Intergas XTREME 24 Installation Manual
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Intergas XTREME 24 Installation Manual

High efficiency wall-mounted gas boiler
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XTREME 24
G.C. 47-291-10
XTREME 30
G.C. 47-291-11
XTREME 36
G.C. 47-291-12
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.

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  • Page 1 XTREME 24 G.C. 47-291-10 XTREME 30 G.C. 47-291-11 XTREME 36 G.C. 47-291-12 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...

  • Page 2: Table Of 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.
  • Page 3 Connection of domestic hot water ................... . 22 6.2.1 DHW circuit resistance graph .
  • Page 4 Maintenance 10.1 Disassembly ....................... . . 68 10.2 Cleaning .

  • Page 5: Preface

    ► EMC Directive (2014/30/EC) ► RED Directive (2014/53/EU) ► Ecodesign (2009/125/EG) ► Energy labelling 2010/30/EU Intergas declares that the materials used in the manufacturing of this appliance are nonhazardous and that no substances harmful to health are contained within the appliance. Warnings...

  • Page 6: Pictograms

    Pictograms The following pictograms are used in this installation manual: CAREFUL / IMPORTANT Procedures which, if these are not performed with the required caution, can damage the product, the surrounding or the environment or may result in personal injury. COMMENT Procedures and/or instructions which, if they are not followed, can negatively affect the operation of the boiler.

  • Page 7: Safety Regulations

    SAFETY REGULATIONS Safety precautions If you smell gas A gas leak could potentially cause an explosion. If you smell gas, observe the following rules: ► Prevent flames or sparks: - Do not smoke, use a lighter or strike matches. - Do not operate any electrical switches or unplug any equipment.

  • Page 8: General Boiler Information

    GENERAL BOILER INFORMATION General The Intergas Xtreme wall-mounted gas boiler is a closed unit. The boiler is intended solely to provide heat for the water in a central heating system and domestic hot water installation for household use. The Intergas Xtreme meets the European directives and additional national regulations that are indicated by CE marking.

  • Page 9: Data Plate

    Operation The Intergas Xtreme is a modulating high efficiency boiler. This means that the capacity is adjusted according to the desired heating capacity. Two separate copper circuits are integrated in the aluminium heat exchanger. In addition, the Intergas Xtreme has a second heat exchanger (heat recovery unit).

  • Page 10: Control Panel

    Control panel The boiler has a fully integrated touch screen control panel that displays information about the operational mode of the boiler. Symbols (buttons), numbers, points and/or letters are displayed. The buttons light up so that they can be operated. For extensive control options, see §8.

  • Page 11: Main Components

    MAIN COMPONENTS Air supply duct (not to be removed) Flue adapter Ignition unit Air supply duct Ignition pin (not to be removed) Flue sensor Heat exchanger sensor Heat exchanger Expansion vessel shown in broken lines Gas valve Pressure relief valve Central heating Pump flow sensor...

  • Page 12: Standard Scope Of Delivery

    Also check for any damages to the boiler or accessories and, if present, immediately notify the supplier. Boiler Wall bracket Flexible condensate hose Garantiebewijs Intergas HR-ketel Garantiebewijs Intergas HR-ketel Garantiebewijs Intergas HR-ketel Postzegel niet nodig Type/Serienr.

  • Page 13: Accessories

    Accessories Original Intergas accessories can be ordered separately at the regular wholesaler. Instructions about the correct way to assemble and use these accessories are provided upon order and are therefore not included in this installation manual. Item no 090347 Item no 842177...

  • Page 14: Installer Important Points

    This should be done particularly where boilers are being fitted to existing radiator circuits (please refer to current Standard Codes of Practice). ► Intergas recommend water treatment in accordance with the Benchmark Guidance on Water Treatment in Central Heating Systems, we recommend the use of FERNOX, SENTINEL or ADEY inhibitors.

  • Page 15: Installation

    - hot Condensation Ødn25 drain Ø60/100 Flue pipe / Air (concentric, supply wall terminal ) Overall dimensions 650 mm Xtreme 24 =320= 650 mm Xtreme 30 710 mm Xtreme 36 766 mm Xtreme 24 766 mm Xtreme 30 826 mm Xtreme 36 5.1.1...

  • Page 16: Installation Location

    Installation location The boiler must be installed on a wall that has sufficient strength to be able to bear the boiler filled with water. There must be a Earthed fuse spur available at a maximum distance of one (1) metre from the boiler. The condenstate must be connected from the boiler and drain away to the sewer.

  • Page 17: Removing/Installing The Front Panel

    5.2.2 Removing/installing the front panel ► The front panel of the boiler must be removed to perform various maintenance activities. Do this as follows: ► Unscrew both (lossless) socket screws (1) under the boiler by using a 5 mm socket wrench. ►...

  • Page 18: Installing The Boiler

    (ref.: TB115 Gas Safe & HHIC). 7. Install the air supply duct and the flue (see §6.6). COMMENT ► The Intergas Xtreme has a boiler-specific siphon cup. Ensure that the proper version is ordered upon replacement. (Item no 510054) 1.

  • Page 19: Connection

    The appliance is fitted with a expansion vessel adequate for a system with a water volume not exceeding 100 litres, typically 8 radiators. For larger volume systems, an additional expansion vessel must be fitted. Contact Intergas for advice in these cases. 6.1.2 Thermostatic radiator valves...

  • Page 20: Lt/Ht Zone System

    6.1.4 LT/HT zone system The central heating system can be divided into two groups, each with a different heating temperature, for example a high- temperature zone (HT) with radiators and a low-temperature zone (LT) with underfloor heating system without its own circulation pump.

  • Page 21: Division Of Central Heating System In Groups With Extra Heat Source

    6.1.5 Division of central heating system in groups with extra heat source Operational principle If the room thermostat switches off the boiler because another heat source is heating the room, it is possible that the other rooms will cool down. This can be prevented by dividing the central heating system into two groups.

  • Page 22: Connection Of Domestic Hot Water

    ► The Xtreme 24 is equipped with a flow restrictor with a nominal value of 8l/min. The Xtreme 30 and Xtreme 36 do not have this feature. If desired, this can be ordered from Intergas as an option.

  • Page 23: Boiler With Heat Pump Boiler

    As soon as the exhaust temperature of the heat pump boiler becomes lower than the set temperature of the switch valve, the flow through the Intergas Xtreme will increase. If the flow becomes greater than the domestic hot water threshold of the Intergas Xtreme , the boiler will start domestic hot water...

  • Page 24: Boiler With Pre-Heated Solar Boiler)

    This prevents the boiler operating with each tap request. Influence of water flows: To prevent the flow being influenced by the Intergas Xtreme during the switching of the valve, the domestic hot water ‘out’ pipeline of the combination must run straight (see connection diagram [F]).

  • Page 25: Electrical Connection

    ► When the power mains cord must be replaced, this must be ordered from Intergas. If maintenance activities to the electric circuit must be performed: ► Remove the front panel (see §5.2.2) and pull the burner controller unit forward;...

  • Page 26: Connecting Room Thermostat

    Connecting room thermostat The boiler is suitable for connection to the following room thermostats: ► OpenTherm (OT) thermostat ► On/off thermostat ► RF thermostat; see §8.1.4. 6.5.1 Connecting Modulating OpenTherm thermostat The boiler is standardly provided with an OpenTherm connection. This allows the connection of modulating OpenTherm thermostats without any additional modifications.

  • Page 27: Connecting Outdoor Sensor

    6.5.4 Connecting outdoor sensor The boiler has a connection for an Intergas outdoor sensor. The outdoor sensor must be used in combination with an on/off or OpenTherm room thermostat. In principle, any on/off or OpenTherm room thermostat can be combined with an Intergas outdoor sensor. With an on/ off thermostat, the boiler will adjust the flow temperature according to the set heating line.

  • Page 28: Connecting Boiler Sensor/Thermostat

    PC connection 6.5.8 Comfort Touch It is possible to combine the Xtreme with the Intergas Comfort Touch wireless and Comfort Touch OpenTherm (available as an option). This set consists of a LAN2RF gateway and a connection set. The LAN2RF gateway provides a connection between an...

  • Page 29: Flue And Air Supply Duct

    Flue and air supply duct ► For the installation of the flue and air supply duct material, see the manual included with the materials. Contact the manufacturer of the relevant flue and air supply duct materials for extensive technical information and specific assembly instructions.

  • Page 30: Pipeline Lengths

    Pipeline lengths As the resistance of the flue and air supply duct pipes increases, the capacity of the boiler will decrease. The allowed decrease in capacity is a maximum of 5%. The resistance of the air supply duct and the flue depends on the length and diameter of the piping system and all associated components.

  • Page 31: General Layout Of The Flue

    Inspection to Xtreme  requirement The terminal is located in the façade; the inlet for the air Terminal Intergas supply duct is located in the same pressure area as the terminal. Example: combined façade terminal Other components Gastec QA or Intergas The terminal is located above the roof;...

  • Page 32: Wall Terminal With Twin-Pipe Horizontal Terminal C13

    The individual flue pipe (Ø80) must be constructed of stainless steel or plastic PP T120. ► Intergas twin-pipe horizontal wall terminal (item no 09027). To be extended, in the case of a balcony terminal, with one or two standard pipes (Ø80 mm).

  • Page 33: Façade Combi-Pipe Horizontal Terminal C13

    PP T120. Allowed pipeline length ► Twin-pipe Air supply duct and flue pipe together, excluding the length of the combi-pipe wall terminal. Boiler Length Intergas Xtreme 24 100 m Intergas Xtreme 30 85 m Intergas Xtreme 36 80 m ► Concentric...

  • Page 34: Roof Terminal With Combi-Pipe Vertical Terminal And Twin-Pipe Vertical Terminal C33

    6.8.3 Roof terminal with combi-pipe vertical terminal and twin-pipe vertical terminal C33 IMPORTANT ► If the Intergas combi-pipe vertical terminal cannot be used, the air supply duct and flue must be implemented separately. ► The individual flue pipe (Ø80) and/...

  • Page 35: Roof Terminal And Air Supply Duct From The Façade C53

    ► Shorten the air supply duct pipe to the desired length out of the wall. ► Install the Intergas intake grille and attach this to the pipe. ► Slide the air supply duct pipe in the opening and cover the opening, if necessary, with a rosette.

  • Page 36: Clamping The Flue System (Parallel And Concentric)

    6.8.5 Clamping the flue system (parallel and concentric) IMPORTANT IMPORTANT ► These regulations are typical for both ► Do not mix any components, concentric and parallel flue systems. materials or ways of coupling ► The flue system must be secured to a from different manufacturers.
  • Page 37 COMMENT ► Shown examples are typical for both parallel and concentric clamping. Second element after first elbow Second element after first elbow...

  • Page 38: Operation

    OPERATION Using the control panel Tapping Touching and holding for 2 seconds 2sec Preparation activities 7.2.1 Filling and venting central heating system ► Connect to 3 amp fused spur. ► Connect the appliance to mains A 2 may briefly appear on the right display; this means that the connected sensors are being inspected.

  • Page 39: Domestic Hot Tap Water Facility

    ► Connect the filling loop and fill the installation with clean drinking water to a maximum pressure of 1-2 bar in the case of a cold installation (Indicated on left display.) ► Bleed the appliance with the manual bleed screw. ►...

  • Page 40: Commissioning Procedure

    ► Instruct the end user about filling and venting and the operation of the heating and the domestic hot water facility. ► Give the operation instructions and guarantee card ‘for customer’ to the end user. Garantiebewijs Intergas HR-ketel Type/Serienr. Datum installatie: Voor de ‘Garantiebepalingen Volgens geldende voorschriften Intergas HR-ketels’...

  • Page 41: Clock Function

    Clock function The boiler is equipped with a digital clock and offers the possibility to program points in time for both CH operation and DHW operation. To activate the clock program the following parameters have to be set: For CH operation parameter P040 = 1 For DHW operation parameter P087 = 1 ►...

  • Page 42: Shutting Down The Boiler

    If an external boiler is installed (Parameter P001 = 1) ► P-on (Program on): The external boiler will be kept on temperature within the chosen time blocks . If the clock program does not contain any valid switching points, the external boiler will continuously be kept on temperature.

  • Page 43: Settings And Adjustments

    SETTINGS AND ADJUSTMENTS The functioning of the boiler can be influenced by the various (parameter) settings in the burner controller. Based on a number of specific menus, these settings can be made and modified via the display. Some of the settings are only accessible after entering the installer’s code (see §8.1.5 and §8.3).

  • Page 44: Domestic Hot Water Menu

    8.1.2 Domestic hot water menu The domestic hot water menu has 2 settings and is accessible by tapping on the Domestic Hot Water symbol from the main menu. Via the domestic hot water menu: ► the domestic hot water temperature can be modified ►...

  • Page 45: Central Heating Menu

    8.1.3 Central heating menu The central heating menu has 3 settings and is accessible by tapping on the Central Heating symbol from the main menu. Via the central heating menu: ► the maximum temperature of the central heating water can be modified ►...
  • Page 46 To modify an RF room thermostat: 1. Touch the Central Heating symbol and hold for 2 seconds. Central heating 2. The method of assignment is dependent on the type menu 2sec of room thermostat and is described in the installation manual and operation instructions of the wireless room thermostat.

  • Page 47: Service Menu

    8.1.5 Service menu The service menu is accessible by touching the Service button from the menu and holding it for 2 seconds. Via the service menu: ► the test programs can be activated ► access to the (installer’s) parameters can be obtained Main menu 2sec The following buttons will light up:...
  • Page 48 (Installer’s) parameters The (installer’s) parameters of the burner controller are factory- set according to the table in §8.3. These parameters can only be modified using the installer’s code. The installer’s code is shown on the left display and is preceded by the letter The parameters are also shown on the left display and are preceded by the letter...

  • Page 49: Setting And Adjusting The Clock Functions

    Setting and adjusting the clock functions Show actual time ► From a boiler that is in standby or in operational mode tap just above the power LED to access the main menu (also see §8.1.1). The actual time is shown in the left display. The Clock shown (boiler standby) symbols also light up.

  • Page 50: Setting The Clock Program On Dhw Operation

    To apply the clock program ► From a boiler that is in standby or in operational mode tap just above the power LED to access the main menu (also see §8.1.1). ► Tap on the Central Heating button. The current temperature of the central heating water is displayed in the left display.
  • Page 51 To apply the clock program ► From a boiler that is in standby or in operational mode tap just above the power LED to access the main menu (also see §8.1.1). ► Tap on the Domestic Hot Water button . The current temperature of the central heating water is displayed in the left display.

  • Page 52: Parameters

    2 = Xtreme Tap 3 = Xtreme Solo 75 = Xtreme 36 Set maximum central heating output ------- 100 = Xtreme 24 / Xtreme 30 P010 25% to 100% (see §8.5) 0 = overrun active Central heating pump setting P030...

  • Page 53: Switching Dhw Comfort Function On And Off

    If the central heating load modulates between the minimum and maximum value, the pump capacity will modulate along proportionately. Pressure loss graph boiler central heating side A. Xtreme 24 B. Xtreme 30 C. Xtreme 36 l/hr 1000...

  • Page 54: Weather-Dependent Control

    Weather-dependent control When an outdoor sensor is connected, the flow temperature will be automatically controlled according to the set heating line, depending on the outside temperature. The weather-dependent control functions solely with an on/off room thermostat. When using an OpenTherm room thermostat, the outside temperature will be relayed, but the heating line of the central heating boiler will not be active.

  • Page 55: Conversion To Another Gas Type

    Conversion to another gas type CAREFUL ► Only qualified competent gas safe registered engineers may work on the boiler. If the boiler is connected to another gas type than that for which the boiler has been set by the manufacturer, the gas restriction ring must be replaced.

  • Page 56: Gas/Air Control

    Gas/air control IMPORTANT ► Work on gas supply pipe components as well as the adjustment of the gas air control must be performed by an authorised installer. The gas/air control is set in the factory such that the combustion is optimal for the gas type used. The gas type (natural gas or LPG) for which the boiler is adjusted is indicated on the data plate under the boiler.

  • Page 57: Inspection Of Gas Air Control

    8.10 Inspection of gas air control 8.10.1 Measuring flue gas at maximum output A. Switch off the boiler. – A line will appear on the right display and the central heating pressure will be visible on the left display. B. Remove the front panel of the boiler by unscrewing the 2 attachment screws (1) and then removing the panel forward (2).
  • Page 58 Table 2a: Allowed O (H) limits at maximum output (open casing) Gas category Value limits Natural gas Upper limit 5.60 6.05 Lower limit 3.85 4.50 Table 2b: Allowed CO (H) limits at maximum output (open casing) Gas category Value limits Natural gas Upper limit 10.8...

  • Page 59: 8.10.2 Measuring Flue Gas At Minimum Output

    8.10.2 Measuring flue gas at minimum output Before measuring the flue gases at minimum output, the measurement at maximum output must be completed. The measured O (H) or CO (H) value at maximum output is important for determining the correct value for the check at minimum output.
  • Page 60 IMPORTANT ► The gas air control is correctly set if the measured value at minimum output falls within the indicated upper and lower limits. Adjustment of the gas air control is not necessary in this case. The setting at minimum output must be adjusted using the method described in §8.10.3 if the measured value lies outside the indicated limits.

  • Page 61: 8.10.3 Minimum Output Correction

    8.10.3 Minimum output correction Before the min. output correction is performed, the maximum output and minimum output measurements must be completed. The measured O (H) or CO (H) value at maximum output is important for determining the correct value for the setting at minimum output (see §8.10.1 and §8.10.2).
  • Page 62 Table 4a: Determination of O (L) setting value Table 5a: Determination of CO (L) setting value for natural gas (open casing) natural gas 2EK (open casing) Natural gas G20 (20 mbar) Natural gas G20 (20 mbar) Measured value at Setting value minimum Measured value at Setting value minimum maximum output...

  • Page 63: Faults

    FAULTS Fault codes Requesting fault code If the burner controller detects a fault, this is shown by a flashing service symbol on the display. A fault code, such F004 , is shown on the left display for 30 seconds. Then the left display will be extinguished.
  • Page 64 ► Check for the correct operation of central heating flow sensor S1. ► Replace central heating flow sensor S1. IMPORTANT ► Replace defective components exclusively with original Intergas components. ► Not or incorrectly installing the sensors can lead to serious damage.

  • Page 65: Other Faults

    Other faults 9.2.1 No heat (central heating) Possible causes Analysis Solution The power LED is not shown. → → Check the power supply. Check the fuse; see Electrical schematic §11.1 . ↓ → Switch on the boiler by touching just above the power LED and →...

  • Page 66: No Domestic Hot Water (Dhw)

    9.2.4 No domestic hot water (DHW) Possible causes Analysis Solution The power LED is not shown. → → Check the power supply. Check the fuse; see Electrical schematic § 11.1. ↓ Flow sensor does not work. → → Replace the flow sensor. ↓...

  • Page 67: Burner Resonates

    9.2.7 Burner resonates Possible causes Analysis Solution Gas inlet pressure lower than 20 mbar → → The home pressure regulator may be defective. Contact the or sometimes disappears. energy company. ↓ There is recirculation of flue gases. → → Check the flue and air supply duct. ↓...

  • Page 68: Maintenance

    MAINTENANCE The boiler and the system must be inspected annually by an qualified competent gas safe registered engineer and cleanded if necessary. The annual maintenance interval is based on an expected operation time of approx. 1,500 heating hours/year (average domestic use), via Comfort Touch dashboard and installerd app. If not monitored by Comfort Touch then the boiler must be serviced annually.

  • Page 69: Installation

    Installation IMPORTANT ► Replace the front plate O-ring every 3 years. Art.no: 877927 — Xtreme 24/30 620274 — Xtreme 36 ► Check and replace any other gaskets. Also check the correct positioning. ► Check whether there is a thin layer of ceramic grease between the flange of the shoulder bolt and the front panel.

  • Page 70: Checklist

    10.4 Checklist Activity Inspection at Maintenance every annual must be carried service out at regularly Isolate the boiler from the fuse spur and make safe (ref TB118) check the correct 3amp fuse fitted. Carry out inspection of boiler for dust and dirt and clean where necessary.

  • Page 71: Technical Specifications

    TECHNICAL SPECIFICATIONS Boiler category C13; C33; C53 Gas inlet pressure G20: 20 mbar, G31: 37 mbar Suitable for gas 2H3P Technical data Xtreme Domestic hot water Nom. input rating (lower value) 3.6 – 25.1 3.6 – 30.5 3.6 – 32.7 Tap threshold l/min ∆T 25°C...

  • Page 72: Electrical Schematic

    11.1 Electrical schematic...
  • Page 73 230V~ component Connector Connections Designation Description 1 – 2 – 3 – 4 – 5 – 6 1 – 2 – 3 Central heating pump 1 – 2 On/off room thermostat 230V Shut-off valve underfloor heating or groups adjustment 1 – 2 – 3 (1=N (blue), 2=L (brown), 3=T (black)) Three-way valve 1 –...

  • Page 74: Product Card According To Celex-32013R0811

    11.2 Product card according to CELEX-32013R0811, Appendix IV Intergas Heating Ltd Unit 2 Easter Park Supplier Worcester Road Kidderminster DY11 7AR Intergas Xtreme Type designation Symbol Unit Seasonal energy efficiency class for room heating Nominal heat output (capacity) rated Seasonal energy efficiency class for ŋ...

  • Page 75: Guarantee Provisions And Ce Declaration

    Combimate* or Water softener* should be installed.) during an engineers visit. (*serviceable item) The boiler warranty must be registered with Intergas by either The central heating system must be maintained in accordance the installer or you the householder, within 30 days of the with the Benchmark Guidance on Water Treatment in Central boiler being installed.

  • Page 76: Gas Boiler System Commissioning Checklist

    GAS BOILER SYSTEM COMMISSIONING CHECKLIST GAS BOILER SYSTEM COMMISSIONING CHECKLIST This Commissioning Checklist is to be completed in full by the competent person who commissioned the boiler as a means of demonstrating compliance with the appropriate Building Regulations and then handed to the customer to keep for future reference. Failure to install and commission this equipment to the manufacturer’s instructions may invalidate the warranty but does not affect statutory rights.

  • Page 77: Service Record

    SERVICE RECORD SERVICE RECORD It is recommended that your heating system is serviced regularly and that the appropriate Service Record is completed. Service Provider Before completing the appropriate Service Record below, please ensure you have carried out the service as described in the manufacturer’s instructions.
  • Page 80 All rights reserved. The information provided applies to the standard version of the product. Intergas Heating Ltd can therefore not be held liable for any damage ensuing from specifications that deviate from the standard version of the product. Although the available information has been composed with all possible care, Intergas Heating Ltd cannot be held liable for any errors in the information or for the consequences of such.

This manual is also suitable for:

Xtreme 30Xtreme 36

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