HT three-way valve set
Item no 081286
Extension L=100 incl.
wall bracket (for plume
management kit)
Item no 084661
Bend 45°
Item no 084660
Bend 90°
Item no 081295
Deflector kit
Item no 087910
Weather slate (steep roof)
Item no 087372
Weather slate (flat roof)
Item no 089975
Extension L=100
incl. wall bracket
Item no 081298
Horizontal telescopic
oset wall terminal
1
Item no 082980
Horizontal straight wall
terminal extended
1
Item no 081297
Horizontal telescopic wall
terminal
1
Item no 0821973
Vertical roof terminal
(incl. boiler adapter 60/100)
Item no 081294
Plume management kit
Item no 081284
Elbow 90° (for plume
management kit)
Item no 081285
Elbow 60° (for plume
management kit)
4.2 Accessories
Original Intergas accessories can be ordered separately at
the regular wholesaler. Instructions about the correct way to
assemble and use these accessories are provided upon order
and are therefore not included in this installation manual.
1
Only to be used in combination with the base adapter on the boiler
14
4 INSTALLER IMPORTANT POINTS
Please read all instructions before fitting this appliance
► The installer shall instruct the user on the operation of the boiler, safety devices contained within
the boiler and on the location of the filling loop and how to re-pressurise the system if the water
pressure falls.
► The installer should hand over the installation and user instructions upon completion with the
completed Benchmark Commissioning Checklist.
► The service engineer must complete the service record on the Benchmark Checklist aer each
service.
► It is required under Gas Safe Regulations for the installation to be notified to and registered with
Gas Safe, Intergas and Building Control (Gas Safe Notifcation).
► Before proceeding to commission the boiler check the gas inlet pressure is 20mbar (NG) or
37mbar for Propane.
► Combustion analysis with a correctly calibrated and certificated analyser is essential for safe
commissioning of the boiler.
► A pressure reducing valve set to 3.5 bar must be fitted if supply mains pressure is above 4 bar.
► In hard water areas where the PH is 200ppm or above, appropriate protection actions must be
taken in accordance with BS 7593 in line with building regulations Part L.
See also Guarantee Provisions on page 75, point 4.
► The user should be instructed to keep the instructions in a safe place for servicing and future
reference.
► It is important to keep the boiler clear of dust during the installation. In particular, do not allow
debris to enter the flue connection at the top.
► Before fitting the boiler ensure that the pipe work that you are installing is connected to the
appropriate connections on the boiler.
It is important to thoroughly flush the water circuits, aer isolating the boiler, in order to remove
any fluxes and debris from them. This should be done particularly where boilers are being fitted to
existing radiator circuits (please refer to current Standard Codes of Practice).
► 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 on 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 7593:2006)
► This boiler has been factory set but adjustment may be required to the heating input 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).
► Please do not use the pressure relief valve as a means of flushing the system.
► Remember that aer hot water draw of a possible delay may occur before the heating system will
fire up.
► All fluxes, residues and cleaner must be flushed from pipe-work and radiators prior to
commissioning.
► External expansion vessels are best connected water side downwards to allow correct draining/
cleaning of system and to prolong the life of the vessel diaphragm.
► 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.
► 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).
15
450
277
120
120
6565120 6565 70
275
148 98h
H
=320=
50
65
95
Connections
A
Central heating
flow
3/4"
B
Central heating
return
3/4"
C
Gas flow 1/2"
D
Domestic hot
water - cold
1/2"
E
Domestic hot
water - hot
1/2"
F
Condensation
drain
Ødn25
Z
Flue pipe / Air
supply
Ø60/100
(concentric,
wall terminal )
5 INSTALLATION
A
E C D
B
F
A B
D E
F
Z
C
5.1 Overall dimensions of boiler + assembly bracket
5.1.1 Installing the wall bracket and assembly bracket
Using the corresponding fasteners, attach the wall bracket and
the assembly bracket horizontally to the wall. Refer to the drill
pattern in §5.1 or refer to the installation instructions supplied
with the assembly bracket.
Overall dimensions
h =
650 mm Xtreme 24
650 mm Xtreme 30
710 mm Xtreme 36
H =
766 mm Xtreme 24
766 mm Xtreme 30
826 mm Xtreme 36
16
5.2.1 Installation in a kitchen cabinet
The boiler can be placed between two kitchen cabinets or
inside one cabinet. Make sure, however, that there is suicient
ventilation below and above the boiler. If the boiler is placed
inside a cabinet, ventilation openings of at least 50cm2 must
be created above as well as below.
The boiler must be installed on a wall that has suicient
strength to be able to bear the boiler filled with water.
There must be a Earthed fuse spur available at a maximum
distance of one (1) metre from the boiler. The condenstate
must be connected from the boiler and drain away to the
sewer.
To prevent freezing of the condensation drain piping, the boiler
must be installed in a frost-free area.
Make sure the boiler is easily accessible by ensuring that there
is suicient free space surrounding the boiler. This facilitates
the maintenance of the boiler, amongst other things.
5.2 Installation location
at least 50cm
2
at least 50cm
2
min. 200
H
min. 250
min. 50
277
450
min. 10
17
5.2.2 Removing/installing the front panel
► The front panel of the boiler must be removed to perform
various maintenance activities. Do this as follows:
► Unscrew both (lossless) socket screws (1) under the boiler
by using a 5mm socket wrench.
► Slide the front panel (2) upward and then remove it by
pulling it towards you.
1
2
Replace front panel
To replace the front panel, proceed as follows:
► Position the front panel (3) against the boiler and slide
it downwards until it is properly connected to the
boiler.
► Screw tight both socket screws under the boiler using
a 5mm socket spanner.
3
18
5.3 Installing the boiler
1. Install the wall bracket.
2. Place the boiler: Slide the boiler from the top down, over the
wall bracket.
3. Remove the siphon cup.
4. You must fill the siphon cup just over half full with water.
5. Replace the cup. Install the flexible hose on the spout of the
siphon.
6. Connect the flexible hose of the siphon to a 19 mm solvent
weld pipe. To minimize the risk of freezing the condensate
pipe should be connected internally and terminate to an
internal sol stack (ref.: TB115 Gas Safe & HHIC).
7. Install the air supply duct and the flue (see §6.6).
COMMENT
► The Intergas Xtremehas a boiler-specific
siphon cup. Ensure that the proper
version is ordered upon replacement.
(Item no 510054)
1. Assemble wall bracket
4. Fill siphon cup 5. Replace siphon cup in position and
attach flexible hose
6. Connect the flexible hose to the
sewer via an open connection.
2. Place boiler 3. Remove siphon cup
Open connection
to sewer
19
6.1.2 Thermostatic radiator valves
6.1.1 Expansion vessel
► Flush the central heating system thoroughly.
► Fit the flow and return pipes to the isolation valves.
► All pipes must be fitted unstressed in order to prevent pipes
from ticking.
► Existing connections must not be twisted, in order to avoid
leakages.
The CH system should be equipped with:
► A drain tap in the return pipe immediately below the
appliance.
► A drain tap at the lowest point(s) of the installation.
► A non return valve, if pipes run upwards at a short
distance from the appliance. This avoids the occurrence of
thermosyphon eect during DHW operation mode.
If all radiators have thermostatic radiator valves or valves that
can be closed to separate the flow completely from the return,
a minimum amount of water circulation must be ensured by
the installation of bypass piping, for example (also see §8.5).
The appliance is fitted with a expansion vessel adequate for a
system with a water volume not exceeding 100 litres, typically 8
radiators. For larger volume systems, an additional expansion
vessel must be fitted. Contact Intergas for advice in these cases.
6 CONNECTION
6.1.3 Floor heating
Floor heating with pump
For eective 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 floor heating system in a hydraulically neutral
manner to the appliance, or equip the CH circuit with an
electric shut-o valve or check valve to prevent flow
through the appliance when there is no CH request for heat.
Make sure there is a minimum of water circulation; see §8.5.
Underfloor heating connection diagram
A. Boiler
B. Central heating pump
C. Thermostatic control valve
D. Spring-operated non-return valve
E. Electric shut-o valve 230V~
F. Radiators
G. Room/clock thermostat
H. Maximum thermostat
A
G
H
F
C
B
C
E
D
6.1 Connecting the central heating system
Return pipe
Flow piping
20
6.1.4 LT/HT zone system
The central heating system can be divided into two groups,
each with a dierent heating temperature, for example a hightemperature zone (HT) with radiators and a low-temperature
zone (LT) with underfloor heating system without its own
circulation pump.
Both zones must have their own room thermostat. LT/HR
zone control is activated by the adjustment of a number of
parameters.
There are two dierent installation sets available for installing
the LT/HT zone system:
► Installation set with two-way valve (item no 093697).
► Installation set with three-way valve (item no 093707).
Operational principle
The valve divides the heat over both zones. Both zones have
their own room thermostat and are alternately (time-limited)
heated through switching over the valve.
IMPORTANT
► Ensure that the external pump pressure
of the central heating pump in the boiler
is taken into consideration during the
design phase of the underfloor heating.
► If the radiators in the HT zone have
thermostatic radiator valves, this zone
must have a bypass valve.
21
Operational principle
If the room thermostat switches o the boiler because another
heat source is heating the room, it is possible that the other
rooms will cool down.
This can be prevented by dividing the central heating system
into two groups. The group with the external heat source (Z2)
can be closed o from the main circuit with an electric shut-o
valve. Both groups have their own room thermostat.
Note: This ‘external heat source’ control can only be applied if
no external boiler must be heated.
Installation manual
► Place the shut-o valve (B) according to the connection
diagram.
If an OpenTherm or an on/o thermostat is used:
6.1.5 Division of central heating system in groups with extra heat source
Connection diagram ‘external heat source’
control
A. Boiler
B. Electric shut-o valve 230V~
C. Radiators
T1. Room thermostat Group 1
T2. Room thermostat Group 2
Z1. Group 1
Z2. Group 2
A
Z1
B
C
T
1
Z2
C
T
2
COMMENT
► All types of thermostats (OpenTherm, on/
o or RF) can be used in both groups.
12
X13 X12
12
12
12
T2 T1
► Connect the room thermostat of Group 1 (T1) to Connector
X12 1/2.
► Connect the room thermostat of Group 2 (T2) to Connector
X13 1/2.
► Change parameter P081 (see §8.3).
If an RF thermostat is used:
► Connect the RF thermostat using the RF menu; see §7.1.4.
The RF thermostat can only be used for Group 2.
► Change parameter P081 (see §8.3).
Connect thermostats Groups 1 and 2
22
6.2.1 DHW circuit resistance graph
► Flush the installation thoroughly to clean (please refer to
current Standard Codes of Practice).
► Fit the cold and hot water pipes into the shut o valve and
the elbow.
► Existing connections must not be twisted, in order to avoid
leakages. Make sure the compression fittings are tightened
thoroughly to prevent leakage.
Comments
► The specific pipeline length with a piping diameter of
12/10mm or 15/13mm is 30 meters and 17.7 meters,
respectively.
► If the boiler is only used for the domestic hot water facility,
the heating function can be switched o. Parameter P001
must then be changed from 0 to 2. In this case, the central
heating system does not need to be connected or filled.
► If the boiler is out of order and disconnected from the
electricity network during the winter months, the water
must be drained to prevent freezing. Disconnect the
domestic hot water connections immediately directly under
the boiler.
► The Xtreme 24 is equipped with a flow restrictor with a
nominal value of 8l/min. The Xtreme 30 and Xtreme 36 do
not have this feature. If desired, this can be ordered from
Intergas as an option.
The Xtreme 36 allows larger volume flows with high water
pressures; to ensure an exhaust temperature of 55°C, the
DHW facility has to be set at 9 l/min.
6.2 Connection of domestic hot water
Cold water pipe
Water supply system (bar)
Domestic hot water
piping
Flow rate (l/min)
B, C
A
A. Xtreme 24
B. Xtreme 30
C. Xtreme 36
23
A
B
C
D
E
F
A. Heat pump
B. Boiler
C. Switch valve
D. Cold water inlet
E. DHW temperature of heat pump
F. DHW temperature of domestic hot water
Connection diagram of boiler with heat pump boiler
Installation:
The combination must be connected according to the
connection diagram. The following points are important to
guarantee a correct operation of the combination.
Thermostatic switch valve:
The thermostatic switch valve used is a modified valve that
meets the specific requirements to which the combination
heat pump boiler and Intergas Xtremeare subject. For the
correct operation of the combination, the switch valve has a
fixed temperature setting. The thermostatic switch valve can be
ordered from Intergas (item no: 065127).
6.2.2 Boiler with heat pump boiler
The boiler is suitable for use in combination with a heat pump
boiler.
If the exhaust temperature of a heat pump boiler is lower than
55°C, the Intergas Xtrememakes sure that the domestic hot
water from the heat pump boiler is post-heated under HE
conditions.
Operational principle:
The domestic hot water connection of the heat pump boiler
is connected to the mix input of the thermostatic switch valve
(see the principle diagram). If the DHW temperature of the
boiler is higher than the set temperature of the switch valve,
the heat pump boiler will be tapped. Because the switch valve
is not fully closing, a small amount will also run through the
Intergas Xtreme(about 10% of the total flow).
As soon as the exhaust temperature of the heat pump boiler
becomes lower than the set temperature of the switch valve,
the flow through the Intergas Xtremewill increase. If the flow
becomes greater than the domestic hot water threshold of
the Intergas Xtreme, the boiler will start domestic hot water
demand.
When the exhaust temperature of the heat pump boiler has
become lower than the set temperature of the switch valve
minus 12K, almost the entire domestic hot water flow goes
through the Intergas Xtreme. The small leakage flow is now
taken from the heat pump boiler. Aer the entire switching of
the switch valve, the domestic hot water flow will be limited by
the Intergas Xtreme.
24
Domestic hot water inlet pressure:
For a flow volume of 20 litres per minute, the initial pressure
must be a minimum of 2.3 bar. The allowed domestic hot
water operational pressure for the combination may be a
maximum of 6 bar. A safety group (6 bar) must be installed for
this purpose.
Maximum flow volume:
If the domestic hot water flow is greater than 20 litres per
minute, the Intergas Xtremewill start domestic hot water
demand, regardless of the exhaust temperature of the heat
pump boiler.
Maximum temperature setting of the heat pump boiler:
The temperature of the heat pump boiler may not be set higher
than 60°C.
Position of thermostatic switch valve:
To prevent the thermostatic switch valve being influenced too
much by the surrounding air, this valve must be placed in a
vertical position and as close as possible to the domestic hot
water connection of the boiler (maximum distance of 100mm).
This prevents the boiler operating with each tap request.
Influence of water flows:
To prevent the flow being influenced by the Intergas
Xtremeduring the switching of the valve, the domestic hot
water ‘out’ pipeline of the combination must run straight (see
connection diagram [F]).
6.2.3 Boiler with Pre-Heated Solar Boiler)
A connection set and a thermostatic mixing valve are available
to order for this purpose.
Comment:
The cold water sensor must be connected to Connector X13
4/5. When combined with a solar energy system, a thermostatic
mixing valve, set at 62.5°C, must always be placed aer the
boiler.
► Pre-heated Solar boiler conversion set item no 090347
► Thermostatic mixing valve item no 842177
C
C
H
D
B
A
C
E
G
F
I
ART.NR.
842177
A
Connection diagram:
A. Boiler
B. Solar boiler
C. Cold water
D. Safety group
E. T max. 85°C
F. Domestic hot water
G. Thermostatic mixing valve 35°C-65°C
(set at 62.5°C)
H. Domestic hot water mixed
I. Cold water sensor
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