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  5. Installation, Service And User Instructions Manual

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

Summary of Compact HRE 18 SB

  • 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) 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 scheme 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 instr...

  • 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 sb 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 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 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 intergas compact hre sb range of central ...

  • Page 8

    Intergas heating ltd 8 2.4 technical data appliance category c13; c33; c43; c53; c63; c83 gas supply pressure 20 mbar -g20 ; 37 mbar – g31 gas category ii2h3p technical data compact hre 18 sb 24 sb 30 sb sedbuk rating a a a gas council number g.C. 41-291-01 g.C. 41-291-02 g.C. 41-291-03 ch nom. Inpu...

  • Page 9

    Intergas heating ltd 9 2.5 components a. Ch pump k. Flue pipe adapter b. Gas valve l. Air supply cap c. Boiler controller m. Connection block / terminal strip x4 d. Sensor s1 n. Condensate drain pan e. Sensor s2 o. Condensate trap f. Fan p. Heat exchanger g. Ch pressure sensor q. Operating panel and...

  • Page 10

    Intergas heating ltd 10 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 deliver heat to the water in a ch system and when an indirectly heated domestic hot water (dhw) storage cylinder is installe...

  • Page 11

    Intergas heating ltd 11 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 12

    Intergas heating ltd 12 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 13

    Intergas heating ltd 13 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 14

    Intergas heating ltd 14 5 installer handy hints • 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 system if the water pressure falls. The installer should then hand o...

  • Page 15

    Intergas heating ltd 15 6 accessories description article number pipe cover set (incl. Mounting material) 093217 wall mounting frame + exp. Vessel 8 litres hre sb 30 093207 wall mounting frame + exp. Vessel 8 litres hre sb 24 093197 wall mounting frame + exp. Vessel 8 litres hre sb 18 093187 outside...

  • Page 16

    Intergas heating ltd 16 description article number vertical roof terminal 086842 plume management kit 082974 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 robo kit 090000

  • Page 17

    Intergas heating ltd 17 7 installation 7.1 overall dimensions appliance with connections downwards: appliance + mounting bracket + frame 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 h = 780 compact hre sb 24 h = 720 com...

  • Page 18

    Intergas heating ltd 18 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 19

    Intergas heating ltd 19 7.3 assembly the boiler must be mounted on a wall mounting frame with an expansion vessel. The jig can be placed in the sleeves of the frame and does not need any extra assembly. The appliance can also be connected without the wall mounting frame using the robo kit. 7.3.1 fit...

  • Page 20

    Intergas heating ltd 20 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 instructions • operating instructions • warranty card 3. Check the appliance for possib...

  • Page 21

    Intergas heating ltd 21 8 connection 8.1 connecting ch installation 1. Flush the ch system thoroughly to clean. 2. Fit the supply pipe 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 ...

  • Page 22

    Intergas heating ltd 22 8.3 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 working on the electrical circuit always isolate ...

  • Page 23

    Intergas heating ltd 23 8.3.2 on / off room thermostat 1. Connect the room thermostat . 2. Adjust the feedback resistance of the room thermostat to 0.1 a. In case of doubt measure the current and adjust this accordingly . The allowed maximum electrical resistance of the room thermostat and wiring is...

  • Page 24

    Intergas heating ltd 24 8.5 flue system 8.5.1 flue pipe and air supply the boiler utilises a concentric flue arrangement, which consists of a 60 mm- diameter inner flue and 100 mm-diameter outer air inlet duct, which comes in either horizontal or vertical arrangements. Note only use approved interga...

  • Page 25

    Intergas heating ltd 25 8.5.3 horizontal flue system the 60/100 mm horizontal flue system may be extended up to a maximum of 15 metres. For every bend used the following flue length reductions apply: - 45° bend = 1 metre and for a 90° bend this is 1,5 metres. Caution only an intergas approved flue i...

  • Page 26

    Intergas heating ltd 26 9 commissioning the appliance at the time of commissioning, complete all relevant sections of the benchmark checklist located on page 43 of this document. 9.1 filling and venting the appliance and the installation 9.1.1 ch system caution if an additive is added to the ch wate...

  • Page 27

    Intergas heating ltd 27 9.1.5 flue system the flue system must be connected correctly to the appliance in accordance with the manufacturer’s instructions. The flue termination should also be checked. Where suitable access for a visual inspection of an existing flue system has not been provided the a...

  • 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. Adjust the diverter valve to manual operation (only when an indirectly heated dhw storage cylinder is applied). 2. Drain the appli...

  • 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 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 33

    Intergas heating ltd 33 10.7 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...

  • Page 34

    Intergas heating ltd 34 a. Co 2 demands at low setting for natural gas the co 2 level at low setting must be equal to or max. 0.3 % lower than the level at high setting. Important: the co 2 level at low setting must never be under 8.6%. For example (natural gas): 1: co 2 level at high setting is 9.2...

  • Page 35

    Intergas heating ltd 35 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 36

    Intergas heating ltd 36 11.2.2 burner ignites noisily possible causes: solution: gas supply pressure to high. ¨ the house pressure switch may be faulty. Contact the gas company . No ª incorrect ignition gap. ¨ replace the ignition pin . Check the ignition electrode gap. No ª gas/air adjustment not c...

  • Page 37

    Intergas heating ltd 37 11.2.5 the power is reduced possible causes: solution: at high rpm the power has fallen by more than 5%. ¨ check appliance and flue system for fouling. Clean the appliance and flue system. 11.2.6 ch does not reach temperature possible causes: solution: room thermostat setting...

  • Page 38

    Intergas heating ltd 38 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 39

    Intergas heating ltd 39 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. Failure to fit the sensors s1 and/or s2, or to fit them cor...

  • Page 40

    Intergas heating ltd 40 13 electrical diagram a earth connections heat-exchanger f fuse (2a t) p1 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 controll...

  • Page 41

    Intergas heating ltd 41 14 short spares list description article number boiler controller 074277 fan 074397 wall mounting strip 145308 temperature sensor (heat exchanger) 200117 ch pump 210177 ignition / ionisation electrode 209367 ignition cable 221357 gas valve siemens 801467 ignition module 80147...

  • Page 42

    Intergas heating ltd 42 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 43

    Intergas heating ltd 43 17 gas boiler system commissioning checklist.

  • Page 44

    Intergas heating ltd 44 18 service record.

  • Page 45

    Intergas heating ltd 45 __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ ______________________________________________...

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    Intergas heating ltd 46 __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ ______________________________________________...

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    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 88322702 intergas heating limited unit 6, west court buntsford park road bromsgrove worcestershire b60 3dx telephone : 01527 888000 fax : 01527 888001 info@intergasheatin...