Intergas Rapid 25 Installation Manual

Intergas Rapid 25 Installation Manual

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Rapid 25
Rapid 32
Installation Manual
Intergas Heating Ltd.

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Summary of Contents for Intergas Rapid 25

  • Page 1 Rapid 25 Rapid 32 Installation Manual Intergas Heating Ltd.
  • Page 2: Table Of Contents

    TABLE OF CONTENTS 1. Safety Regulations General ..................................6 The Installation ................................6 Approvals ..................................6 2. Description of the Appliance General ..................................7 Operation ..................................7 Operating conditions ..............................8 Clock function ................................10 PC Interface ................................10 Test program’s ................................10 2.6.1 Frost protection .................................
  • Page 3 14. SERVICE RECORD © 2015 Intergas Heating Ltd The information provided applies to the product in the standard model. Intergas Verwarming BV can therefore not be held liable for any damage resulting from the product specifications that deviate from the standard model.
  • Page 4 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 parties. To be changed without prior notice...
  • Page 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...
  • Page 6: Safety Regulations

    Intergas is committed to the continual development of their appliances and reserves the right to make changes without notification to ensure their customers benefit from the latest advances in combustion technology and energy conservation.
  • Page 7: Description Of The Appliance

    DESCRIPTION OF THE APPLIANCE 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 of two separate pipes.
  • Page 8: Operating Conditions

    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.
  • Page 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 panel.
  • Page 10: Clock Function

    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.
  • Page 11: Frost Protection

    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 actuated code 7 ‘...
  • Page 12: Installer Important Points

    • commissioning guidelines within the boiler instruction manual. If necessary, please contact Intergas Heating Ltd (See § 1.8). Remember it is a requirement to complete the Benchmark code of practice logbook before leaving the installation. You are also required to register the boiler...
  • Page 13: Main Components

    MAIN COMPONENTS CH pump Flue discharge Gas valve Connecting block / terminal list X Burner controller with operating panel Condensate discharge Supply sensor S1 Hot water sensor S3 Return sensor S2 Siphon cup Heat exchanger Flow switch Operating panel and display Pressure gauge Ionisation/ignition probe 1m connecting cable 230 V ~...
  • Page 14: Accessories

    Accessories Description Concentric adapter 60/100 086807 Rear mounting frame for top pipe connection 092757 Pipework cover 092527 Conversion set to Propane (G31) 076077...
  • Page 15: Installation

    Ø22 (male) Return CH Ø22 (male) G ½” DHW cold Ø15 (male) Ø15 (male) Condensate Condensate hose ø25 flex 640mm Rapid 25 700mm Rapid 32 750mm Rapid 25 810mm Rapid 32 Flue gas outlet Ø80 (seal) Air supply inlet Ø80 (seal)
  • Page 16: Boiler Location

    Remove the optional pipework cover and the front panel for carrying out work on the appliance as follows:- 1. Remove the pipework cover (A), if used, forwards. 2. Unscrew both screws (B) at the bottom of the appliance. 3. Lift the front panel (C) and remove it forwards. Intergas Heating Ltd...
  • Page 17: Assembly

    2. Make sure the strip is levelled correctly. 5.3.2 Fitting the rear mounting frame 1. Fasten the frame vertically to the wall, using the screws and plugs supplied. 2. Make sure the frame is levelled correctly. Caution The appliance is wider than the frame. Intergas Heating Ltd...
  • Page 18: Mount The Appliance

    7. When needed the condensate outlet (behind the cup) can be extended using the flexible hose that has been delivered together with the boiler. 8. Fill the internal siphon by removing the hose coming from the PRV. Make sure the hose is placed again afterwards. Intergas Heating Ltd...
  • Page 19: Connections

    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.
  • Page 20: Appliance With Zone Control

    4. Modify parameter A in the parameter list. (See § 8.3) Note : The room thermostat for zone 1 must be an on/off type. The room thermostat for zone 2 can be either on/off or “Open Therm”. Intergas Heating Ltd...
  • Page 21: Domestic Hot Water System

    DHW water must be drained in order to prevent freezing. For this purpose the DHW connections below the appliance must be removed. Flow Resistance graph for appliance DHW circuit A. Not applicable B. Rapid 25 C. Rapid 32 X. kPa (Bar) Y. Litres per minute 6.2.1 Appliance with solar water heater post-heating The appliance carries the NZ label: suitable for “solar water heater post-heating”.
  • Page 22: Electrical Connection

    Temperature control Connector X2 Notes Room thermostat 230 V 1 – 3 Remove link 6 – 7 or external control 230 V (connector X4) Frost thermostat 230 V 1 – 3 Remove link 6 – 7 (connector X4) Intergas Heating Ltd...
  • Page 23: On / Off Room Thermostat

    1 on X2. Set in-built timer to C-ON. Always remove link between 6-7 on X4 when fitting external temperature controls or the boiler will run constantly Warning High Voltage Isolate the appliance from the electrical supply before connecting the thermostat. Intergas Heating Ltd...
  • Page 24: Condensate Disposal

    - the use of fittings, elbows etc should be kept to a minimum ans any internal ‘’burrs’’ on cut pipework should be removed so that the internal pipe section is as smoooth as possible. For more information about preventive measures against freezing please visit the HHIC website http://www.centralheating.co.uk/checklists/frozen- condensate-pipes. Intergas Heating Ltd...
  • Page 25: Gas Connection

    Fit the connection from the gas tap preferably directly into the ½”connection at the mounting braket. Install a gas filter mesh in the connection for the appliance if the gas may be contaminated. Connect the appliance to the gas supply. Check the gas carrying parts for leakage. Intergas Heating Ltd...
  • Page 26: 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. For the appropriate types see chapter 4.1 Accessories.
  • Page 27: Length Flue Pipe And Air Inlet When Connecting To A Concentric Flue System

    Please note that the terminal is suitable for a flat or pitched roof and only approved Intergas flue products can be used with this boiler. CAUTION Only an Intergas approved flue is to be used with this product. Failure to comply with this requirement will invalidate your...
  • Page 28: Plume Management Kit

    1. Check condensate trap is filled with water and correctly connected to boiler. 2. All flue joints are correctly made, unstressed and adequately supported. 3. All parts of the flue can be visually inspected -ensure suitable access where flue is positioned within voids- Intergas Heating Ltd...
  • Page 29: Commissioning

    Gas supply 1. De-aerate the gas pipe with the inlet pressure measuring nipple on the gas valve. 2. Check the connections for leaks. 3. Check the inlet pressure and the burner pressure. See Gas and air control. Intergas Heating Ltd...
  • Page 30: Combustion

    The flue termination should also be checked. Where suitable access for a visual inspection of an existing flue system has not been provided the appliance must not be commissioned and it must be disconnected from the gas supply. Intergas Heating Ltd...
  • Page 31: Commissioning Of The Appliance

    This will occur at the the time of the last request for heat. To change this time the room thermostat should be turned up briefly at the desired time. The pump does not run during DHW operation. • Intergas Heating Ltd...
  • Page 32: 7.3 Setting And Adjusting The Clock Functions

    1. Drain the appliance at the drain tap. 2. Drain the installation at the lowest point. 3. Close the main cock for the water supply to the DHW section. 4. Drain the appliance by removing the DHW couplings below the appliance. Intergas Heating Ltd...
  • Page 33: Frost Protection

    Connect this according to the wiring diagram. See § 11.2. Note! The external frost thermostat is not active when the appliance has been switched off at the operating panel or when the mains voltage has been interrupted. Intergas Heating Ltd...
  • Page 34: Setting And Adjustment

    30°C and 90°C (default value 80°C). 8.1.6 DHW temperature Press the key until the LED at starts to flash. With the keys set the temperature between 40°C and 65°C (default value 55°C). Intergas Heating Ltd...
  • Page 35: Settings Through The Service Code

    2 = n/a Setting CH power Setting maximum CH load Setting range : value par. c – 90 % (Rapid 25) Value par. c – 100 % (Rapid 32) Max. power for modulating pump Setting range : value of pararmeter c. until 100...
  • Page 36: Enable/Disable Keep Hot Facility By Open Therm Room Thermostat

    DHW coefficient Setting range 0, 24, 30, 30 0 = Applicable for combi boilers with flow switch 24 = not applicable 30 = Rapid 25 36 = Rapid 30 Summer mode 0 = Summer mode inactive 1 = Summermode to be set in display...
  • Page 37: Setting Maximum Ch Power

    This table gives the relation between the fan speed and the appliance power. Setting CH power Required CH power Setting on service display (approx. in kW) (% of the maximum speed) Rapid 25 Rapid 32 22.6 26.2 ± 83 19.1 22.0...
  • Page 38: Conversion To Different Gas Type

    § 8.9 . Place a sticker for the gas type set over the existing sticker next to the gas valve. Place a sticker for the gas type set next to the identification plate. Intergas Heating Ltd...
  • Page 39: Gas-Air Ratio Control

    Model 20 mBar 30 mBar Gas ring Rapid 25 Rapid 32 The correct setting of the Gas-Air ratio can be checked by measuring the flue gases using a calibrated O measuring device. The measurement must be performed first at maximum power and thereafter on the minumum power.(see §...
  • Page 40: Checking The Gas Air Ratio Control

    10. Proceed performing the measurement on minimum output(see § 8.9.2). Intergas Heating Ltd...
  • Page 41: Checking Flue Gas At Minimum Power

    8. Remove the measuring probe of the flue gas analyser and replace the cap on the sampling point. 9. Check the tightness of the sampling point 11. Switch the appliance off with the button and check that the appliance is functioning well. Intergas Heating Ltd...
  • Page 42: Correction Gas Air Ratio On Minimum Power

    Measured value am maximim power Prescribed value at minimum power (See § 8.9.1 ) (= O (H) + 0.5) (H) [%] (L) [%] 6.05 6.55 ±0.2 5.70 6.20 ±0.2 5.40 5.90 ±0.2 5.10 5.60 ±0.2 4.80 5.30 ±0.2 4.50 5.00 ±0.2 Intergas Heating Ltd...
  • Page 43: Intergas Heating Ltd

    Repeat the measurement at maximum and minimum output (see § 8.9.1 and § 8.9.2) to ensure the correct operation of the boiler. Important Work on gas carrying parts may only be carried out by a qualified competent person. Intergas Heating Ltd...
  • Page 44: Faults

    29, 30 Relay gas valve defect Replace burner controller • CAUTION Always use original Intergas spare parts when replacing components. Failure to fit the sensors S1 and/or S2, or to fit them correctly can result in serious damage. CAUTION * The boiler is equipped with a non-return valve (A), positioned above the fan.
  • Page 45: Other Faults

    Check the setting. See gas/air adjustment. Check the ignition gap. Weak spark. Replace the ignition electrode. Replace the ignition unit on the gas valve. Checking ignition pin position using test tool Pin must touch test tool Pin must not touch test tool Intergas Heating Ltd...
  • Page 46: Burner Resonating

    The boiler power has not been correctly set Adjust the power. See setting maximum CH power. for the installation. No heat transfer as a result of lime scale or De-scale or flush the heat exchanger on the CH side. fouling in the heat exchanger. Intergas Heating Ltd...
  • Page 47: No Hot Water (Dhw)

    Reset the pump by shutting of the boiler (stand-by or powerless) for at least 20 seconds. Pump is not running Note: If the pump is set on “continuously active” (parameter 2 = 1) the boiler must be made powerless for at least 20 seconds. Intergas Heating Ltd...
  • Page 48: Servicing The Boiler

    CAUTION Work on gas carrying parts may only be carried out by an authorised installer. When the appliance has just been operating parts may be hot. CAUTION The integrated insolation and burner seal contain ceramic fibres. Intergas Heating Ltd...
  • Page 49: Disassembly

    CAUTION The boiler is equipped with a non-return valve (A), positioned above the fan. Check that the valve is still in good condition and ensure the valve is repositioned correctly when replacing the fan. Intergas Heating Ltd...
  • Page 50: Assembly

    11. Check the front cover and the connection of the fan to the front cover for leaks. 12. Check the combustion (see § 10.3) 13. Fit the cover and screw it left and right at the bottom of the appliance. 14. Check the heating system and the hot water supply. Intergas Heating Ltd...
  • Page 51: Combustion

    § 10.8. When the CO percentage at high setting is not within the prescribed tolerance band please contact Intergas Heating. Intergas Heating Ltd...
  • Page 52: Technical Specifications

    TECHNICAL SPECIFICATIONS Appliance category B13; B33; C13; C 33; C 43; C53; C63; C83 Gas inlet pressure 20 mbar Suitable for gas Rapid 25 Rapid 32 SEDBUK Rating Gas Council number G.C. G.C. Nom. Input rating (lower value) 1.1 – 29.1 7.6 –...
  • Page 53 Intergas Heating Ltd...
  • Page 54: Electrical Diagram

    (2 = Live (brown), 4 = Neutral (blue)) CV-pump (8 = Live (brown), 7 = Neutral (blue) Shut-off valve, floor heating (3 = Live (brown), 5 = Switch (black), 6 = Neutral (blue) (VC4013 Honeywell 3-5-6 230V~) Connector X5 Computer interface Intergas Heating Ltd...
  • Page 55: 12. Warranty Conditions

    A copy of these conditions will be sent to you free of charge on request. Conditions to the contrary are expressly rejected. With due regard for the conditions indicated below, Intergas Furthermore all offers of and agreements regarding products Heating Ltd warrants to the authorised installer the soundness of...
  • Page 56 BOILER SYSTEM COMMISSIONING CHECKLIST Intergas Heating Ltd...
  • Page 57: 14. Service Record

    14. SERVICE RECORD Intergas Heating Ltd...
  • Page 58 Intergas Heating Ltd...
  • Page 59 Intergas Heating Ltd...
  • Page 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.co.uk West Midlands 88923700.docx Intergas Heating Ltd...

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