1. DL manuals
  2. Intergas
  3. Boiler
  4. 24 SB (G.C. 41-291-02)
  5. Installation, Service And User Instructions Manual

Intergas 24 SB (G.C. 41-291-02) Installation, Service And User Instructions Manual

Summary of 24 SB (G.C. 41-291-02)

  • Page 1

    Intergas heating ltd 1 compact hre 18 sb (g.C. 41-291-01) 24 sb (g.C. 41-291-02) 30 sb (g.C. 41-291-03) 40 sb (g.C. 41-291-07 ) installation, service and user instructions please read these installation instructions carefully before installing and using the appliance. Keep these installation instruc...

  • Page 2

    Intergas heating ltd 2 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 compet...

  • Page 3

    Intergas heating ltd 3 9 commissioning the appliance 29 9.1 filling and venting the appliance and the installation .................................................................................................................... 29 9.2 commissioning the appliance ....................................

  • Page 4

    Intergas heating ltd 4 1 preface 1.1 regulation the intergas boiler meets the requirements of statutory instrument 'the boiler (efficiency) regulations' and is deemed to meet the requirements of: • gas appliance directive 90/396/eec • boiler efficiency directive 92/42/eec • low voltage directive 200...

  • Page 5

    Intergas heating ltd 5 frost protection procedures which must be followed to prevent frost damage. 1.6 abbreviations and descriptions used description referred to as high efficiency he intergas compact hre sb wall mounted gas fired boiler appliance appliance plus pipe work for central heating ch ins...

  • Page 6

    Intergas heating ltd 6 2 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 compact hre sb high efficiency...

  • Page 7

    Intergas heating ltd 7 2.3 approvals natural gas intergas compact hre sb pre-mix condensing system boiler british gas service listing: compact hre 40 sb g.C.N. 41-291-07 compact hre 30 sb g.C.N. 41-291-03 compact hre 24 sb g.C.N. 41-291-02 compact hre 18 sb g.C.N. 41-291-01 notified /body the interg...

  • Page 8

    Intergas heating ltd 8 2.4 technical data appliance category c13; c33; c43; c53; c83 gas supply pressure 20 mbar -g20 ; 37 mbar – g31 gas category ii2h3p technical data compact hre 18 sb 24 sb 30 sb 40 sb gas council number g.C. 41-291-01 g.C. 41-291-02 g.C. 41-291-03 g.C. 41-291-07 ch nom. Input ra...

  • Page 9

    Intergas heating ltd 9 2.5 product fiche according to celex-32013r0811, annex iv supplier intergas heating ltd building 94, bay 1 vantage point the pensnett estate kingswinford west midlands dy6 7fs type designation symbol unit compact hre 18 sb 24 sb 30 sb 40 sb seasonal space heating energy effici...

  • Page 10

    Intergas heating ltd 10 2.6 components a. Ch pump k. Sight glass b. Gas valve l. Air supply cap c. Boiler controller m. Flue pipe adapter (only to be used in combination with the accompanying elbow in flue sets). D. Sensor s1 n. Connection block / terminal strip x4 e. Sensor s2 o. Condensate drain p...

  • Page 11

    Intergas heating ltd 11 3 general boiler information 3.1 general the intergas compact hre sb wall mounted, gas fired boiler is a closed appliance. The appliance is intended to transfer heat to the water circuit in a ch system and when an indirectly heated domestic hot water (dhw) storage cylinder is...

  • Page 12

    Intergas heating ltd 12 4 operation 4.1 general the intergas compact hre sb wall mounted, gas fired system boiler is a modulating high efficiency boiler. This means that the power is adjusted in line with the desired heat requirement. The appliance is equipped with an electronic boiler controller wh...

  • Page 13

    Intergas heating ltd 13 5 ch operation an on/off thermostat, an opentherm thermostat, an external sensor or a combination of the latter can be connected to the boiler controller. When a request for heat is received from a thermostat, the fan is started (code 3 ), followed by ignition (code 4 ) and c...

  • Page 14

    Intergas heating ltd 14 4.6 test programs the boiler controller has a facility for placing the appliance in test mode. Activation of a test program will result in the appliance starting operation at a fixed fan speed, without the control functions being actuated. The safety functions do remain activ...

  • Page 15

    Intergas heating ltd 15 5 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-pressurise the syst...

  • Page 16

    Intergas heating ltd 16 6 accessories description article number pipe cover set (incl. Mounting material) 093217 wall mounting jig + exp. Vessel 8 litres hre sb 30 & sb 40 093207 wall mounting jig + exp. Vessel 8 litres hre sb 24 093197 wall mounting jig + exp. Vessel 8 litres hre sb 18 093187 outsi...

  • Page 17

    Intergas heating ltd 17 description article number horizontal telescopic offset wall terminal only to be used in combination with the base adapter on the boiler 081298 vertical roof terminal (incl. Boiler adapter 60/100) 082973 plume management kit 081294 elbow 90° ((for plume management kit) 081284...

  • Page 18

    Intergas heating ltd 18 7 installation 7.1 overall dimensions appliance inclusive wall mounting jig: appliance + wall mounting jig + bracket a = supply ch Ø22 b = return ch Ø22 c = gas ½” f = condensate drain Ø25 (flexible) g = drain prv Ø15 h= 840 (*) compact hre sb 30 & sb 40 h = 780 compact hre s...

  • Page 19

    Intergas heating ltd 19 7.2 installation location • if the boiler is to be installed in any room or compartment, it does not require any purpose made ventilation for combustion air. If sited in a room containing a bath or shower then particular reference is drawn to the current i.E.E. Wiring regulat...

  • Page 20

    Intergas heating ltd 20 7.3 assembly the boiler can be mounted either on the fixing strip which is supplied in the box or to a wall mounting jig with an expansion vessel. The wall mounting jig includes an expansion vessel and shut off valves. If the fixing strip is used an external robo kit must be ...

  • Page 21

    Intergas heating ltd 21 7.4 installing the appliance 1. Unpack the appliance. 1. Check the contents of the packaging. It consists of: • appliance (a) • fixing strip (b) • condensate trap (c) • installation instructions and operating instructions • warranty card • templates for either wall or jig mou...

  • Page 22

    Intergas heating ltd 22 8 connection 8.1 connecting ch installation 1. Flush the ch system thoroughly to clean. 2. Fit the flow and the return pipe into the shut off valves. 3. All pipes must be fitted unstressed in order to prevent the pipes from ticking. 4. Existing connections must not be twisted...

  • Page 23

    Intergas heating ltd 23 8.2 electrical connection caution a 3 amp fused spur or an unswitched socket must be located no more than 1 metre from the appliance. For installation in damp rooms a fixed connection is obligatory. When working on the electrical circuit always isolate the electric supply . 1...

  • Page 24

    Intergas heating ltd 24 8.2.2 on / off room thermostat (low voltage) 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 ...

  • Page 25

    Intergas heating ltd 25 8.3 condensate disposal the appliance is provided with a 25 mm flexible pipe from its condensate trap. Connect the flexible tube from the condensate to the drain via an open connection. Caution always fill the condensate trap with water and place it on the boiler before power...

  • Page 26

    Intergas heating ltd 26 8.4 flue system 8.4.1 flue pipe and air supply the boiler utilises a special concentric flue adapter which can only be used with the elbow that is part of the horizontal flue pipes. For the appropriate types see chapter 6 accessories. When using a vertical flue system the ada...

  • Page 27

    Intergas heating ltd 27 8.4.3 length flue pipe and air inlet the following lengtths (l = meters) for the combustion system are valid: hre 18 sb c13(1) c33(2) c13(1) c33(2) c53(3) c33(4) 60/100 60/100 twin-80 twin-80 60/100 l1 60 l2 60/100 l1 80 l2 l l l l 10.2 11 37.6 37.6 7 1 9 1 1 12 1 33.7 hre 24...

  • Page 28

    Intergas heating ltd 28 8.4.6 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 ...

  • Page 29

    Intergas heating ltd 29 9 commissioning the appliance at the time of commissioning, complete all relevant sections of the benchmark checklist located in section 17 of this document. 9.1 filling and venting the appliance and the installation 9.1.1 ch system caution when an additive is added to the ch...

  • Page 30

    Intergas heating ltd 30 9.1.4 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...

  • Page 31

    Intergas heating ltd 31 9.2 commissioning 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 (not applicable for compact hre sb ) c - button 4 des...

  • Page 32

    Intergas heating ltd 32 9.3 setting and adjusting the clock functions note setting and adjusting the clock is only applicable when using the boiler as “heat only” or in combination with a system as mentioned under § 8.1.3 . When using a s and y plan wired system the clock always has to be set on “c-...

  • Page 33

    Intergas heating ltd 33 9.5 shutting down caution drain the appliance and the installation if mains power has been interrupted and there is a possibility of freezing. 1. Adjust all valves to manual operation. 2. Drain the appliance at the drain tap. 3. Drain the installation at the lowest point. 9.5...

  • Page 34

    Intergas heating ltd 34 10 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. 10.1 directly via the...

  • Page 35

    Intergas heating ltd 35 10.2 setting via the service code the boiler controller in the appliance is factory set in accordance with the parameters. These parameters can only be changed using the service code. Proceed as follows to activate the program memory: 1. Press the and keys simultaneously unti...

  • Page 36

    Intergas heating ltd 36 max. Fan rpm 45 44 48 65 adjustment range: nominal value ± 200 rpm. With this parameter the maximum rpm can be set. H legionella prevention (only applicable when using external tank and w-plan) 0 0 0 0 0 = legionella prevention disabled. 1 = legionella prevention weekly 2 = l...

  • Page 37

    Intergas heating ltd 37 10.5 setting maximum ch power the maximum ch power is set at maximum (85% ) in the factory. If less power is necessary for the ch installation, the maximum ch power can be changed by changing the fan rpm. See table setting ch power. This table shows the relationship between t...

  • Page 38

    Intergas heating ltd 38 10.7 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...

  • Page 39

    Intergas heating ltd 39 10.8 checking the gas air ratio control 10.8.1 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 t...

  • Page 40

    Intergas heating ltd 40 10.8.2 checking flue gas at minimum output before measuring the flue gasses at minimum output the measurement of the maximum output must be completed. The measured o 2 or co 2 value at maximum output is important for determining the correct value for the measurement at minimu...

  • Page 41

    Intergas heating ltd 41 10.8.3 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 o 2 or co 2 value at maximum output is important for determining the correct value for the measu...

  • Page 42

    Intergas heating ltd 42 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 § 10.8.1) 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...

  • Page 43

    Intergas heating ltd 43 10.9 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...

  • Page 44

    Intergas heating ltd 44 11 faults 11.1 fault codes if the fault led is flashing, the boiler controller has detected a fault. A fault code will be indicated on the temperature display. Once the fault has been rectified the boiler controller can be restarted. Press the reset key on the operating panel...

  • Page 45

    Intergas heating ltd 45 11.2 other faults 11.2.1 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 to low. Contact the gas supply company. No no ignition. Replace ignition electrode. No no spark...

  • Page 46

    Intergas heating ltd 46 11.2.5 no heating (ch) possible causes: solution: room thermostat / weather-dependent adjustment not closed or faulty. Check the wiring. Replace the thermostat. Replace the weather-dependant adjustment. No no current (24 v). Check the wiring against the diagram. Check the con...

  • Page 47

    Intergas heating ltd 47 11.2.9 hot water does not reach temperature (only when an indirectly heated dhw storage cylinder is applied) solution: temperature setting for dhw storage cylinder too low. Set the dhw storage cylinder temperature. See 10 setting and adjustment. 11.2.10 led on ch pump is flas...

  • Page 48

    Intergas heating ltd 48 12 maintenance 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: 1. Cross head screwdriver 2. Allen key 8 mm 3. Fork spanner 30 mm after servicing, com...

  • Page 49

    Intergas heating ltd 49 12.3 assembly caution it is recommended that the front plate seal is replaced every time the front plate is removed from the heat exchanger. When fitting the remaining seals check for damage, hardening, tears or hairline tears and/or discoloration. Where necessary fit a new s...

  • Page 50

    Intergas heating ltd 50 13 electrical diagram 13.1 electrical diagram hre sb a earth connections heat-exchanger f fuse (2a t) p1 ch pump v fan b spark plug cover g gas valve + ignition unit s1 flow sensor c boiler controller i ionisation-/ ignition probe s2 return sensor e earth connections boiler c...

  • Page 51

    Intergas heating ltd 51 13.3 typical y plan connection 13.4 typical s plan connection..

  • Page 52

    Intergas heating ltd 52 14 short spares list description article number fan 24 v, hre 18 sb, 24 sb & 30 sb 074507 fan 230 v, hre 40 sb 074577 fixing strip 145308 temperature sensor (heat exchanger s1 & s2) 200117 temperature sensor (dhw) 200127 ch pump hre 24/18, 28/24 & 36/30 (wilo yonos para rs15-...

  • Page 53

    Intergas heating ltd 53 15 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 ...

  • Page 54

    Intergas heating ltd 54 17 gas boiler system commissioning checklist.

  • Page 55

    Intergas heating ltd 55 18 service record.

  • Page 56

    Intergas heating ltd 56 intergas boilers are manufactured in a kiwa iso 9001 certified production faccility. Intergas heating ltd intergas heating ltd tel: 01527 888000 88322802 building 94, bay 1 vantage point fax: 01384 279480 the pensnett estate info@intergasheating.Co.Uk kingswinford www.Interga...