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  5. Installation Manual

Intergas Rapid 25 Installation Manual

Summary of Rapid 25

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    Intergas heating ltd. Rapid 25 rapid 32 installation manual.

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    2 table of contents 1. Safety regulations 6 1.1 general ....................................................................................................................................................................... 6 1.2 the installation ........................................................

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    3 7.2 commissioning of the appliance ............................................................................................................................... 31 7.3 setting and adjusting the clock functions .........................................................................................

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    4 the information provided has been compiled with the utmost care. However, intergas verwarming bv cannot be held liable for any faults in the information nor for the consequences thereof. Intergas verwarming bv cannot be held liable for any damage resulting from the activities carried out by third ...

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    5 this manual using this manual you can safely install and maintain this appliance. Carefully follow the instructions. In case of doubt, contact intergas verwarming bv keep these instructions near the appliance. Abbreviations and names used description to be referred to as high efficiency he interga...

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    6 1. Safety regulations 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 combi compact hre high efficiency wall mounted gas...

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    7 2. Description of the appliance 2.1 general the intergas rapid hr wall mounted, gas fired 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 flue can be connected to the appliance by means ...

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    8 2.3 operating conditions a code on the service display of the operating panel indicates the appliance’s operating mode. - off the appliance is out of operation but is supplied with electrical power. No response occurs to calls for dhw or ch. The appliance frost protection is active. This means tha...

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    9 in the case of 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...

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    10 2.4 clock function the boiler is equipped with a digital clock and offers the possibility to program 4 points in time to switch from ch off or ch on. During the “clock active” periods the boiler will respond on ch demands from the room thermostat. During the “clock inactive” periods the boiler wi...

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    11 2.6.1 frost protection • to prevent freezing of the appliance it is equipped with appliance frost protection. If the heat exchanger temperature falls to low, the burner switches on and the pump runs until the heat exchanger temperature is sufficient. When the appliance frost protection is actuate...

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    12 3. Installer important points please read all instructions before fitting this appliance • the installer shall instruct the user on the operation of the boiler, safety devices contained within the boiler and on the location of the filling loop and how to re-pressurize the system if the water pres...

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    13 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 displa...

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    14 4.1 accessories description concentric adapter 60/100 086807 rear mounting frame for top pipe connection 092757 pipework cover 092527 conversion set to propane (g31) 076077.

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    Intergas heating ltd 15 5. Installation 5.1 overall dimensions appliance + mounting plate 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 flex h = 640mm rapid 25 700mm rapid 32 h = 750mm rapid 25 810mm rapid 3...

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    Intergas heating ltd 16 5.2 boiler location the appliance can be fitted to a mounting frame. The assembly or just the appliance should be mounted to a wall with sufficient bearing strength. In case of light wall constructions, resonance sounds may occur. There must be an earthed electrical supply wi...

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    Intergas heating ltd 17 5.3 assembly depending on the connection situation, to mount the appliance use is made of a suspension strip or a top connection frame. A connection set with shut off valves and a gas valve is included in the boiler. 5.3.1 fitting the mounting strip 1. Fasten the mounting str...

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    Intergas heating ltd 18 5.4 mount the appliance 1. Unpack the appliance. 2. Check the content of the packaging. This consists of:- • appliance (a) • mounting strip (b) • siphon cup (c) • flexible hose (d) • installation instructions • guarantee card 3. Check the appliance for any damage: report dama...

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    Intergas heating ltd 19 6. Connections 6.1 connect the ch system 1. Flush the ch system thoroughly. 2. Mount the flow and return pipes to the mounting bracket. All pipes must be mounted tension-free in order to avoid ticking of the pipes. Existing connections must not be twisted in order to avoid le...

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    Intergas heating ltd 20 6.1.4 appliance with zone control. If there is, next to the ch system an other heating source (as for example a stove or a fireplace) in the living room often the problem occurs that the other rooms cool down. This can be solved by splitting up the ch system into two separate...

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    Intergas heating ltd 21 6.2 domestic hot water system a. Flush the installation thoroughly to clean (please refer to current standard codes of practice). B. Fit the cold and hot water pipes into the shut off valve and the elbow. A. Existing connections must not be twisted, in order to avoid leakages...

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    Intergas heating ltd 22 6.3 electrical connection caution an earthed wall socket must be located no more than 1 metre from the appliance. The wall socket must be easily accessible. For installation in damp rooms a fixed connection is obligatory. When workin on the ectrical circuit always remove the ...

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    Intergas heating ltd 23 6.3.2 on / off room thermostat to be connected to contacts 6 and 7 of connector x4. This is a 24 volt connection and no mains power must be applied to these terminals. See chapter 13, electrical diagram. Note when a 24 volt thermostat is connected to contacts 6 and 7, the loo...

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    Intergas heating ltd 24 6.4 condensate disposal the appliance is provided with a 25 mm flexible pipe from its condensate trap. Connect the flexible tube from the condensate trap to the drain via an open connection. Caution always fill the condensate trap with water and place it on the boiler before ...

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    Intergas heating ltd 25 6.5 gas connection 1. Fit a gas tap (a) between the gas supply and the appliance. 2. Fit the connection from the gas tap preferably directly into the ½”connection at the mounting braket. 3. Install a gas filter mesh in the connection for the appliance if the gas may be contam...

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    Intergas heating ltd 26 flue system 6.5.1 flue pipe and air supply for connecting the boiler to a concentric flue system a special concentric flue adapter has to be used. An adapter for connecting to a 60/100 flue system or to a concentric 80/125 flue system can be ordered at intergas heating ltd. F...

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    Intergas heating ltd 27 6.5.2 length flue pipe and air inlet when connecting to a concentric flue system the following lengths (l = meters) for the combustion system are valid: rapid 25 c13(1) c33(2) c53(3) c33(4) 60/100 60/100 60/100 l1 60 l2 60/100 l1 l l 9.7 10 6.5 1 9 1 10 1 rapid 32 c13(1) c33(...

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    Intergas heating ltd 28 6.5.6 plume management kit the plume management kit comprises of a 710 mm horizontal section with elbow to connect the 1m vertical condensing tube, which has a horizontal or vertical terminal dependant on your requirements. The maximum length of horizontal flue including the ...

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    Intergas heating ltd 29 7. Commissioning 7.1 fill and de-aerate the appliance and the system warning connect the appliance to the mains voltage only after filling and de-aerating! 7.1.1 ch system warning when an additive is added to the ch water, this should be suitable for the materials used in the...

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    Intergas heating ltd 30 7.1.4 combustion the combustion for this appliance has been checked, adjusted and preset at the factory for operation on the gas type defined on the appliance data plate. Do not adjust the air/gas ratio valve. Having checked: • that the boiler has been installed in accordance...

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    Intergas heating ltd 31 7.2 commissioning of the appliance read-out operation 1 on / off a on / off button 2 ch operation or setting maximum ch temperature b dhw / ch button, for setting desired temperature 3 dhw operation or setting dhw temperature c - button 4 desired temperature of ch or dhw in °...

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    Intergas heating ltd 32 7.3 setting and adjusting the clock functions 7.3.1 setting the clock • press the button for less than 1 second and repeat this untill ‘’24hr clock’’ appears. For adjusting the clock to the correct time press the [+] or [-] button. Note: holding the button for more than 1 sec...

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    Intergas heating ltd 33 7.5.1 frost protection • to avoid freezing of the condensate drain pipe the appliance must be installed in a frost-free area. • to avoid freezing of the appliance it is equipped with frost protection. If the temperature of the heat exchanger becomes too low, the burner switch...

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    Intergas heating ltd 34 8. Setting and adjustment the functioning of the appliance is determined primarily by the (parameter) settings in the boiler controller. Part of this can be set directly via the operating panel; another part can only be adjusted using the installer code. 8.1 directly via the ...

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    Intergas heating ltd 35 8.2 settings through the service code the burner controller of the appliance has been set in the factory according to the parameters of § 8.3. These parameters can only be changed with the service code. Proceed as follows to activate the program memory:- 1. Set the appliance ...

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    Intergas heating ltd 36 e min. Supply temperature during ot demand (ot = opentherm stat) 40 40 setting range 10°c to 60°c. If the ot thermostat demands a supply temperature that is below this set value, the heat demand cannot be met. E. Ot reaction 1 1 0 = ignore ot demand if 1 = if ot demand e 2 = ...

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    Intergas heating ltd 37 8.4 setting maximum ch power the maximum ch power is set to 70% in the factory. When the ch system requires more or less power, the maximum ch power can be changed by adjusting the fan speed. See table: setting ch power. This table gives the relation between the fan speed and...

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    Intergas heating ltd 38 8.7 conversion to different gas type caution work on gas carrying parts may only be carried out by a qualified competent person. If a different type of gas is connected to the appliance than that for which the appliance has been set by the manufacturer, the gas metering ring ...

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    Intergas heating ltd 39 8.8 gas-air ratio control. The gas air ration control of the boiler is set to the correct value in the factory and does not need to be adjusted. The gas type of the boiler on which the boiler has been set is noted on the data plate. The boiler is only to be used in combinatio...

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    Intergas heating ltd 40 8.9 checking the gas air ratio control 8.9.1 checking flue gas at maximum power. 1. Switch the appliance off with the button . [-] will appear in service display. 2. Remove the front panel by untightening the 2 screws. 3. Remove the cap x of the flue gas sampling point on the...

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    Intergas heating ltd 41 8.9.2 checking flue gas at minimum power before measuring the flue gasses at minimum output the measurement of the maximum output must be completed. The measured o2 or co2 value at maximum output is important for determining the correct value for the measurement at minimum ou...

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    Intergas heating ltd 42 8.9.3 correction gas air ratio on minimum power before the correction of the gas air ratio on minimum output the measurement of the maximum output must be completed. The measured o2 or co2 value at maximum output is important for determining the correct value for the measurem...

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    Intergas heating ltd 43 tabel 5a: determining the correct setting of co 2 at minimum output for natural gas g20 (open casing) natural gas g20 (20 mbar) measured value am maximim power (see § 8.9.1 ) prescribed value at minimum power (= 0.5 x co 2 (h) + 4.2) co 2 (h) [%] co 2 (l) [%] 9.6 9.0 ±0.1 9.4...

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    Intergas heating ltd 44 9. Faults 9.1 faultcodes when the service display or the operating panel is flashing, the burner controller has detected a fault. In case of several faults, the temperature display shows an additional code. After the fault has been remedied, the burner controller can be resta...

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    Intergas heating ltd 45 9.2 other faults 9.2.1 burner does not ignite possible causes: solution: gas tap is closed. Open gas tap. No air in the gas pipe. Remove air form gas pipe. No gas supply pressure too low. Contact the gas supply company. No no ignition. Replace ignition electrode. No no spark....

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    Intergas heating ltd 46 9.2.3 burner resonating possible causes: solution: gas supply pressure too low. The house pressure switch may be faulty. Contact the gas company. No recirculation of combustion gasses. Check the gas flue an the air supply. No gas/air adjustment not correctly set. Check the se...

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    Intergas heating ltd 47 9.2.7 no hot water (dhw) possible causes: solution: flow sensor not functioning. Dhw flow replace the flow sensor. No no voltage at the flow sensor (5v dc). Check the wiring according to the diagram. No burner not firing on dhw: s3 faulty. Replace s3. No burner does not ignit...

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    Intergas heating ltd 48 10. Servicing the boiler the appliance and the installation should be checked and if necessary cleaned every year by a registered expert. For assembly and disassembly the following tools can be used: 4. Cross head screwdriver 5. Allen key 8 mm 6. Fork spanner 30 mm after serv...

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    Intergas heating ltd 49 10.1 disassembly 1. Switch off the appliance using the on/off key on the operating panel. 2. Switch off the electrical supply to the appliance. 3. Close the gas tap. 4. Unscrew the two sunken screws left and right at the front underneath the appliance and lift/remove the fron...

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    Intergas heating ltd 50 10.2 assembly caution when fitting the various seals check for damage, hardening, tears or hairline tears and/or discoloration. Where necessary fit a new seal. Also check whether seals are still correctly positioned. Check warranty will be void by not correctly replacing remo...

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    Intergas heating ltd 51 10.3 combustion during routine servicing, and after any maintenance or change of part of the combustion circuit the following must be checked: • the integrity of the flue system and the flue seals, as described in § 8.5 and the british standards codes of practices, specifical...

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    Intergas heating ltd 52 11. Technical specifications appliance category b13; b33; c13; c 33; c 43; c53; c63; c83 gas inlet pressure 20 mbar suitable for gas ii 2 h 3 p rapid 25 rapid 32 sedbuk rating a a gas council number g.C. G.C. Dhw nom. Input rating (lower value) kw 1.1 – 29.1 7.6 – 32.7 dhw th...

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    Intergas heating ltd 53.

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    Intergas heating ltd 54 11.2 electrical diagram a earth connections heat-exchanger f fuse (3.15 a t) p1 ch pump s3 dhw sensor b spark plug cover g gas valve + ignition unit s5 flow sensor dhw c boiler controller i ionisation-/ ignition probe s1 flow sensor s7 ch water pressure sensor e earth connect...

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    Intergas heating ltd 55 12. Warranty conditions with due regard for the conditions indicated below, intergas heating ltd warrants to the authorised installer the soundness of the materials used in and the correct operation of its central heating products, when used for the purpose for which they are...

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    Intergas heating ltd 56 gas boiler system commissioning checklist.

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    Intergas heating ltd 57 14. Service record.

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    Intergas heating ltd 58.

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    Intergas heating ltd 59.

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    Intergas heating ltd 60 intergas boilers are manufactured in a kiwa iso 9001 certified production faccility. Intergas heating ltd intergas heating ltd tel: 01527 888000 building 94, bay 1 vantage point fax: 01384 279480 the pensnett estate info@intergasheating.Co.Uk kingswinford www.Intergasheating....