1. DL manuals
  2. Intergas
  3. Boiler
  4. Compact HRE 18 OV
  5. Installation, Service And User Instructions Manual

Intergas Compact HRE 18 OV Installation, Service And User Instructions Manual

Summary of Compact HRE 18 OV

  • Page 1

    Intergas heating ltd 1 compact hre 18 ov (g.C. 41-291-04) 24 ov (g.C. 41-291-05) 30 ov (g.C. 41-291-06) installation, service and user instructions please read these installation instructions carefully before installing and using the appliance. Keep these installation instructions with the appliance...

  • 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 26 9.1 filling and venting the appliance and the installation .................................................................................................................... 26 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 1.6 abbreviations and descriptions used description referred to as high efficiency he intergas compact hre ov wall mounted gas fired boiler appliance appliance plus pipe work for central heating ch installation appliance plus pipe work for domestic hot water dhw installation 1...

  • 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 ov high efficiency...

  • 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 compact hre ov 18 24 30 sedbuk rating a a a gas council number g.C. 41-291-04 g.C. 41-291-05 g.C. 41-291-06 ch nom. Input rating (l...

  • Page 8

    Intergas heating ltd 8 2.5 components a. Flue adapter (only to be used in combination with the accompanying elbow in flue sets) j. Mains lead 230 v ac without plug (stripped) b. Flow ch k. Condensate trap c. Return ch m. Ionisation / ignition electrode d. Sight glass n. Fan e. Sensor s1 o. Gas valve...

  • Page 9

    Intergas heating ltd 9 3 general boiler information 3.1 general the intergas compact hre ov wall mounted, gas fired boiler is suitable for use in open vent systems with a heating system feed tank. The appliance is designed to transfer heat to the water circuit in a ch system and when an indirectly h...

  • Page 10

    Intergas heating ltd 10 4 operation 4.1 general the intergas compact hre ov wall mounted, gas fired open vent boiler is a modulating high efficiency boiler. This means that the power is adjusted in line with the desired heat requirement. It is designed to be used in an open vented system with heatin...

  • Page 11

    Intergas heating ltd 11 4 ignition when the fan has reached the starting speed, the burner is ignited by means of electrical sparks. During ignition the code 4 is visible. If the burner does not ignite, a new ignition attempt occurs after approximately 15 seconds. If after 4 ignition attempts the bu...

  • Page 12

    Intergas heating ltd 12 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 13

    Intergas heating ltd 13 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 14

    Intergas heating ltd 14 6 accessories description article number pipe cover set (incl. Mounting material) 093217 outside sensor 203207 dhw storage cylinder sensor 065117 diverter valve 230 v 092647 sampling cap 847000 bend 45° 084661 bend 90° 084660 deflector kit 081295 weather slate (steep roof) 08...

  • Page 15

    Intergas heating ltd 15 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.

  • Page 16

    Intergas heating ltd 16 7 installation 7.1 overall dimensions a = supply ch Ø22 b = return ch Ø22 c = gas ½” f = condensate drain Ø25 (flexible) g = drain prv Ø15 h = 710 compact hre ov 30 h = 650 compact hre ov 24 h = 590 compact hre ov 18 z1= standard flue pipe Ø60/100 (concentric) z2= standard of...

  • Page 17

    Intergas heating ltd 17 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 18

    Intergas heating ltd 18 7.3 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) • pressure fitting 22 mm (2 pcs) • gas isolation valve 15/22 mm compression • installation instruction...

  • Page 19

    Intergas heating ltd 19 8 connection 8.1 connecting ch installation 1. Flush the ch system thoroughly to clean. 2. Connect the flue and return pipe to the installation using the enclosed press fittings 22 mm. 3. All pipes must be fitted unstressed in order to prevent the pipes from ticking. Make sur...

  • Page 20

    Intergas heating ltd 20 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 21

    Intergas heating ltd 21 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 22

    Intergas heating ltd 22 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 23

    Intergas heating ltd 23 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 24

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

  • Page 25

    Intergas heating ltd 25 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 26

    Intergas heating ltd 26 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 27

    Intergas heating ltd 27 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. 9.2 commissioning the appliance read-out operation 1 on / off a on / off button 2 ch operation or s...

  • Page 28

    Intergas heating ltd 28 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 ‘’clock’’ appears. For adjusting the clock to the correct time press the [+] or [-] button. Note: holding the button for more than 1 second w...

  • Page 29

    Intergas heating ltd 29 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. Drain the appliance at the drain tap. 2. Drain the installation at the lowest point. 9.5.1 frost protection • to avoid freezing of...

  • Page 30

    Intergas heating ltd 30 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 31

    Intergas heating ltd 31 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 32

    Intergas heating ltd 32 10.4 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 33

    Intergas heating ltd 33 10.7 checking gas-/air ratio the gas-/air adjustment has been set in the factory and in principle requires no adjustments. The setting can be checked by measuring the co 2 percentage in the combustion gases (x). In the case of possible disturbance of the adjustment, replaceme...

  • Page 34

    Intergas heating ltd 34 10.8 setting gas/air adjustment procedure 1. Switch the appliance off with the on/off key ( - on service display). 2. Remove the front panel from the appliance. 3. Unscrew the co 2 measuring nipple (x) and connect the measuring hose. 4. Switch the appliance on with the on/off...

  • Page 35

    Intergas heating ltd 35 examples : co 2 adustment at low setting for natural gas the co 2 percentage at low setting must be equal to or max. 0.3 % lower than the value at high setting. Important: the co 2 co 2 percentage at low setting must never be under 8.6%. Example 1: co 2 level at high setting ...

  • Page 36

    Intergas heating ltd 36 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 pane...

  • Page 37

    Intergas heating ltd 37 no ignition. Replace ignition electrode. No no spark. Ignition unit on gas valve faulty. Check the cabling. Check the spark plug cap. Replace the ignition unit. No gas/air adjustment not correctly set. Check adjustment. See gas/air adjustment . No fan faulty . Check the wirin...

  • Page 38

    Intergas heating ltd 38 no burner not firing on ch: sensor s1 or s2 faulty. Replace sensor s1 or s2. See fault code. No burner does not ignite. See burner does not ignite. 11.2.5 the power is reduced possible causes: solution: at high rpm the power has fallen by more than 5%. Check appliance and flu...

  • Page 39

    Intergas heating ltd 39 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. Adjustable spanner after servicing, com...

  • Page 40

    Intergas heating ltd 40 12.4 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. Warranty will be void by not correctly replacing removed pa...

  • Page 41

    Intergas heating ltd 41 13 electrical diagram a earth connections heat-exchanger f fuse (2a t) p1 external ch pump s7 ch water pressure sensor b spark plug cover g gas valve + ignition unit r resistance v fan c boiler controller i ionisation-/ ignition probe s1 flow sensor e earth connections boiler...

  • Page 42

    Intergas heating ltd 42 13.2 typical y plan connection 13.3 typical s plan connection.

  • Page 43

    Intergas heating ltd 43 14 short spares list description article number boiler controller 074277 fan 074397 wall mounting strip 145308 temperature sensor (heat exchanger) 200117 ignition / ionisation electrode 209367 ignition cable 074607 gas valve siemens 801467 ignition module 801477 condensate tr...

  • Page 44

    Intergas heating ltd 44 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 45

    Intergas heating ltd 45 17 gas boiler system commissioning checklist.

  • Page 46

    Intergas heating ltd 46 18 service record.

  • Page 47

    Intergas heating ltd 47 __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ ______________________________________________...

  • Page 48

    Intergas heating ltd 48 intergas boilers are manufactured in a kiwa iso 9001 certified production faccility. Intergas heating ltd 883247-08 intergas heating ltd tel: 01527 888000 building 94, bay 1 vantage point fax: 01384 279480 the pensnett estate info@intergasheating.Co.Uk kingswinford www.Interg...