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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) 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 28 9.1 filling and venting the appliance and the installation .................................................................................................................... 28 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 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 pa...

  • 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 transfer heat to the water circuit in a ch system and when an indirectly heated domestic hot water (dhw) storage cylinder is...

  • 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 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 ch operating mod...

  • 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 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 15

    Intergas heating ltd 15 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 16

    Intergas heating ltd 16 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 17

    Intergas heating ltd 17 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 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 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 20

    Intergas heating ltd 20 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 21

    Intergas heating ltd 21 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 22

    Intergas heating ltd 22 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 23

    Intergas heating ltd 23 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 24

    Intergas heating ltd 24 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 25

    Intergas heating ltd 25 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 adapter on the boil...

  • Page 26

    Intergas heating ltd 26 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 27

    Intergas heating ltd 27 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 28

    Intergas heating ltd 28 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 29

    Intergas heating ltd 29 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 30

    Intergas heating ltd 30 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 31

    Intergas heating ltd 31 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 32

    Intergas heating ltd 32 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 33

    Intergas heating ltd 33 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 34

    Intergas heating ltd 34 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 35

    Intergas heating ltd 35 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 36

    Intergas heating ltd 36 10.6 weather– compensation adjustment when an external sensor is connected the supply temperature is adjusted automatically depending on the outside temperature, in accordance with the heating line set. The maximum supply temperature (tmax) is set via the temperature display....

  • Page 37

    Intergas heating ltd 37 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 38

    Intergas heating ltd 38 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 insert analyser probe. 4. Switch the appliance on with the on/off key....

  • Page 39

    Intergas heating ltd 39 examples : co 2 adustment at low setting for natural gas the co 2 percentage low setting must be equal to or max. 0.3 % lower than the percentage at high setting. Important: the co 2 percentage at low setting must never be under 8.6%. Example 1: co 2 percentage at high settin...

  • Page 40

    Intergas heating ltd 40 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 41

    Intergas heating ltd 41 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. Ignition unit on gas valve faulty. Check the cabling. Check the spark plug cap. Replace the ignition unit. No...

  • Page 42

    Intergas heating ltd 42 replace the faulty manager. No pump not running. Check the power supply. Check connector x2. Replace faulty pump. 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 pow...

  • Page 43

    Intergas heating ltd 43 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 44

    Intergas heating ltd 44 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 45

    Intergas heating ltd 45 13 electrical diagram 13.1 electrical diagram hre 18 sb, 24 sb & 30 sb 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 s...

  • Page 46

    Intergas heating ltd 46 13.2 electrical diagram hre 40 sb 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 boi...

  • Page 47

    Intergas heating ltd 47 13.4 typical y plan connection 13.5 typical s plan connection..

  • Page 48

    Intergas heating ltd 48 14 short spares list description article number boiler controller hre 18 sb, 24 sb & 30 sb 074447 boiler controller hre hre 40 sb 074637 fan 24 v, hre 18 sb, 24 sb & 30 sb 074397 fan 230 v, hre 40 sb 074577 fixing strip 145308 temperature sensor (heat exchanger s1 & s2) 20011...

  • Page 49

    Intergas heating ltd 49 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 50

    Intergas heating ltd 50 17 gas boiler system commissioning checklist.

  • Page 51

    Intergas heating ltd 51 18 service record.

  • Page 52

    Intergas heating ltd 52 intergas boilers are manufactured in a kiwa iso 9001 certified production faccility. Intergas heating ltd 883227-09 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...