Intergas Rapid 25 User manual

Intergas Heating Ltd.
Rapid 25
Rapid 32
Installation Manual

2
TABLE OF CONTENTS
1. Safety Regulations 6
1.1 General ....................................................................................................................................................................... 6
1.2 The Installation ............................................................................................................................................................ 6
1.3 Approvals .................................................................................................................................................................... 6
2. Descri tion of the A liance 7
2.1 General ....................................................................................................................................................................... 7
2.2 Operation .................................................................................................................................................................... 7
2.3 Operating conditions ................................................................................................................................................... 8
2.4 Clock unction ............................................................................................................................................................ 10
2.5 PC Inter ace .............................................................................................................................................................. 10
2.6 Test program’s .......................................................................................................................................................... 10
2.6.1 Frost protection ......................................................................................................................................................... 11
3. Installer IMPORTANT POINTS 12
4. Main Com onents 13
4.1 Accessories ............................................................................................................................................................... 14
5. Installation 15
5.1 Overall dimensions .................................................................................................................................................... 15
5.2 Boiler location ............................................................................................................................................................ 16
5.2.1 Installation in a kitchen cupboard .............................................................................................................................. 16
5.2.2 Installation in an airing cupboard............................................................................................................................... 16
5.2.3 Remove ront panel ................................................................................................................................................... 16
5.3 Assembly ................................................................................................................................................................... 17
5.3.1 Fitting the mounting strip ........................................................................................................................................... 17
5.3.2 Fitting the rear mounting rame ................................................................................................................................. 17
5.4 Mount the appliance .................................................................................................................................................. 18
6. Connections 19
6.1 Connect the CH system ............................................................................................................................................ 19
6.1.1 Expansion vessel ...................................................................................................................................................... 19
6.1.2 Thermostatic radiator valves ..................................................................................................................................... 19
6.1.3 Under loor heating ..................................................................................................................................................... 19
6.1.4 Appliance with zone control. ..................................................................................................................................... 20
6.2 Domestic hot water system ....................................................................................................................................... 21
6.2.1 Appliance with solar water heater post-heating ......................................................................................................... 21
6.3 Electrical connection ................................................................................................................................................. 22
6.3.1 Electrical connections ............................................................................................................................................... 22
6.3.2 On / O room thermostat .......................................................................................................................................... 23
6.3.3 Open Therm room thermostat .................................................................................................................................. 23
6.3.4 Outside temperature sensor ...................................................................................................................................... 23
6.3.5 230 volt room thermostat .......................................................................................................................................... 23
6.3.6 S and Y zone plans ................................................................................................................................................... 23
6.4 Condensate disposal ................................................................................................................................................. 24
6.5 Gas connection ......................................................................................................................................................... 25
6.5.1 Flue pipe and air supply ............................................................................................................................................ 26
6.5.2 Length lue pipe and air inlet when connecting to a concentric lue system .............................................................. 27
6.5.3 Equivalent lengths ..................................................................................................................................................... 27
6.5.4 Horizontal lue system ............................................................................................................................................... 27
6.5.5 Vertical lue system ................................................................................................................................................... 27
6.5.6 Plume management kit ............................................................................................................................................. 28
6.5.7 Flues in voids ............................................................................................................................................................ 28
7. Commissioning 29
7.1 Fill and de-aerate the appliance and the system ....................................................................................................... 29
7.1.1 CH system ................................................................................................................................................................. 29
7.1.2 Hot water supply ....................................................................................................................................................... 29
7.1.3 Gas supply ................................................................................................................................................................ 29
7.1.4 Combustion ............................................................................................................................................................... 30
7.1.5 Flue system ............................................................................................................................................................... 30

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7.2 Commissioning o the appliance ............................................................................................................................... 31
7.3 Setting and adjusting the clock unctions .................................................................................................................. 32
7.3.1 Setting the clock ........................................................................................................................................................ 32
7.3.2 Setting the timer unction .......................................................................................................................................... 32
7.4 Additional unctions ................................................................................................................................................... 32
7.5 Shutting down ........................................................................................................................................................... 32
7.5.1 Frost protection ......................................................................................................................................................... 33
7.6 System Shutdown ..................................................................................................................................................... 33
7.6.1 Frost protection ......................................................................................................................................................... 33
8. Setting and Adjustment 34
8.1 Directly via the operating panel ................................................................................................................................. 34
8.1.1 Appliance on/o ........................................................................................................................................................ 34
8.1.2 DHW com ort ............................................................................................................................................................. 34
8.1.3 Resetting ................................................................................................................................................................... 34
8.1.4 Changing the settings o the various unctions: ......................................................................................................... 34
8.1.5 Maximum CH supply temperature ............................................................................................................................. 34
8.1.6 DHW temperature ..................................................................................................................................................... 34
8.2 Settings through the service code ............................................................................................................................. 35
8.3 Parameters ................................................................................................................................................................ 35
8.3.1 Enable/disable keep hot acility by Open Therm room thermostat. .......................................................................... 36
8.3.2 Summer mode. .......................................................................................................................................................... 36
8.4 Setting maximum CH power...................................................................................................................................... 37
8.5 Setting pump position ................................................................................................................................................ 37
8.6 Weather-dependent control ....................................................................................................................................... 37
8.7 Conversion to di erent gas type................................................................................................................................ 38
1.1.1 Converting the gas restriction.................................................................................................................................... 38
8.8 Gas-Air ratio control. ................................................................................................................................................. 39
8.9 Checking the gas air ratio control .............................................................................................................................. 40
8.9.1 Checking lue gas at maximum power. ..................................................................................................................... 40
8.9.2 Checking lue gas at minimum power ....................................................................................................................... 41
8.9.3 Correction gas air ratio on minimum power ............................................................................................................... 42
9. Faults 44
9.1 Faultcodes ................................................................................................................................................................. 44
9.2 Other aults ............................................................................................................................................................... 45
9.2.1 Burner does not ignite ............................................................................................................................................... 45
9.2.2 Burner ignites noisily ................................................................................................................................................. 45
9.2.3 Burner resonating ...................................................................................................................................................... 46
9.2.4 No heating (CH) ........................................................................................................................................................ 46
9.2.5 The power is reduced ................................................................................................................................................ 46
9.2.6 CH does not reach temperature ................................................................................................................................ 46
9.2.7 No hot water (DHW) .................................................................................................................................................. 47
9.2.8 Hot water does not reach temperature ...................................................................................................................... 47
9.2.9 LED on CH pump is lashing alternately red and green. ........................................................................................... 47
9.2.10 LED on CH pump is lashing red. .............................................................................................................................. 47
10. SERVICING THE BOILER 48
10.1 Disassembly .............................................................................................................................................................. 49
10.2 Assembly ................................................................................................................................................................... 50
10.3 Combustion ............................................................................................................................................................... 51
11. Technical S ecifications 52
11.1 NTC resistances ........................................................................................................................................................ 52
11.2 Electrical diagram ...................................................................................................................................................... 54
12. Warranty CoNDiTions 55
13. CE DECLARATION 55
14. SERVICE RECORD 57
© 2015 Intergas Heating Ltd
The in ormation provided applies to the product in the standard model. Intergas
Verwarming BV can there ore not be held liable or any damage resulting rom the
product speci ications that deviate rom the standard model.

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The in ormation provided has been compiled with the utmost care. However, Intergas
Verwarming BV cannot be held liable or any aults in the in ormation nor or the
consequences thereo .
Intergas Verwarming BV cannot be held liable or any damage resulting rom the
activities carried out by third parties.
To be changed without prior notice

5
This manual
Using this manual you can sa ely install and maintain this appliance.
Care ully ollow the instructions.
In case o doubt, contact Intergas Verwarming BV
Keep these instructions near the appliance.
Abbreviations and names used
Descri tion
To be referred
to as
High E iciency
HE
Intergas Rapid
wall
-
mounted gas heater
Appliance
Appliance with piping or central heating
CH system
Appliance with piping or domestic water
DHW system
Icons
The ollowing symbols are used in this manual:-
CAUTION
Procedures that, when not carried out with due care,
may result in damage to the roduct or the
environment or in ersonal injury.
Service and technical su ort
For in ormation about speci ic adjustments, installation, maintenance
and repair activities, please contact:
Intergas Heating Ltd, Kingswin ord
Tel. 01527 - 888000
Fax 01384 - 279480
in [e-mail]
Product identification
You will ind the appliance data on the data plate on the underside o the
appliance.
•Appliance type
•Hot water power rating (kW)
•Power rating, upper and lower value (kW)
•Rated power (kW)
•Gas category
•Gas connection pressure (mbar)
•Gas type set
•Pin
•Appliance category
•Maximum CH pressure (bar)
•Maximum CH water temperature (°C)
•Maximum DHW pressure (bar)
•Electrical connection
•NOx number
•Serial number
•Year o manu acture

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1. SAFETY REGULATIONS
The manu acturer Intergas Heating Ltd accepts no liability whatsoever or damage or
injury caused by ailure to adhere (strictly) to the sa ety regulations and instructions, or
carelessness during installation o the Intergas Combi Compact HRE High E iciency
wall mounted gas ired boiler and any associated accessories.
1.1 General
It is law that all gas appliances are installed by a Gas Sa e registered
competent engineer and in accordance with the ollowing recommendations:
•Current Gas Sa ety (Installation and Use) Regulations
•All current building regulations
•Building Standards (Scotland) Consolidated
•This appliance must be installed in accordance with the Gas (Sa ety and
Use) Regulations, current Building Regulations, Building Standards
(Scotland), I.S.813 Installation o Gas Appliances (Ireland), IEE Wiring
Regulations (BS 7671), Health and Sa ety Document No. 635 (Electricity
at Work Regulations) and Local Water Authority Bye Laws
•UK Water Regulations and Bye Laws
•Health & Sa ety
1.2 The Installation
The installation must comply with the ollowing British Standards codes o
practice:
•BS 5440: Flues and Ventilation or gas appliances o rated input not exceeding
70kW (Part 1 Flues)
•BS 5440: Flues and Ventilation or gas appliances o rated input not exceeding
70kW (Part 2 Air Supply)
•BS 5546: 2000 Installation o gas hot water supplies or domestic purposes.
•BS 5549: 1990 Forced circulation hot water systems
•BS 6700: 1997 Design, Installation, testing and maintenance o services supplying
hot water
•BS 6798: 2000 Speci ication or installation o gas ired hot water boilers o rated
input not exceeding 70kW
•BS 6891: 1998 Installation o low pressure gas pipe-work installations up to 35mm
(RI)
•BS 7593: 1992 Code o practice or treatment o water in heating systems
•BS 7671: 2001 Requirements or electrical installations, IEE Wiring regulations
Reference should also be made to:
•Guide to condensing boiler installation assessment procedures or dwellings
•The institute o Gas Engineers document IGE/UP/7 or timber rame dwellings
1.3 A rovals
Natural Gas
Intergas Combi Compact HRE Pre-mix Condensing Combination Boiler
British Gas Service Listing:
Rapid 25 G.C.N.
Rapid 32 G.C.N.
Noti ied /Body
The Intergas Rapid range o central heating boilers are manu actured rom high quality
materials and designed or reliability and optimum per ormance.
Intergas is committed to the continual development o their appliances and reserves the right to make changes without
noti ication to ensure their customers bene it rom the latest advances in combustion technology and energy conservation.
Gastec
0063BT3576
Directive 90/396/EEC
Directive 92/42/EEC

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2. DESCRIPTION OF THE APPLIANCE
2.1 General
The Intergas Rapid HR wall mounted, gas ired boiler is a closed appliance. The
appliance is intended to deliver heat to the water in a CH system and the DHW
installation.
The air supply and combustion gas lue can be connected to the appliance by
means o two separate pipes. A concentric connection can be supplied i
requested. The appliance has been inspected in combination with the Intergas
“combi duct”, but it can also be connected to combi ducts that comply with the
universal requirements or combi ducts and which carry a ‘Gaskeur’(Dutch gas
certi ication).
Depending on pre erence, the appliance may be connected to a mounting
bracket, a rame with top connection and various connection sets. These are
supplied separately.
The Intergas Rapid HR wall mounted gas ired boilers carry the CE label and
electrical protection class P44
It is possible to use the appliance solely or hot water or solely or heating. The
unused system does not have to be connected. (See section 8.3)
The appliance is supplied as standard or natural gas (G25). On request an
appliance can be supplied or propane (G31).
2.2 O eration
The Intergas Rapid is a wall-mounted modulating high e iciency boiler. This
means that the power is adjusted to the heat demand.
In the aluminium heat exchanger two separate copper circuits have been
integrated.
Because o the separated circuits or central heating and hot water, the heating
and the hot water supply can operate independently o each other. The hot
water supply has priority over the heating. They cannot work simultaneously.
The appliance has been provided with an electronic burner controller that
controls the an with the heat demand rom the heating system or the hot water
supply, opens the gas valve and ignites the burner and continuously monitors
the lame and controls it dependent on the power required.

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2.3 O erating conditions
A code on the service display o the operating panel indicates the
appliance’s operating mode.
- Off
The appliance is out o operation but is supplied with electrical power. No
response occurs to calls or DHW or CH. The appliance rost protection is
active. This means that the pump operates and the exchanger is heated
up i the temperature o the water present in it alls too ar.
I the rost protection is actuated, code 7 is displayed (heating
exchanger).
In this operating mode the pressure in the CH installation (in Bar) can
also be read on the temperature display.
Waiting mode
The LED at the button is lit and possibly one o the LEDs or the DHW
com ort unction. The appliance is ready to respond to a request or CH
o DHW.
0 Running on of CH
A ter the end o CH operation the pump continues to run. The running on
time is actory set at he value in accordance with section 8.3 , page:35.
This setting can be changed.
In addition, the pump runs automatically or 10 seconds once every 24
hours in order to prevent seizing. This automatic switching on o the
pump occurs at het time o the last call or heat.
1 Desired temperature reached
The burner manager can temporarily block the request or heat. The
burner is then stopped. Blocking occurs because the requested
temperature has been reached. When the temperature has allen
su iciently the blocking is cancelled.
2 Self-test
The connected sensors are checked regularly by the burner manager.
During the check the manager does not per orm any other tasks.
3 Ventilation
When the appliance is started the an is irst brought to starting speed.
When the starting speed has been reached the burner is lit. Code 3 is
also visible when post-ventilation is taking place a ter the burner has
stopped.
4 Ignition
When the an has reached the starting speed, the burner is ignited by
means o electrical sparks. During ignition the code 4 is visible. I the
burner does not ignite, a new ignition attempt occurs a ter approximately
15 seconds. I a ter 4 ignition attempts the burner is not yet burning, the
burner manager goes into ault mode. (See section 9).
5 CH operation
An o /o thermostat, an OpenTherm thermostat, an external sensor or a
combination o the latter can be connected to the burner manager. (See
section 11.2)
When a request or heat is received rom a thermostat, the an is started
(code 3 ), ollowed by ignition(code 4 ) and CH operating mode(code 5
During CH operation the an speed and hence the appliance power are
controlled by the burner manager so that the CH water temperature
reaches the desired CH supply temperature.
I an on/o thermostat is connected, this is the CH supply temperature set
on the display. In the case o an OpenTherm thermostat the desired CH
supply temperature is determined by the thermostat.

9
In the case o an external sensor the desired CH supply temperature is
determined by the heating line programmed in the burner manager. For
the latter two, however, the maximum is the temperature set on the
display.
The CH operation the requested CH supply temperature is indicated on
the operating panel.
The CH supply temperature can be set between 30°C and 90°C. (See
section 8.1).
The actual CH supply temperature can be read by pressing the service
button during CH operation.
When the DHW com ort unction is switched on (See code 7 ) any
OpenTherm request or heat o less than 40°C is ignored.
The resistance R may be removed i the room thermostat does not need
anticipation current. (See section 11.2)
6 DHW operation
The hot water supply takes priority over the heating. I the low switch
detects a need or more than 2 l/min o DHW, any demand or CH will be
interrupted. A ter the an has reached speed (code 3 ) and ignition has
taken place (code 4 ) the manager goes to DHW mode (code 6 ).
During DHW operation the an speed, and hence the power o the
appliance, are controlled by the burner manager so that the DHW water
temperature reaches the DHW temperature setting.
The water temperature can be set between 40°C and 65°C (See section
8.1) and is displayed on the operating panel during DHW operation.
The actual DHW temperature can be read by pressing the service button
during DHW operation.
7 Pre heating exchanger
To enable ast delivery o domestic hot water the burner manager is
equipped with the DHW com ort unction. This unction maintains the
temperature o the heat exchanger to an adjustable temperature (See
section 8.1.). The DHW com ort unction has the ollowing settings:
•On: ( LED on) The appliance’s DHW com ort unction is
switched on continuously. The appliance always delivers hot water
immediately.
•Eco: ( LED on) The appliance’s DHW com ort unction is sel
learning. The appliance will adapt to the pattern o use o the hot
water tap. As a result, the temperature o the heat exchanger will
not be maintained during the night or in the case o longer period
o absence.
It is possible to control the com ort mode by means o an Open Therm
room thermostat.
•Off: (Both LEDs off) The temperature o the heat exchanger is not
maintained, as a result o which the delivery o domestic hot water takes a
little time. I there is no need or ast delivery o hot water, the DHW
com ort unction can be switched o .

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2.4 Clock function
The boiler is equipped with a digital clock and o ers the possibility to program 4
points in time to switch rom CH o or CH on.
During the “clock active” periods the boiler will respond on CH demands rom the
room thermostat. During the “clock inactive” periods the boiler will not respond on
CH demands.
Additionally the ollowing special modes can be chosen:
A. t-on (temporary on).
The boiler will respond to every CH demand rom the room thermostat until
the next switch moment.
B. c-on (continuous on).
The boiler will respond to every CH demand rom the room thermostat
without any time limit.
C. OFF.
The boiler will not respond to any CH demand rom the room thermostat.
Note
For setting and adjusting the clock see § 9.3 Setting and adjusting the clock
functions
2.5 PC Interface
The burner manager is equipped with an inter ace or a PC, which can be
connected by means o a special cable and associated so tware. This acility
allows the behaviour o the burner manager , the appliance and the heating
installation to be monitored over a longer period.
2.6 Test rogram’s
The burner manager has a acility or placing the appliance in test mode.
Activation o a test program will result in the appliance starting operation
at a ixed an speed, without the control unctions being actuated.
The sa ety unctions do remain active.
The test program is ended by pressing the and simultaneously.
Test rograms
Program descri tion
Button
combinations
Dis lay reading
Burner on at minimum CH power
and
“L”
Burner on with maximum CH power
setting (See section 8.3, parameter 3) and (1x) “h”
Burner on with maximum DHW power
(See section 8.3, parameter 4) and (2x) "H"
Switch o test program and
Standard
situation
Additional readings :
During test mode the ollowing data can be read :
•By pressing the button continuously in the display the CH water pressure is
shown.
•By pressing the button continuously in the display the ionisation current is
shown.

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2.6.1 Frost rotection
•
To prevent reezing o the appliance it is equipped with appliance
rost protection. I the heat exchanger temperature alls to low, the
burner switches on and the pump runs until the heat exchanger
temperature is su icient. When the appliance rost protection is
actuated code 7 ‘ is displayed (pre heating exchanger).
•I the installation (or a part o it) can reeze, an (external) rost
thermostat must be itted to the return line at the coldest location.
This must be connected in accordance with the wiring diagram.
(See section 11.2.)
Remark
When the a liance is out of action ( -
--
- on the service dis lay), the
a liance frost rotection is still active. However, there will be no
res onse to heat demand from an (external) frost thermostat.

12
3. INSTALLER IMPORTANT POINTS
Please read all instructions before fitting this a liance
•The installer shall instruct the user on the operation o the boiler, sa ety
devices contained within the boiler and on the location o the illing loop and
how to re-pressurize the system i the water pressure alls.
•During servicing the boiler the condensate trap needs to be cleaned.
•The installer should then hand over the instructions indicating the included
Benchmark Commissioning Checklist that has been completed.
•It is required under Gas Sa e Regulations or the installation to be noti ied to
Building Control (Gas Sa e Noti ication).
•Be ore proceeding to commission the boiler check the gas inlet pressure is
20mbar (NG) or 37mbar or Propane.
•Combustion analysis with a correctly calibrated and certi icated analyzer is
essential or sa e commissioning o the boiler.
•A pressure reducing valve set to 3.5 bar must be itted i supply mains
pressure is above 4 bar.
•A suitable scale reducer must be itted i water hardness is above 200 ppm.
•The user should be instructed to keep the instructions in a sa e place or
servicing and uture re erence.
•It is important to keep the boiler clear o dust during the installation. In
particular, do not allow debris to enter the lue connection at the top.
•Be ore itting 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 lush the water circuits, a ter isolating the boiler,
in order to remove any luxes and debris rom them. This should be done
particularly where boilers are being itted to existing radiator circuits (please
re er to current Standard Codes o Practice).
•BS 7593:2006 or the details to clean DHW and Central heating system).
•This boiler has been actory 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 3 (= max. power CH) or parameter 4
(= max. power domestic water).
•Please do not use the pressure relie valve as a means o lushing the
system.
•Remember that a ter hot water draw o a possible delay may occur be ore
the heating system will ire up.
•All luxes, residues and cleaner must be lushed rom pipe-work and
radiators prior to commissioning.
•External expansion vessels are best connected water side downwards to
allow correct draining/cleaning o system and to prolong the li e o the vessel
diaphragm.
•Note: an anti-cycle delay time can be set up to a maximum o 15 minutes by
adjusting parameter P as described in § 10.3.
•I you experience any problems please re er to the installation and
commissioning guidelines within the boiler instruction manual. I necessary,
please contact Intergas Heating Ltd (See § 1.8).
Re e ber it is a require ent to co plete the Bench ark code of practice
logbook before leaving the installation. You are also required to register the boiler
through the Gas Safe registration sche e.

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4. MAIN COMPONENTS
A
CH pump
M
Flue discharge
B
Gas valve
N
Connecting block / terminal list X
C
Burner controller with operating panel
O
Condensate
discharge
D
Supply sensor S1
P
Hot water sensor S3
E
Return sensor S2
Q
Siphon cup
F
Fan
R
Heat exchanger
G
Flow switch
S
Operating panel and display
H
Pressure gauge
T
Ionisation/ignition probe
I
1m connecting cable 230 V ~
U
Position type plate
J
Manual air vent
V
Expansion vessel (shown in broken lines)
K
Sight glass and mirror
W
Pressure relie sa ety valve, 3 bar
L
Air supply

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4.1 Accessories
Descri tion
Concentric adapter 60/100 086807
Rear mounting rame or top pipe connection 092757
Pipework cover 092527
Conversion set to Propane (G31) 076077

Intergas Heating Ltd 15
5. INSTALLATION
5.1 Overall dimensions
A liance + mounting late
A = Flow CH Ø22 (male)
B = Return CH Ø22 (male)
C = Gas G ½”
D = DHW cold Ø15 (male)
E = DHW Ø15 (male)
F = Condensate Condensate hose ø25 lex
h = 640mm Rapid 25
700mm Rapid 32
H = 750mm Rapid 25
810mm Rapid 32
Z = Flue gas outlet Ø80 (seal)
Y = Air supply inlet Ø80 (seal)
A liance + wall mounting frame + to
connection
A = Flow CH Ø22 (male)
B = Return CH Ø22 (male)
C = Gas G ½”
D = DHW cold Ø15 (male)
E = DHW Ø15 (male)
F = Condensate Condensate hose ø25 lex
H = 940mm Rapid 25
1000mm Rapid 32
Z = Flue gas outlet Ø80 (seal)
Y = Air supply inlet Ø80 (seal)
AB
C D
E
(Top connection)
AB
C D
E

Intergas Heating Ltd 16
5.2 Boiler location
The appliance can be itted to a mounting rame. The assembly or just the
appliance should be mounted to a wall with su icient bearing strength. In
case o light wall constructions, resonance sounds may occur.
There must be an earthed electrical supply within a distance o 1 m rom
the appliance.
In order to avoid reezing o the condensate discharge, the appliance
should be installed in a rost- ree room.
Keep 5 cm ree space above the appliance in order to be able to remove
the ront panel rom the casing.
5.2.1 Installation in a kitchen cu board
Make sure there is su icient ventilation above and below the appliance.
When the appliance is placed in a small cupboard, ventilation openings o
at least 50 cm
2
must be made.
5.2.2 Installation in an airing cu board
Compartment ventilation is not required or a standard airing cupboard (eg
0.6 x 0.6 x 2.3m high).
5.2.3 Remove front anel
Remove the optional pipework cover and the ront panel or carrying out
work on the appliance as ollows:-
1. Remove the pipework cover (A), i used, orwards.
2. Unscrew both screws (B) at the bottom o the appliance.
3. Li t the ront panel (C) and remove it orwards.

Intergas Heating Ltd 17
5.3 Assembly
Depending on the connection situation, to mount the appliance use is made o a
suspension strip or a top connection rame.
A connection set with shut o valves and a gas valve is included in the boiler.
5.3.1 Fitting the mounting stri
1. Fasten the mounting strip horizontally to the wall.
2. Make sure the strip is levelled correctly.
5.3.2 Fitting the rear mounting frame
1. Fasten the rame vertically to the wall, using the screws and plugs supplied.
2. Make sure the rame is levelled correctly.
Caution
The appliance is wider than the fra e.

Intergas Heating Ltd 18
5.4 Mount the a liance
1. Unpack the appliance.
2. Check the content o the packaging. This consists o :-
•Appliance (A)
•Mounting strip (B)
•Siphon cup (C)
•Flexible hose (D)
•Installation instructions
•Guarantee card
3. Check the appliance or any damage: report damage to the supplier
immediately.
1. Check when using a connection kit whether the compression rings are
straight in the connectors.
2. Place the appliance: slide it top-down over the mounting strip.
3. The lexible tube rom the condensate siphon should be inserted into an
open waste pipe o not less than 32 mm diameter. I connected to a soil
pipe or waste system, the waste pipe must include a trap (similar to
arrangement or washing machine).
4. Tighten the compression ittings.
5. Mount the air supply and the lue discharge.
6. Mount the siphon cup (C) to the siphon connection at the bottom side o
the boiler.Make sure the O-ring is placed correctly in the cup.
7. When needed the condensate outlet (behind the cup) can be extended
using the lexible hose that has been delivered together with the boiler.
8. Fill the internal siphon by removing the hose coming rom the PRV.
Make sure the hose is placed again a terwards.

Intergas Heating Ltd 19
6. CONNECTIONS
6.1 Connect the CH system
1. Flush the CH system thoroughly.
2. Mount the low and return pipes to the mounting bracket.
All pipes must be mounted tension- ree in order to avoid ticking o the
pipes.
Existing connections must not be twisted in order to avoid leaks at the
connections with the external pipes.
The CH system should be rovided with:-
•A illing/draining tap (A) in the return pipe immediately below the
appliance.
•A drain tap at the lowest point(s) o the installation.
•A 3 bar pressure relie valve (B) in the supply pipe at a maximum
distance o 500 mm rom the appliance.
There must be no valve or constriction between the appliance and the
over low valve.
•An expansion vessel in the return pipe.
•A check valve, i pipes run upwards at a short distance rom the
appliance. This avoids the occurrence o thermosiphon e ect during
DHW operation mode.
6.1.1 Ex ansion vessel
The appliance is itted with a expansion vessel adequate or a system with a
water volume not exceeding 100 litres, typically 8 radiators. For larger volume
systems, an additional expansion vessel must be itted. Contact Intergas or
advice in these cases.
6.1.2 Thermostatic radiator valves
I all radiators are equipped with thermostatic or regular radiator valves, a
bypass must be itted in order to guarantee minimum water circulation. The
bypass must be at a distance o at least 6 m rom the appliance in order to
prevent overheating o the appliance.
6.1.3 Underfloor heating
For a good operation o the domestic hot water supply, there must be no
undesired circulation through the appliance caused by a second pump o the
CH circuit.
Connect under loor heating with an electric shut-o valve (two-way valve) to
prevent circulation through the appliance when there is no demand or central
heating.
A. Boiler
B. Pump
C. Thermostatic control valve
D. Spring-operated non-return valve
E. Electrical shut-o valve 230 V ~
F. Radiators
G. Room/clock thermostat
H. Maximum thermostat

Intergas Heating Ltd 20
6.1.4 A liance with zone control.
I there is, next to the CH system an other heating source (as or example a stove
or a ireplace) in the living room o ten the problem occurs that the other rooms cool
down.
This can be solved by splitting up the CH system into two separate zones.
The zone regulation can only be used when there is no external DHW tank present
(in case o a system boiler)
Schedule zone-regulation
1. A. Appliance
B. Electrical Shut-o valve 230 V ~
C. Radiators
2. T1. Room thermostat zone 1
T2. Room thermostat zone 2
Z1. Zone 1
Z2. Zone 2
O erating rinci le
The zone regulation contains 2 room thermostats and a shut o valve. When the
room thermostat o zone 2 generates a heat demand, the shut o valve opens and
the complete CH system heats up (zone 1 and 2). When the heat demand o zone
2 is not or no longer present, room thermostat 1 controls the room temperature in
zone 1.
Installation
1. Place the shut-o valve into the heating system according to the schedule.
2. Connect the room thermostat o zone 1 on to connector X4 – 6/7.
3. Connect the room thermostat o zone 1 on to connector X4 – 11/12.
4. Modi y parameter A in the parameter list. (See § 8.3)
Note : The roo ther ostat for zone 1 ust be an on/off type. The roo ther ostat
for zone 2 can be either on/off or “Open Ther ”.