Intergas G.C. 47-291-13 Installation Manual Download

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INSTALLATION MANUAL

High Efficiency 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.

Xclusive 24
Xclusive 30
Xclusive 36

G.C. 47-291-13

G.C. 47-291-14

G.C. 47-291-15

Smart Opentherm™

Summary of Contents for G.C. 47-291-13

Page 1: ...this installation manual thoroughly before the installation and use of the boiler Follow all indicated instructions This installation manual must remain with the boiler Xclusive 24 Xclusive 30 Xclusi...

Page 2: ...s 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 i...

Page 3: ...c 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 faci...

Page 4: ...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...

Page 5: ...ective 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 substanc...

Page 6: ...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 affect the operation of the...

Page 7: ...S 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 fo...

Page 8: ...ar II2H3P Natural gas G20 20 LPG G31 37 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 Based o...

Page 9: ...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 circu...

Page 10: ...perature settings demand symbols and fault codes The display has multiple functions and options please refer to section 9 for further detail 3 5 Operational modes Boiler is switched off mains voltage...

Page 11: ...lating Pump Flow turbine sensor Condense syphon Printed circuit board and housing Touch screen fascia panel Heat exchanger Expansion vessel shown as silhouette NTC Domestic hot water sensor S3 3bar Pr...

Page 12: ...idelijk 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 G...

Page 13: ...on L 1000mm inc wall bracket Item no 081298 Horizontal telescopic offset wall terminal1 Item no 082980 Horizontal non telescopic straight wall terminal1 Item no 081297 Horizontal telescopic wall termi...

Page 14: ...p 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...

Page 15: ...clearances on the boiler template supplied with this appliance Overall dimensions h 618 mm Xclusive 24 618 mm Xclusive 30 678 mm Xclusive 36 H 766 mm Xclusive 24 766 mm Xclusive 30 826 mm Xclusive 36...

Page 16: ...nse 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 loft space or ga...

Page 17: ...ed 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...

Page 18: ...n lift 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...

Page 19: ...h 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...

Page 20: ...ect 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 w...

Page 21: ...43B normally open Parameter P081 must adjusted to value 1 Time control to Heating circuit L N HTG on OpenTherm Heating Control EARTH SWITCHED LIVE GREY P LIVE M V SWITCHED LIVE NEUTRAL EARTH M V SWITC...

Page 22: ...ally 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 06...

Page 23: ...V X14 4 5 X13 24V X12 24V X11 24V N A X10 24V N A X8 230V X5 230V X4 230V X3 230V X2 230V X1 230V 1 2 F1 3 15 AT FUSE 3 1 2 1 2 1 2 3 24V 230V A B C D E Zone Valve D H W V4043H normally closed Cylinde...

Page 24: ...well 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 Syste...

Page 25: ...r Wiring Centre Zone Valve C HEATING V4043H normally closed Twin channel Programmer L N HTG on EARTH S L TO BOILER DHW P LIVE M V S L NEUTRAL EARTH L N Cylinder thermostat NEUTRAL DHW on 2 1 3 1 C 1 2...

Page 26: ...l Programmer L N HTG on EARTH S LIVE DHW S LIVE HTG P LIVE P LIVE M V S L NEUTRAL G YELLOW L N Cylinder thermostat BLUE M V S L DHW on 2 1 3 1 C 1 2 3 4 5 6 7 8 9 10 DHW S L HTG S L Outdoor Sensor S6...

Page 27: ...programmer C Cylinder thermostat D Boiler pressure reflief valve 3 Bar E Hot water draw off Gravity F Mid position zone valve G Cold feed and expansion tank H System By pass Should be 3 meters from b...

Page 28: ...230Vac 3amp Switched Fused Spur Wiring Centre L N HTG on L N Cylinder thermostat DHW on 2 1 3 1 C 1 2 3 4 5 6 7 8 9 10 DHW off 2 Twin channel Programmer EARTH S L to BOILER LIVE M V S L NEUTRAL NEUTRA...

Page 29: ...al 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 circuit...

Page 30: ...roducing 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 throu...

Page 31: ...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 bein...

Page 32: ...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 co...

Page 33: ...tats OpenTherm OT thermostat Intergas Comfort Touch On off thermostat TPI RF thermostat see 9 1 4 The boiler is suitable for connection to a 2 wire on off room thermostat Position the thermostat in th...

Page 34: ...if required it will ignite the burner until the temperature of the water is up to approximately 15 C Comment With the on off TPI room thermostat fitted as per 7 5 2 you must locate the frost stat in a...

Page 35: ...ppliance 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 03...

Page 36: ...ect 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 affected when grease is applied a...

Page 37: ...ry change in direction Each bend should have a bracket fitted either side Connect the final section to the chosen terminal outlet The flue gas section must be installed with a fall of 5mm mtr back tow...

Page 38: ...inlet for the air supply duct is located in the same pressure area as the terminal Example combined fa ade terminal Terminal Other components C33 The terminal is located above the roof the inlet for...

Page 39: ...e gas exhaust pipe together excluding the length of the combi pipe wall terminal 7 8 1 Horizontal wall terminal 60 100mm C13 Boiler C13 60 100 Intergas Xclusive 24 10 m Intergas Xclusive 30 10 m Inter...

Page 40: ...25mm F From internal or external corners 300mm G Above ground roof or balcony level Terminal guards must be fitted if less than 2 metres from the ground 300mm H From a surface facing a terminal 600mm...

Page 41: ...erminals in relation to boundaries Adjacent to a boundary line 600mm 300mm 2 Internal external corners The air intake clearance can be reduced to 150 mm providing the flue exhaust outlet has a 300 mm...

Page 42: ...e a diameter of 80 mm All the flue pipe components and any terminal used must must be approved by Intergas heating ltd Pitched roof Pitched roof Flat roof Flat roof Assembly of twin pipe vertical term...

Page 43: ...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 prev...

Page 44: ...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...

Page 45: ...ical for both twin and concentric flue bracket positioning m ax 250m m m ax 1000m m m ax 1000m m max 250 mm max 250 mm max 250 mm max 500 mm fall back to boiler Second element after first elbow Second...

Page 46: ...han 2 metres from the ground 200mm 50mm G Above ground or balcony or roof Terminal guards must be fitted if less than 2 metres from the ground 150mm 25mm H From internal or extrnal corners or to bound...

Page 47: ...left display The boiler enters standby power off mode characterised by a line on the right display and the central heating system pressure on the left display When the central heating pressure is lowe...

Page 48: ...orrectly Switch on boiler 2sec Switch off boiler 2sec Manual air vent 8 2 2 Domestic hot water facility 8 2 3 Gas supply P1 Inlet pressure measurement test point Open the cold water main isolation val...

Page 49: ...have been adjusted correctly see 9 3 Switch off 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...

Page 50: ...liance 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 progr...

Page 51: ...f to the boiler Remove the 3 amp fuse from the wall spur Turn off the gas isolation valve under the boiler Drain the boiler completely Drain the heating system at the lowest point Turn off the mains c...

Page 52: ...us 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 heatin...

Page 53: ...nfirm Domestic hot water Temperature adjustment For a swifter supply of domestic hot water the boiler has a DHW comfort function with the following options P On The DHW comfort function is activated w...

Page 54: ...inal menu or standby mode 9 1 3 Central heating menu 9 1 4 RF menu Central heating menu Main menu Confirm Central heating menu 2sec The central heating menu has 3 settings and is accessible by gently...

Page 55: ...3 After a successful assignment rF1 appears in the left display Tap the Enter symbol to save Central heating menu 2sec Central heating menu 2sec To remove an assignment 1 Touch the Central Heating sym...

Page 56: ...ating symbol will be extinguished 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 Burn...

Page 57: ...symbol Parameter P001 will now be shown on the left 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...

Page 58: ...ion 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...

Page 59: ...ust 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...

Page 60: ...ater 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 left display Tapping the or symbo...

Page 61: ...vate the programmed time settings Using the Plus or Minus buttons set the desired program setting P on On Eco or Off Tap the Enter symbol to confirm The chosen program setting will be saved in the boi...

Page 62: ...e time central heating 5 Delay time for central heating only 0 to 15 minutes this does not delay DHW production p040 p040 Activate clock program CH operation 1 0 inactive 1 active P057 P057 Response f...

Page 63: ...therefore switched off See section 8 4 for further options 25 50 75 100 1 0 2 3 4 5 6 7 H M L M 0 8 17 25 33 C B A The maximum central heating output is factory set If this needs to be adjusted to sui...

Page 64: ...cording to the set heating curve depending on the outside temperature at that time The weather dependent control functions solely with an on off room thermostat When using an OpenTherm room thermostat...

Page 65: ...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...

Page 66: ...est 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 9 9 Gas...

Page 67: ...surement 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 IMPORTANT Make sure that the capital letter H H ap...

Page 68: ...nimum output A Switch on the boiler at minimum output To do this tap simultaneously the Service symbol and the Minus symbol until the capital letter L L appears on the right display B Wait until the r...

Page 69: ...10 3 if the measured value is outside the indicated limits 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 val...

Page 70: ...Dust cap 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...

Page 71: ...or 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 F0...

Page 72: ...he sensor correctly f016 f016 DHW sensor S3 mounting fault Domestic hot water sensor S3 is not mounted correctly Attach the sensor correctly F018 F018 Flue and or air supply duct is blocked restricted...

Page 73: ...If an outdoor sensor is present check the sensor location or for damage check curve setting see 9 7 Poor or no flow in the system Yes No Check the t 20 C between central heating flow and return Ensur...

Page 74: ...hot water circuit within the boiler heat exchanger The central heating system becomes warm while operating the domestic hot water Yes No For thermo syphon Install a check valve in the CH return pipewo...

Page 75: ...otification returns repeatedly The following notifications are distinguished Notification Description Possible cause solution N030 DHW demand is blocked Check if parameter P001 is set correctly Check...

Page 76: ...components with water the inside of syphon base plastic ball circlip syphon cup opening of the exhaust manifold 2 1 1 1 1 2 3 4 5 CAREFUL After completion of the Annual service procedure all 26 9 safe...

Page 77: ...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 Make s...

Page 78: ...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 be...

Page 79: ...er 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 ga...

Page 80: ...the return Check the pressure in the expansion vessel Recharge if necessary 8 Remove the front plate and clean the inside of the heat exchanger 9 Check the front plate seal replace the seal if damage...

Page 81: ...mass flow minimum maximum kg h 5 9 41 6 5 9 50 5 5 9 54 1 Maximum counterpressure Pa 250 Overall dimensions and weight Height mm 766 766 826 Width mm 450 Depth mm 277 Weight Empty kg 30 30 33 Weight F...

Page 82: ...2 3 4 5 6 Earth connections heat exchanger Power cord Earth connections burner controller Fan Central heating pump 230V 50Hz Ignition pin 230V 24V 4 5 3 4 Central heating pressure sensor 2 1 3 2 1 3...

Page 83: ...nnector Connections Designation Description X12 1 2 Optional OpenTherm thermostat X12 1 2 Aan Uit Optional On off room thermostat X12 1 2 Optional Frost thermostat if OT thermostat on X13 X13 1 2 Open...

Page 84: ...r capacity profile L XL XL Energy efficiency class for water heating A A A Domestic hot water efficiency WH 85 86 87 Annual electricity use AEC kWh 13 17 15 Annual fuel use AFC GJ 11 18 17 IMPORTANT B...

Page 85: ...5mm 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 8757...

Page 86: ...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 acces...

Page 87: ...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 househol...

Page 88: ...no what is the maximum central heating output selected kW Dynamic gas inlet pressure mbar C Central heating return temperature C System correctly balanced rebalanced Yes COMBINATION BOILERS ONLY Is t...

Page 89: ...eer name Company name Telephone No Gas Safe registration No Max rate CO ppm CO CO CO Min rate CO ppm CO CO CO undertaken in accordance with manufacturers instructions and readings are correct yes Gas...

Page 90: ...eer name Company name Telephone No Gas Safe registration No Max rate CO ppm CO CO CO Min rate CO ppm CO CO CO undertaken in accordance with manufacturers instructions and readings are correct yes Gas...

Page 91: ...91...

Page 92: ...g 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 po...

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