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  5. Installation, Service And User Instructions Manual

Intergas Combi Compact HRE 24/18 Installation, Service And User Instructions Manual

Summary of Combi Compact HRE 24/18

  • Page 1

    Intergas heating ltd 1 combi compact hre 24/18 (g.C. 47-291-01) hre 28/24 (g.C. 47-291-02) hre 36/30 (g.C. 47-291-03) hre 36/40 (g.C. 47-291-04) installation, service and user instructions please read these installation instructions carefully before installing and using the appliance. Keep these ins...

  • 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 8.5 flue system ................................................................................................................................................................................... 27 9 commissioning the appliance 30 9.1 filling and venting the appliance and the...

  • Page 4

    Intergas heating ltd 4 1 preface 1.1 regulation the intergas combination boiler meets the requirements of statutory instrument 'the boiler (efficiency) regulations' and is deemed to meet the requirements of: • gas appliance directive 2009/142/ec • boiler efficiency directive 92/42/eec • low voltage ...

  • Page 5

    Intergas heating ltd 5 1.6 abbreviations and descriptions used description referred to as high efficiency he intergas combi compact hre wall mounted gas fired boiler appliance appliance plus pipe work for central heating ch installation appliance plus pipe work for domestic hot water dhw installatio...

  • 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 combi compact hre high efficie...

  • Page 7

    Intergas heating ltd 7 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 combi compact hre 24/18 28/24 36/30 36/40 gas council number g.C. 47-291-01 g.C. 47-291-02 g.C. 47-291-03 g.C. 47-291-04 dhw input ...

  • Page 8

    Intergas heating ltd 8 2.5 technical 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 combi compact hre 24/18 28/24 36/30 36/40 seasonal space heati...

  • Page 9

    Intergas heating ltd 9 2.6 components 03010092 a ch pump l. Air supply cap (not te be removed) b gas valve m. Flue pipe adapter (only to be used in combination with the accompanying elbow in flue sets). C boiler controller n. Connection block / terminal strip x4 d sensor s1 o. Condensate drain pan e...

  • Page 10

    Intergas heating ltd 10 3 general boiler information 3.1 general the intergas combi compact hre wall mounted, gas fired boiler is a closed appliance. The appliance is designed to transfer heat to the water circuit in a ch system and the dhw installation. The air supply and combustion gas flue connec...

  • Page 11

    Intergas heating ltd 11 4 operation 4.1 general the intergas combi compact hre wall mounted, gas fired boiler is a modulating high efficiency boiler. This means that the power is adjusted in line with the desired heat requirement. The aluminium heat exchanger comprises of two separate copper circuit...

  • Page 12

    Intergas heating ltd 12 0 pump overrun of ch after the end of ch operation the pump continues to run. The running time is factory set at the value in accordance with § 10.3. This setting can be changed. In addition, the pump runs automatically for 10 seconds once every 24 hours in order to prevent s...

  • Page 13

    Intergas heating ltd 13 7 pre-heating facility to enable fast delivery of domestic hot water the boiler controller is equipped with a dhw comfort function. This function maintains the temperature of the heat exchanger to a pre defined temperature. The dhw comfort function has the following settings:...

  • Page 14

    Intergas heating ltd 14 4.8 frost protection frost protection to prevent freezing the appliance is equipped with an internal frost protection. If the heat exchanger temperature falls too low, the burner switches on and the pump runs until the heat exchanger temperature is sufficient. When the applia...

  • 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 outside sensor 203207 wall mounting jig + exp. Vessel 8 litres hre 36/30 and hre 36/40 093207 wall mounting jig + exp. Vessel 8 litres hre 28/24 093197 wall mounting jig + exp. Vessel 8 l...

  • Page 17

    Intergas heating ltd 17 description article number vertical roof terminal (incl. Boiler adapter 60/100) 082973 plume management kit 081294 elbow 90° (for plume management kit) 081284 elbow 60° (for plume management kit) 081285 extension l = 100 incl. Wall bracket (for plume management kit) 081286 ro...

  • Page 18

    Intergas heating ltd 18 7 installation 7.1 overall dimensions appliance with ch, dhw and gas connections backwards: appliance + wall mounting jig + bracket a = supply ch Ø22 b = return ch Ø22 c = gas Ø22 d = cold tap water Ø15 e = dhw Ø15 f = condensate drain Ø25 (flexible) g = drain prv Ø15 h = 840...

  • 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. 2. Check the contents of the packaging. It consists of: • appliance (a) • wall mounting strip (b) • condensate trap (c) • installation and operation instructions and warranty card • templates for either wall or jig mountin...

  • Page 22

    Intergas heating ltd 22 8 connection 8.1 connecting ch installation 1. Flush the ch system thoroughly (please refer to current standard codes of practice). 2. Fit the flow and return pipes to the isolation valves. 3. All pipes must be fitted unstressed in order to prevent the pipes from ticking. 4. ...

  • Page 23

    Intergas heating ltd 23 8.2 connecting dhw installation 1. Flush the installation thoroughly to clean (please refer to current standard codes of practice). 2. Fit the cold and hot water pipes into the shut off valve and the elbow. 3. Existing connections must not be twisted, in order to avoid leakag...

  • Page 24

    Intergas heating ltd 24 8.3 electrical connection caution a 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. Slid...

  • Page 25

    Intergas heating ltd 25 8.3.2 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 26

    Intergas heating ltd 26 8.4 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 ...

  • Page 27

    Intergas heating ltd 27 8.5 flue system 8.5.1 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 or vertical flue pipes. For the appropriate types see chapter 6 accessories. Note only use approved interg...

  • Page 28

    Intergas heating ltd 28 8.5.3 length flue pipe and air inlet the following lengths (l = meters) for the combustion system are valid: hre 24/18 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 28/...

  • Page 29

    Intergas heating ltd 29 8.5.6 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 ...

  • Page 30

    Intergas heating ltd 30 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 31

    Intergas heating ltd 31 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 32

    Intergas heating ltd 32 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 c - button 4 desired temperature of ch or dhw in °c /...

  • Page 33

    Intergas heating ltd 33 9.3 setting and adjusting the clock functions 9.3.1 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 ...

  • 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 legionella prevention (only applicable when using external tank and w-plan) 0 0 0 0 0 = legionella prevention disabled. 1 = legionella prevention weekly 2 = legionella prevention daily l set point ch (flow temperature) during heating external dhw tank 85 85 85 85 adjustment r...

  • Page 37

    Intergas heating ltd 37 10.6 setting maximum ch power the maximum ch power is set at 70% in the factory. If more or 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 the ...

  • Page 38

    Intergas heating ltd 38 10.8 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...

  • Page 39

    Intergas heating ltd 39 10.9 checking the gas air ratio control 10.9.1 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 t...

  • Page 40

    Intergas heating ltd 40 10.9.2 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 10.9.3 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 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 § 10.9.1) 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...

  • Page 43

    Intergas heating ltd 43 10.10 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 rin...

  • 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 main display. Once the fault has been rectified the boiler controller can be restarted. Press the reset key on the operating panel. The f...

  • 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 too low. Contact the gas supply company. No no ignition. Replace ignition electrode. No no spar...

  • Page 46

    Intergas heating ltd 46 11.2.4 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 11.2.8 hot water does not reach temperature possible causes: solution: dhw flow to high. Adjust the inlet assembly. No temperature setting for water circuit too low. Set the hot water circuit, depending on the desired temperature. No no heat transfer as a result of lime scale...

  • 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 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...

  • Page 50

    Intergas heating ltd 50 13 electrical connections 13.1 electrical wiring a earth connections heat-exchanger f fuse (2a 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 s...

  • Page 51

    Intergas heating ltd 51 14 short spares list description article number fan 24 v, hre 24/18, 28/24 & 36/30 074507 fan 230 v, hre 36/40 074577 wall mounting strip 145308 temperature sensor (heat exchanger) 200117 temperature sensor (dhw) 200127 ch pump hre 24/18, 28/24 & 36/30 (wilo yonos para rs15-7...

  • Page 52

    Intergas heating ltd 52 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 53

    Intergas heating ltd 53.

  • 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 building 94, bay 1 vantage point fax: 01384 279480 88287802 the pensnett estate info@intergasheating.Co.Uk kingswinford www.Interga...