Intergas Xclusive 24 User manual

INSTALLATION MANUAL
High Eiciency Wall-Mounted Gas Boiler
Read this installation manual thoroughly before the installation and use of the
boiler. Follow all indicated instructions. This installation manual must remain
with the boiler.
Xclusive 24
Xclusive 30
Xclusive 36
G.C. 47-291-13
G.C. 47-291-14
G.C. 47-291-15
Smart Opentherm™

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
3.2 Operation ....................................................................................................................9
3.3 Data plate ....................................................................................................................9
3.4 Control panel ................................................................................................................10
3.5 Operational modes...........................................................................................................10
4 Main components 11
4.1 Standard scope of delivery....................................................................................................12
4.2 Accessories ..................................................................................................................13
5 Installer important points 14
6 Installation 15
6.1 Overall dimensions of boiler including the wall bracket .........................................................................15
6.1.1 Mounting the wall bracket ....................................................................................................15
6.2 Installation location ..........................................................................................................16
6.2.1 Installation within a kitchen area or wall cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
6.2.2 Removing/installing the front panel ...........................................................................................17
6.3 Installing the boiler...........................................................................................................18
7 Connection 19
7.1 Connecting to the central heating system circuit ...............................................................................19
7.1.1 Expansion vessel .............................................................................................................19
7.1.2 Thermostatic radiator valves..................................................................................................20
7.1.3 Underfloor heating ...........................................................................................................20
7.1.4 X-Plan zone Hydraulic diagram................................................................................................22
7.1.5 X-Plan wiring diagram (Unvented cylinder option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
7.1.6 S-Plan zone hydraulic diagram ................................................................................................24
7.1.7 S-Plan wiring diagram ........................................................................................................25
7.1.8 S-Plan wiring diagram (With outside weather compensation kit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
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 90 , and complete all sections, as required by law, relevant to
the appliance and installation. Failure to install and commission according to the manufacturer’s instructions and complete the
Benchmark Commissioning Checklist will invalidate the warranty for the Gas Boiler installation. The details within the Checklist will
be required in the event of any warranty work. On completion the Checklist must be le with the end user. The relevant sections of
the Service Record, pages 91 & 92, must be completed on each subsequent Service visit.
Installers are required to carry out installation, commissioning and servicing work in accordance with the Benchmark Code of
Practice which is available from the Heating and Hotwater Industry Council who manage and promote the scheme. Visit www.
centralheating.co.uk for more information.

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7.1.9 Y-Plan zone hydraulic diagram ................................................................................................27
7.1.10 Y-Plan wiring diagram ........................................................................................................28
7.2 Connection of domestic hot water ............................................................................................29
7.2.1 DHW circuit resistance graph..................................................................................................29
7.2.2 Boiler with heat pump boiler..................................................................................................30
7.2.3 Boiler with Pre-Heated Solar Boiler) ...........................................................................................31
7.3 Electrical connection .........................................................................................................32
7.4 Gas connection ..............................................................................................................32
7.5 Connecting room thermostat .................................................................................................33
7.5.1 Connecting Modulating OpenTherm thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7.5.2 Connecting on/o volt free TPI room thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
7.5.3 Connecting 230V room thermostat ............................................................................................33
7.5.4 Connecting outdoor sensor ...................................................................................................34
7.5.5 Frost protection..............................................................................................................34
7.5.6 Connecting boiler sensor/thermostat..........................................................................................35
7.5.7 PC interface .................................................................................................................35
7.5.8 Comfort Touch...............................................................................................................35
7.6 Flue and air supply duct ......................................................................................................36
7.6.1 Flue, materials and compounds...............................................................................................36
7.7 Pipeline lengths..............................................................................................................37
7.7.1 Replacement lengths .........................................................................................................37
7.7.2 Example calculation..........................................................................................................37
7.8 General layout of the flue .....................................................................................................38
7.8.1 Horizontal wall terminal 60/100mm C13 .......................................................................................39
7.8.2 Flue terminal positions 60/100mm C13 ........................................................................................40
7.8.3 PMK terminal positions 60mm ................................................................................................41
7.8.2 Vertical roof terminal for twin-pipe 80mm flue system C33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
7.8.3 Vertical roof terminal and air supply duct from the facade C53 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
7.8.4 Clamping the flue system (twin and concentric) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
7.8.7 Twin flue terminal positions ..................................................................................................46
8 Operation 47
8.1 Using the control panel.......................................................................................................47
8.2 Boiler preparation............................................................................................................47
8.2.1 Filling and venting the central heating system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
8.2.2 Domestic hot water facility....................................................................................................48
8.2.3 Gas supply...................................................................................................................48
8.3 Commissioning procedure....................................................................................................49
8.4 Clock function ...............................................................................................................50
8.5 Shutting down the boiler .....................................................................................................51
9 Settings and adjustments 52
9.1 Navigate the settings .........................................................................................................52
9.1.1 Main menu ..................................................................................................................52
9.1.2 Domestic hot water menu ....................................................................................................53
9.1.3 Central heating menu ........................................................................................................54
9.1.4 RF menu.....................................................................................................................54
9.1.5 Service menu ................................................................................................................56
9.1.6 Info menu ...................................................................................................................58
9.2 Setting and adjusting the clock functions ......................................................................................59
9.2.1 Programming the CH on / o times............................................................................................59
9.2.2 Programming the DHW pre-heat on / o times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
9.3 Parameters ..................................................................................................................62
9.4 Switching DHW comfort function on and o. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
9.5 Adjusting the maximum central heating output ................................................................................63
9.6 Adjusting pump capacity .....................................................................................................63
9.7 Outside weather compensation ...............................................................................................64
9.8 Conversion to another gas type ...............................................................................................65
9.9 Gas/air control ...............................................................................................................66
9.10 Inspection of the gas air control valve .........................................................................................67
9.10.1 Measuring the flue gas at maximum output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
9.10.2 Measuring the flue gas at minimum output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
9.10.3 Minimum output correction...................................................................................................70
10 Faults 71
10.1 Fault codes ..................................................................................................................71
10.2 Other faults ..................................................................................................................73
10.2.1 No heat (central heating) .....................................................................................................73
10.2.2 Central heating does not reach the correct temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
10.2.3 Central heating system remains too warm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
10.2.4 No domestic hot water (DHW).................................................................................................74

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10.2.5 Domestic hot tap water does not reach the correct temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
10.2.6 Burner ignites loudly .........................................................................................................74
10.2.7 Burner resonates.............................................................................................................75
10.3 Notifications .................................................................................................................75
11 Maintenance 76
11.1 Annual service procedure.....................................................................................................76
11.2 Annual service continued (syphon maintenance). ..............................................................................76
11.3 Annual service continued (internal maintenance) ..............................................................................78
11.3.1 Annual service continued (cleaning) ...........................................................................................78
11.4 Annual service (re-assemble)..................................................................................................79
11.5 Annual service checklist ......................................................................................................80
12 Technical specifications 81
12.1 Electrical schematic ..........................................................................................................82
12.2 Product Fiche according to CELEX-32013R0811, Appendix IV ....................................................................84
12.3 NTC resistances ..............................................................................................................84
13 Spares short list 85
15 Benchmark Commissioning & Warranty Validation Service record 87
To be completed at each annual service, not subsequent.

5
1 PREFACE
1.1 Regulation
1.2 Warnings
1.3 Manual handling
Intergas accepts no responsibility for the unsatisfactory performance of the appliance
or flue arising from the failure to comply with this installation manual. Incorrect
installation could invalidate your guarantee and may lead to prosecution.
The appliance cannot be removed from the original place of installation and transferred
to another site or re-sold without prior consent from Intergas. You must re-register the
appliance with Intergas in order to maintain any remaining warranty.
The boiler must be installed by a competent Gas Safe registered
engineer and in accordance with these instructions, It is the installers responsibility to
ensure that the installation conforms to the current legislation and Standard Codes of
Practice.
Please read these instructions carefully before installing or using the
appliance.
The Intergas combination boiler meets the requirements of Statutory Instrument ‘The
Boiler (Eiciency) Regulations’ and is deemed to meet the requirements of:
►Low Voltage Directive (2014/35/EU)
►Gas Appliances Regulation (EU) 2016/426
►Boiler Eiciency Directive (92/42/EEC)
►EMC Directive (2014/30/EU)
►RED Directive (2014/53/EU)
►Ecodesign (2009/125/EC)
►Energy labelling Regulation (EU) 2017/1369
Intergas declares that the materials used in the manufacturing of this appliance are
non hazardous and that no substances harmful to health are contained within the
appliance.
The manufacturer Intergas Heating Ltd accepts no liability whatsoever for damage or
injury caused by failure to adhere (strictly) to the safety regulations and instructions,
or carelessness during installation of the Intergas wall mounted gas fired boiler and
any associated accessories
Intergas Heating Ltd are continuously developing ways to guarantee the quality of its
products and to improve them where necessary. In so doing we (Intergas Heating Ltd.)
reserve the right to modify at any time the features named within this document.
Read and observe all safety instructions within this instruction manual to prevent
unsafe situations, fire, explosion, damage to property or personal injury.
When moving the boiler always keep your back straight, bend your knees, don’t twist,
move your feet. Avoid bending forwards or sideways and keep the load as close to
your body as possible. Where possible transport the boiler using a suitable trolley, sack
truck or get some assistance. Grip the boiler firmly and before liing establish where
the weight is concentrated to determine the centre of gravity, repositioning yourself if
necessary.

6
1.6 Abbreviations
►DHW: Domestic hot water
►CH: Central heating
►CW: Comfort domestic hot water
►HE: High eiciency
►PHS: Pre Heated Solar water.
►LT: Low temperature (zone).
►HT: High temperature (zone)
►OT: OpenTherm
►RF: Radio frequency
►PC: Personal computer
►NTC: Sensor (Negative temperature coeicient)
►PP: Polypropylene
►CAC: Combination air supply duct and combustible
gas flue system (concentric chimney system)
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 aect the
operation of the boiler.
The following pictograms are used within 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
handle with care do not to drop.
MAX 3 MAX 2
INSTRUCTION (FRAGILE)
This is a fragile piece of equipment: Please
provide dry storage for the appliance.
INSTRUCTION (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 (From a location away from
the gas leak).
L.P.G. boilers: Call the supplier’s number on
the side of the gas tank or cylinder.
It is law that all gas appliances are installed and serviced by a Gas Safe registered
competent engineer, if in any doubt please check with Gas Safe (0800 408 5500)
and in accordance with the following recommendations:
►Current Gas Safety (Installation and Use) Regulations
►All current building regulations
►Building Standards (Scotland) Consolidated
►I.S.813 Installation of Gas Appliances (Ireland)
►IET Wiring Regulations (BS 7671)
►Health and Safety Document (Electricity at Work Regulations)
►UK Water fittings Regulations and Byelaws
►Health & Safety Regulations
2.1 General
2.2 The installation
The installation must comply with the following British Standards codes of practice:
►BS 5440: Flueing and Ventilation for gas appliances of rated input not exceeding 70kW (Part 1 Flues)
►BS 5440: Flueing and Ventilation for gas appliances of rated input not exceeding 70kW (Part 2 Air Supply)
►BS 5546: 2010 Specification for installation and maintenance of gas-fired water-heating appliances of a
rated input not exceeding 70Kw net.
►BS EN 12828:2012+A1:2014 Heating systems in buildings. Design for water-based heating systems
►BS EN 806-1:2000 Specifications for installations inside buildings conveying water for human consumption.
General (802-2 Design, 806-3 Pipe sizing, 806-4 Installation, 806-5 Operation and maintenance).
►BS 6798: 2014 Specification for selection, installation, inspection, commissioning, servicing and
maintenance of gas-fired boilers of rated input not exceeding 70kW net
►BS 6891: 2015+A1:2019 Specification for the Installation and maintenance of low pressure gas installation
pipework of up to 35mm (R1 1/4) on premises
►BS 7593: 2019 Code of practice for the preparation, commissioning and maintenance of domestic central
heating and cooling water in systems
►BS 7671: 2018 Requirements for electrical installations, IET Wiring regulations
►BS 5955-8:2001 Plastic pipework (thermoplastics materials). Specification for the installation of
thermoplastic pipes and associated fittings for use in domestic hot and cold services and heating systems
in buildings.
Reference should also be made to:
►Guide to condensing boiler installation assessment procedures for dwellings (SBSA)
►The institute of Gas Engineers document & managers IGE/UP/7 Gas installations in timber frame and light
steel framed buildings.
2 SAFETY REGULATIONS
Safety precautions If you smell gas
Depending on the year of construction, an Intergas HR boiler may contain part(s)
in which ceramic fibers are used. Always use the recommended personal
protective equipment when working with ceramic fibers.

8
3 GENERAL BOILER INFORMATION
The Intergas Xclusive wall-mounted gas boiler is a room sealed unit. The
boiler is intended solely to provide heat for the water in a central heating
system and domestic hot water installation and is for domestic use only.
The Intergas Xclusive meets the European directives and additional national
regulations that are indicated by CE marking. The associated conformity
declaration can be requested from Intergas Heating Ltd (also see §14)
The Intergas Xclusive meets the electrical protection class IPX4D.
3.1 General
3.1.1 ErP label
3.1.2 Gas category
Gas category Gas type Gas inlet pressure
(mbar)
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 on the European ErP Directive (Energy related Products) all newly
produced gas fired boilers have to meet minimum standards regarding
energy performance.
The Intergas Xclusive carries an European energy label containing specific
information regarding energy eiciency class (CH and DHW), noise level
and maximum power.
The Intergas Xclusive carries label A for both CH and DHW.
In addition the Intergas Xclusive meets the following DHW capacity profile:
►Xclusive 24 : L
►Xclusive 30 : XL
►Xclusive 36 : XL
The extensive product fiche can be found in §12.2.
A+
A
B
C
D
E
F
2019 811/2013
dB
kW
A+++
A++
A+
A
B
C
D
A
A
Intergas Heang Ltd Xclusive --
XL
--
--

9
3.3 Data plate
3.2 Operation
The Intergas Xclusive is a modulating high eiciency boiler. This means
that the output is adjusted according to the desired heating capacity.
Two separate copper circuits are infused within the aluminium
Bithermic heat exchanger.
The boiler has a printed circuit board with microprocessor control, this
allows constant calculations to take place during any demand for either
heating or hot water, these calculations are based on many factors and
measuring points within the boiler.
The microprocessor manages and takes control of the modulating
output, ensuring optimum eiciency is maintained at all times during
production.
****** -yymm****** Production code - Serial number
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
G31-37 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
Identification of the product
You will find the unit details on the data plate on the bottom
of the boiler. The data plate contains, important information
and the boiler specification (boiler type and model name), and
the serial number:

10
The boiler has a number of operational modes:
The boiler is switched o.
The boiler is switched o but is connected to the mains power.
In this mode, the display view is characterised by:
►Displaying the power LED [ ].
►Displays the pressure within the central heating system on
le hand side [ ].
►Displaying a line on the right display [ ].
The boiler is switched on and is ready for a heat demand.
The boiler is switched on and is ready to answer a request for
either domestic hot water or hot central heating water.
In this mode, the display view is characterised by:
►Displaying the power LED [ ]. All other symbols and values
are not displayed.
3.4 Control panel
The boiler has a fully integrated touch screen control panel
that also displays information about the operational status,
temperature settings, demand symbols and fault codes.
The display has multiple functions and options please refer to
section §9 for further detail.
3.5 Operational modes
Boiler is switched o
(mains voltage is present)
Boiler is switched on
(ready for heat demand)
The boiler is operating and producing domestic hot
water.
The boiler is operating and supplying domestic hot water to a
tap or shower etc. The display view is characterised by:
►Displaying the power LED [ ].
►Displaying the flame i.e. burner is switched on [ ].
►Displaying the tap symbol [ ].
The boiler is operating and producing central heating
water.
The boiler is operating and supplying central heating water.
The display view is characterised by:
►Displaying the power LED [ ].
►Displaying the flame i.e. burner is switched on [ ].
►Displaying the radiator symbol [ ].
Boiler is in operation (domestic hot water)
Boiler is in operation (central heating water)
COMMENT
►The touch screen is very sensitive only
use a finger tip and not any sharp objects.

11
4 MAIN COMPONENTS
Flue appliance adapter
Air supply duct
(for 80mm twin flue only) Ignition electrode
Ignition module
vNTC Flue gas sensor (S5)
Fan assembly
24V DC Gas valve
Heating Modulating 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 Pressure relief valve
NTC Central heating
flow sensor (S1)
Central heating
low pressure sensor
Mains lead 230 V
AC (bare)
NTC Heat exchanger
sensor (S0)
Air supply duct
(for 80mm twin flue only)

12
4.1 Standard scope of delivery
Boiler Wall bracket & fixings Flexible condensate hose
GarantiebewijsIntergas HR-ketel
GarantiebewijsIntergas HR-ketel GarantiebewijsIntergas HR-ketel
Datuminstallatie:
Volgensgeldende voorschriften
geïnstalleerddoor:
Naaminstallateur:
Adres:
Postcode:
Woonplaats:
Naamkoper:
Adres:
Postcode:
Woonplaats:
Hetgarantiebewijs is slechts geldig, indien de aan het garantiebewijs gehechte
antwoordkaartbinnen 8 dagen na de installatie wordt ingezonden. Deze kaart
moetvolledig en duidelijk worden ingevuld en voorzien zijn van de handtekening
vankoper en installateur. Door ondertekening van deze kaart verklaart koper
zichakkoord met de staat van de ketel bij aflevering.
Hetgarantiebewijs is slechts geldig, indien de aan het garantiebewijs gehechte
antwoordkaartbinnen 8 dagen na de installatie wordt ingezonden. Deze kaart
moetvolledig en duidelijk worden ingevuld en voorzien zijn van de handtekening
vankoper en installateur. Door ondertekening van deze kaart verklaart koper
zichakkoord met de staat van de ketel bij aflevering.
Voorde ‘Garantiebepalingen
IntergasHR-ketels’ verwijzen
wiju naar onze website:
www.intergasverwarming.nl
ofnaar het bij uw HR-ketel
bijgevoegdeinstallatievoorschrift.
Opuw verzoek sturen wij u
graageen exemplaar toe.
Datuminstallatie:
Naamkoper:
Adres:
Postcode:
Woonplaats:
Installateur
>>Betrouwbaarin warmte >>Betrouwbaarin warmte >>Betrouwbaar in warmte
Type/Serienr.
IntergasVerwarming BV
Antwoordnummer5
7740VB COEVORDEN
Datuminstallatie:
Naamkoper:
Adres:
Postcode:
Woonplaats:
Type/Serienr.Type/Serienr.
Postzegel
nietnodig
voor klant voor fabrikant
12345678910
12345678910
123456 78910
voor installateur
Installation and operation
instruction Guarantee card Connection set
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 (For
use with weather
compensation)
Item no 081285
Elbow 60° (2 per box) (for
plume management kit)
Item no 081286
Extension L=1000mm inc.
wall bracket (for plume
management kit)
Item no 084661
Bend 45°
Item no 084660
Bend 90°
Item no 081295
Plume terminal bend
Item no 087910
60/100 flue weather slate
(pitched roof)
Item no 087372
60/100 flue weather slate
(flat roof)
Item no 082975
60/100 extension
L=1000mm
inc. wall bracket
Item no 081298
Horizontal telescopic oset
wall terminal1
Item no 082980
Horizontal non telescopic
straight wall terminal1
Item no 081297
Horizontal telescopic wall
terminal1
Item no 0821973
Vertical roof terminal
(inc. boiler adapter
60/100)
Item no 081294
Plume management kit
(inc. 2x wall brackets)
Item no 081284
Elbow 90° (for plume
management kit)
4.2 Accessories
Original Intergas accessories can be ordered separately at your local stockist.
Instructions about the correct way to assemble and use these accessories are provided
with the product ordered and are therefore not included within this installation manual.
1 Only to be used in combination with the base adapter on the boiler

14
5 INSTALLER IMPORTANT POINTS
Please read all instructions before fitting this appliance
►The installer must instruct the user on the operation of the boiler, fault code diagnosis and how to reset
the boiler, location of the filling loop and how to re-pressurise the system if the water pressure drops to
below 0.5 bar.
►The installer must hand over these installation and user instructions ensuring the Benchmark
Commissioning Checklist has been completed correctly.
►The attending engineer must complete the service record on the Benchmark Checklist aer each
service and/or replacing any parts within the boiler.
►It is required under Gas Safe Regulations for the installation to be notified and to register the
installation with Gas Safe, and Building Control (Gas Safe Notification).
►You must register the boiler with Intergas heating ltd within 30 days of the installation to validate any
warranty supplied with the boiler, via post, website or MiReg if you are the installer.
►When commissioning the boiler, check the gas inlet working pressure is 20mbar (NG) or 37mbar for
(LPG) on P1 of the boiler gas valve. (Min 17mB (NG) 30mB (LPG) with all connected appliances operating
at full rate).
►Combustion analysis with a correctly calibrated and certificated electronic analyser is essential for safe
commissioning of the boiler, this must be documented within the Benchmark commissioning checklist.
►A pressure reducing valve set to 3.5 bar must be fitted if the mains water supply pressure is above 5 bar,
this should be located no closer than 3 metres proximity to the boiler for expansion purposes.
►In areas where the water hardness is 200ppm or above, appropriate protection must be taken in
accordance with BS 7593 & in line with building regulations Part L. (See Warranty Provisions on page 88,
point 15).
Intergas recommend Hydroflow HS38a wired into the boiler or HS38b which can be powered
separately.
►The end user / home owner should be advised to keep this installation manual in a safe place,
preferably near the appliance for servicing and future reference, it is a legal requirement that any
attending engineer can check the validity of the Benchmark commissioning checklist (Benchmark
certificate).
►It is important to protect the boiler during the installation. In particular, do not allow any dust or debris
to enter the flue connection at the top of the appliance.
►Before operating the boiler please ensure that the copper pipework you are installing is connected
to the appropriate tappings on the boiler. (Plastic pipework where appropriate must be a minimum
distance of 1000mm away from the boiler connections as per BS 5955-2008).
►It is important to chemically treat and thoroughly flush the heating circuits, prior to commissioning
the boiler, in order to remove any residue fluxes and debris from within them, (please isolate the
appliance). The system flush must be carried out to BS 7593:2019 and an appropriate inhibitor added
to the correct dosage, dependant on the system capacity, as indicated on the product used.
►Intergas recommend water treatment in accordance with the Benchmark Guidance on Water Treatment
in Central Heating Systems, we recommend the use of FERNOX, SENTINEL or ADEY inhibitors. It is most
important that correct concentration of water treatment is maintained for the life of the boiler, a water
sample is required upon installation and to be verified by the aforementioned manufacturers should
we attend a warranty call a water sample may be required to keep the warranty valid. (BS 7593:2019)
►As per BS 7593:2019 Intergas recommend the fitting of an approved magnetic type filter to the
heating return pipe under the boiler (Intergas Nickel plated brass system filter recommended).
►This boiler has been factory set but adjustment may be required to the heating output in order to
match the individual heating demand. This can be done by changing parameter P010 (= max. power
CH) or parameter P070 (= max. power domestic water). See §9.1.5 "To modify a parameter".
►Please do not use the pressure relief valve as a means of flushing, draining the boiler or system.
►Aer domestic hot water production a preset time delay will occur this is designed to prevent the boiler
from cycling thus enhancing the overall eiciency further.
Note: an anti-cycle delay time can be set up to a maximum of 15 minutes by adjusting parameter P036
as described in §8.3.
►When required an external expansion vessels should be inverted with the water side facing downwards
and connected to the heating return (not the flow side) this will allow correct draining of system and
help prolong the life of the vessel diaphragm. (precharge air pressure should be set as per the internal
vessel of the boiler i.e. 0.75bar +/- 0.2bar).
►If you experience any problems please refer to the installation and commissioning guidelines within the
boiler instruction manual. (If necessary, please contact Intergas Heating Ltd).

15
450
277
120 120
6565120 6565 70
275
148
98h
H
=320=
50
65
95
100
160
246
6 INSTALLATION
AECDB
F
AB
DE
F
Z
C
6.1 Overall dimensions of boiler including the wall bracket
6.1.1 Mounting the wall bracket
Due to the size and weight of the appliance it is not
recommended to install the boiler on a stud wall as this may
also cause noise issues.
Refer to the installation dimensions and 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
Connections
ACentral heating
flow
22mm with isolation
valve fitted
BCentral heating
return
22mm with isolation
valve fitted
CGas flow 22mm with isolation
valve fitted
DDomestic cold
water - Inlet
15mm with isolation
valve fitted
EDomestic hot
water - Outlet
15mm with isolation
valve fitted
FCondense
syphon outlet Ødn25
Z
Flue / Chimney
appliance
connection
Ø60/100
(concentric, wall
terminal )

16
6.2.1 Installation within a kitchen area or wall cabinet
The boiler can be installed between two kitchen wall units or
inside a cabinet that is of suicient size.
There must be suicient ventilation above and below the
boiler for cooling purposes (as per the adjacent diagram). Any
decor panels or grills used to aid ventilation must be removable
for servicing and maintenance purposes.
The boiler must be installed on a solid brick wall that has
suicient strength to be able to withstand the weight of the
boiler when filled with water (see Technical data).
The appliance must be connected to a 3 amp fused spur within
one (1) meter of the boiler. The condense discharge from the
boiler must be connected to an internal drain or waste system
where possible to prevent freezing during any adverse weather
conditions.
Any unheated area's i.e. a lo space or garage must be treated
as external and therefore adequate frost protection measures
must be taken for the boiler and any pipework etc. (see §6.3)
Make sure the boiler is easily accessible by ensuring that the
adjacent clearances are adhered to.
6.2 Installation location
min. 200
H
min. 250
min. 50
277
450
min. 10
*D
Further dimensions
*D = 600 mm Xclusive 24,30,36
* 5mm clearance from a closing door
600mm for servicing clearnances
H = 766 mm Xclusive 24
766 mm Xclusive 30
826 mm Xclusive 36
Minimum dimension 50cm2
Minimum dimension 50cm2
CAREFUL
►The appliance must not be installed
above any heat source as this will
invalidate any warranty supplied with
the boiler.

17
6.2.2 Removing/installing the front panel
►The front cover of the boiler must be removed to perform
various maintenance activities however you must be a
competent Gas Safe registered engineer before carrying out
the following procedure!
►Loosen both screws (1) under the boiler by using a 5 mm
allen key. (They are captive and therefore will not drop out
of the lower housing).
►Slide the front cover (2) upward and then remove it by
pulling it towards you.
1
2
Replacing the room sealed front cover.
To replace the front panel, proceed as follows:
►Position the front panel (3) against the boiler and slide
it downwards until it is correctly connected to the
lower fascia panel.
►Hand tighten screws under the boiler using a 5 mm
allen key (do not over tighten).
3
COMMENT
►The front cover has a rubber seal around
the inner edge sometimes making it
very sti to slide o so please ensure the
boiler is secured to the wall correctly
before attempting this procedure!
CAREFUL
►This is a room sealed cover and therefore
extremely important that it is fitted
correctly, failure to do so could lead to
products of combustion entering the
room / environment where it is situated.

18
6.3 Installing the boiler
COMMENT
►The Intergas Xclusivehas a boiler-
specific siphon cup. Ensure that
the correct version is ordered upon
replacement. (Item no 510054)
1. Mount the wall bracket (ensure its level)
4. Fill the condense syphon cup 5. Replace the condense syphon cup
and attach the supplied flexible hose
6. Connect the flexible hose to the waste
system via a tundish or similar.
2. Hang the boiler onto the wall bracket 3. Twist and pull to remove the condense
syphon cup
Open connection
to waste system
1. Attach the wall bracket.
2. Li the boiler (2 person li) and slide it down onto the wall bracket.
3. Remove the syphon cup.
4. You must fill the syphon cup just over half full with water.
5. Replace the cup and install the supplied black flexible hose onto boiler
outlet union.
6. Connect the flexible hose to a 22 mm O.D solvent weld pipe. To minimize
the risk of freezing the condensate pipe should be connected internally
and terminate to an internal soil stack, (ref.: TB115 Gas Safe & HHIC).
7. Install the flue system (see §7.6).
8. Install the required pipework as per the following sections.
9. Should the condensate be terminated to an external soil pipe, drain,
rainwater system or soakaway we only recommend the Condensate PRO
system which is available from our normal stockists or heating supplies.
https://condensatepro.co.uk

19
7.1.1 Expansion vessel
7 CONNECTION
7.1 Connecting to the central heating system circuit
►Flush the central heating system thoroughly as per
BS7593:2019.
►Fit the flow and return pipes to the isolation valves using the
supplied 3/4" fibre washers, noting that the filling link valve
attaches to the return side as per the adjacent drawing.
►The pipework must be correctly supported with full wrap
over type clips / brackets.
►Do not over tighten the connections onto the boiler as
this can cause stress damage and possible internal boiler
leakage.
The CH system should include the following:
►As per BS 7593:2019 a magnetic type filter such as the
Intergas system filter, should be fitted onto the return
pipework as shown in the adjacent diagram.
►When installing the Intergas system filter, the supplied
spigot valve should be fitted to the bottom union to enable
combined isolation with the boiler return valve.
►The drain / dosing valve at the bottom of the filter housing
facilitates the easy draining of the appliance, with the spigot
valve and heating flow valve both closed at the same time.
►A drain tap at the lowest point(s) of the installation.
►A full bore spring loaded single check valve, in the
return pipework nextto the boiler whenever the pipework
rises above the appliance. This prevents the occurrence
of thermosyphoning (radiators getting warm) during DHW
production.
Preformed return pipe
Preformed flow pipe
The appliance is fitted with a expansion vessel adequate for a typical
heating system with 8 radiators installed. For larger volume systems,
an additional expansion vessel must be fitted. Refer to the below
table or contact Intergas for further advice in these cases.
SAFETY VALVE
SETTING (bar) 3.0
VESSEL CHARGE
PRESSURE (bar) 0.75 1.0 1.5
INITIAL SYSTEM
PRESSURE (bar) 1.0 1.5 2.0 1.5 2.0 2.0
TOTAL WATER
CONTENT of SYSTEM EXPANSION VESSEL VOLUME (litres)
LITRES
25 3.5 6.5 13.7 4.7 10.3 8.3
50 7.0 12.9 27.5 9.5 20.6 16.5
75 10.5 19.4 41.3 14.2 30.9 24.8
100 14.0 25.9 55.1 19.0 41.2 33.1
125 17.5 32.4 68.9 23.7 51.5 41.3
150 21.0 38.8 82.6 28.5 61.8 49.6
175 24.5 45.3 96.4 33.2 72.1 57.9
200 28.0 51.8 110.2 38.0 82.4 66.2
For syst. volumes other than those
given above, mult. the syst. volume
by the factor across 0.140 0.259 0.551 0.190 0.412 0.33
Intergas system filter.
Drain/Dosing
valve.
Spigot isolation
valve

20
7.1.2 Thermostatic radiator valves
If the radiators have thermostatic radiator valves or valves that
can be closed to isolate the flow completely from the return, a
minimum amount of water circulation (6ltrs/min *) must be
maintained by installing a manual fixed bypass as this will not
interfere with the pump modulation, (* also see §9.5).
7.1.3 Underfloor heating
Underfloor heating with pump
For eective operation of the DHW supply any undesired
circulation through the appliance as a result of a second pump
in the CH circuit must be avoided.
Connect the underfloor heating system in a hydraulically
neutral manner to the appliance, or install the CH circuit with
an normally open zone valve ( I ) to prevent flow through the
appliance heat exchanger when there is no CH demmand.
see §9.5. for minimum permissible water circu lation through
the boiler heat exchanger.
Underfloor heating connection diagram
A. Boiler
B. Under floor circulation pump
C. Thermostatic mixing valve
D. Spring-operated non-return valve
E. Normally closed 230V~ zone valve (Radiators)
E1. Normally closed 230V~ zone valve (Under floor)
F. Radiators (Fitted with TRV's except room stat location)
G. Programmable room thermostat
H. Limit thermostat
I. Normally open 230V~ zone valve (powered via X4 terminal 3)
I01.000.05.0013
A
G
H

F

B
C
D
IE
E1