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Operating Instructions
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Please read these installation instructions carefully before installing and using
the appliance. Keep these installation instructions with the appliance.
Always act in accordance with the instructions indicated.
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Summary of Contents for Intergas 18OV
- Page 1 &RPSDFW +5( 29 *& 29 *& 29 *& ,QVWDOODWLRQ VHUYLFH DQG XVHU LQVWUXFWLRQV Please read these installation instructions carefully before installing and using the appliance. Keep these installation instructions with the appliance. Always act in accordance with the instructions indicated. ,QWHUJDV +HDWLQJ /WG...
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Page 2: Table Of Contents
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 competent persons and that it meets the requirements of the appropriate Building Regulations. The Benchmark Checklist can be used to demonstrate compliance with Building Regulations and should be provided to the customer for future reference. - Page 3 © 2015 Intergas Heating Ltd. All rights reserved. The information provided applies to the standard version of the product. Intergas Heating Ltd cannot therefore be held liable for any loss or damage arising from product specifications deviating from the standard version. The available information has been compiled with all possible care, but Intergas Heating Ltd cannot be held liable for any errors in the information or for the consequences thereof.
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Page 4: Preface
• Electromagnetic Compatibility Directive 2004/108/EC • Intergas declares that the materials used in the manufacturing of this appliance are non- hazardous and that no substances harmful to health are contained within the appliance. 1.2 Warnings Intergas accepts no responsibility for the unsatisfactory performance of the appliance or flue arising from the failure to comply with the installation and user instructions. -
Page 5: Abbreviations And Descriptions Used
1.6 Abbreviations and descriptions used Description Referred to as High efficiency 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 1.7 This manual... -
Page 6: Safety Regulations
Directive 90/396/EEC Directive 92/42/EEC The Intergas Compact HRE OV range of central heating boilers are manufactured from high quality materials and designed for reliability and optimum performance. Intergas is committed to the continual development of their appliances and reserves the right to make changes without notification to ensure their customers benefit from the latest advances in combustion technology and energy conservation. -
Page 7: Technical Data
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 SEDBUK Rating Gas Council number G.C. 41-291-04 G.C. 41-291-05 G.C. 41-291-06 Nom. -
Page 8: Product Fiche According To Celex-32013R0811, Annex Iv
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 Seasonal space heating energy efficiency class Heat rated output... -
Page 9: Components
2.6 Components Flue adapter (only to be used in combination with the Mains lead 230 V AC without plug (stripped) accompanying elbow in flue sets) Flow CH Condensate trap Return CH Ionisation / Ignition electrode Sight glass Sensor S1 Gas valve Heat exchanger Position of data plate Sensor S2... -
Page 10: General Boiler Information
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 heated domestic hot water (DHW) storage cylinder is installed, apply heat to the DHW installation. -
Page 11: Operation
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 heating system feed tank. -
Page 12: Clock Function
The boiler controller is equipped with an interface for a PC, which can be connected by means of a special cable and associated Intergas Diagnostic Software (IDS). This facility allows the behaviour of the boiler controller, the appliance and the heating installation to be monitored over a longer period. -
Page 13: Test Programs
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 active. The test program is ended by pressing the simultaneously or will end automaticaly after 10 minutes. -
Page 14: Installer Important Points
If you experience any problems please refer to the installation and commissioning • guidelines within the boiler instruction manual. If necessary, please contact Intergas Heating Ltd (See § 1.8). Remember it is a requirement to complete the Benchmark code of practice logbook before leaving the installation. -
Page 15: Accessories
6 ACCESSORIES Description Article number Pipe cover set (incl. mounting material) 093217 Outside sensor 203207 065117 DHW storage cylinder sensor Diverter valve 230 V 092647 Sampling cap 847000 084661 Bend 45° Bend 90° 084660 Deflector kit 081295 087910 Weather slate (steep roof) Weather slate (flat roof) 087372 Extension L = 100 incl. - Page 16 Plume management kit 081294 Elbow 90° (for plume management kit) 081284 081285 Elbow 60° (for plume management kit) Extension L = 100 incl. wall bracket (for plume management kit) 081286 ,QWHUJDV +HDWLQJ /WG...
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Page 17: Installation
7 INSTALLATION 7.1 Overall dimensions Supply CH Ø22 Return CH Ø22 ½” Condensate drain Ø25 (flexible) Drain PRV Ø15 Compact HRE OV 30 Compact HRE OV 24 Compact HRE OV 18 Standard flue pipe Ø60/100 (concentric) Standard off-set flue Ø60/100 (concentric) pipe ,QWHUJDV +HDWLQJ /WG... -
Page 18: Installation Location
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 Regulations, local Building Regulations or any other local regulations currently in service. -
Page 19: Installing The Appliance
7.3 Installing the appliance Unpack the appliance. 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 •... -
Page 20: Connection
8 CONNECTION 8.1 Connecting CH installation Flush the CH system thoroughly to clean. Connect the flue and return pipe to the installation using the enclosed press fittings 22 mm. All pipes must be fitted unstressed in order to prevent the pipes from ticking. Make sure the compression fittings are thightened thoroughly to prevent leakage. -
Page 21: Electrical Connection
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. - Page 22 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 and 7, the loop in 6 –...
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Page 23: Condensate Disposal
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 powering up the boiler. -
Page 24: Flue System
For the appropriate types see chapter 6 Accessories. Note Only use approved Intergas flue products with this boiler, which can be sourced from the supplier of your boiler or Intergas stockist 8.5.2 Flue pipe position Min. - Page 25 The vertical flue system contains a flue adapter concentric 60/100 to replace the standard adapter on the boiler. Please note that the terminal is suitable for a flat or pitched roof and only approved Intergas flue products can be used with this boiler.
- Page 26 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 terminal but excluding the initial elbow from the boiler and 1 metre vertical condensing tube is 8 metre.
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Page 27: Commissioning The Appliance
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 water, ensure it is suitable for the materials used in the appliance, such as copper, brass, stainless steel, steel, plastic and rubber. -
Page 28: Commissioning The Appliance
9.2 Commissioning the appliance Read-out Operation On / off On / Off button CH operation or setting maximum CH temperature DHW / CH button, for setting desired temperature DHW operation or setting DHW temperature (not applicable for Compact HRE OV) - button Desired temperature of CH or DHW in °C / Fault code/ Time + button... -
Page 29: Setting And Adjusting The Clock Functions
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 will make the clock run fast. -
Page 30: Shutting Down
9.5 Shutting down CAUTION Drain the appliance and the installation if mains power has been interrupted and there is a possibility of freezing. Drain the appliance at the drain tap. Drain the installation at the lowest point. 9.5.1 Frost protection To avoid freezing of the condensate drain pipe the appliance must be installed in a •... -
Page 31: Setting And Adjustment
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 operating panel The following functions can be operated directly: 10.1.1... -
Page 32: Parameters
10.3 Parameters Compact HRE OV Factory settings Setting Description Parameter Service code [15] Access to installer settings The service code must be entered (= 15) Installation type 0= Combi 1= Heating only + external DHW tank 2= DHW only (no heating system required) 3= Heating only CH pump continuous 0= post purge period only... -
Page 33: Setting Maximum Ch Power
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 fan rpm and the appliance power. -
Page 34: Gas-Air Ratio Control
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 combination with this gas type. -
Page 35: Checking The Gas Air Ratio Control
10.8 Checking the gas air ratio control 10.8.1 Checking flue gas at maximum power. Switch the appliance off with the button . [-] will appear in service display. Remove the front panel by untightening the 2 screws. Remove the cap X of the flue gas sampling point on the adapter. Position the measuring probe or the flue gas analyser into the sampling point. - Page 36 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 or CO value at maximum output is important for determining the correct value for the measurement at minimum output. See §...
- Page 37 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 or CO value at maximum output is important for determining the correct value for the measurement at minimum output.
- Page 38 Tabel 5a: Determining the correct setting of CO at minimum output for natural gas G20 (open casing) Natural gas G20 (20 mBar) Measured value am maximim power Prescribed value at minimum power (See § 10.8.1) (= 0.5 x CO (H) + 4.2) (H) [%] (L) [%] 9.0 ±0.1...
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Page 39: Conversion To Different Gas Type
When the CO percentage at high setting is not within the prescribed tolerance band please contact Intergas Heating. For adjusting CO level at low setting see § 10.8. 12. Place a sticker for the gas type set over the existing sticker next to the gas valve. -
Page 40: Faults
29,30 Gas valve relay faulty Replace boiler controller • CAUTION Always use original Intergas spare parts when replacing components. Failure to fit the sensors S1 and/or S2, or to fit them correctly can result in serious damage. CAUTION * The boiler is equipped with a non-return valve (A), positioned above the fan. - Page 41 No spark. Ignition unit on gas valve faulty. Check the cabling. Check the spark plug cap. Replace the ignition unit. Gas/air adjustment not correctly set. Check adjustment. See gas/air adjustment. faulty. Check the wiring. Check the fuse , if necessary, replace the fan. Fan dirty.
- Page 42 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 Check appliance and flue system for fouling. Clean the appliance and flue system. 11.2.6 CH does not reach temperature Possible causes:...
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Page 43: Maintenance
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, complete the relevant Benchmark Service Record section located on page 45 of this document. -
Page 44: Assembly
§ 10.8. When the CO level at high setting is not within the prescribed tolerance band please contact Intergas Heating. 03010083 ,QWHUJDV +HDWLQJ /WG... -
Page 45: Electrical Connections
13 ELECTRICAL CONNECTIONS 13.1 Wiring diagram Earth connections heat-exchanger Fuse (3,15AT) External CH pump Spark plug cover Gas valve + ignition unit Flow sensor Boiler controller Ionisation-/ ignition probe Return sensor Earth connections boiler controller Main voltage CH water pressure sensor 3,15AT On/off room thermostat and/or frost thermostat (remove connection 6-7) -
Page 46: Typical Y Plan Connection
13.3 Typical Y Plan connection 13.4 Typical S Plan connection ,QWHUJDV +HDWLQJ /WG... -
Page 47: Short Spares List
14 SHORT SPARES LIST Description Article number Fan with tunnel venturi 074507 Wall mounting strip 145308 Temperature sensor (heat exchanger) 200117 Ignition / ionisation electrode 209367 Ignition cable 074607 Gas valve Siemens 801467 Ignition module 801477 Condensate trap 844187 Condensate collector 847037 Seal gas valve (inlet) 875757... -
Page 48: Warranty Conditions
The warranty is effective only if the annex to this warranty certificate has been signed by the purchaser and returned to With due regard for the conditions indicated below, Intergas Heating us within 8 days of the date of installation. By signing the... -
Page 49: Gas Boiler System Commissioning Checklist
17 GAS BOILER SYSTEM COMMISSIONING CHECKLIST ,QWHUJDV +HDWLQJ /WG... -
Page 50: Service Record
18 SERVICE RECORD ,QWHUJDV +HDWLQJ /WG... - Page 51 __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________...
- Page 52 Intergas boilers are manufactured in a Kiwa ISO 9001 certified production faccility. ,QWHUJDV +HDWLQJ /WG Intergas Heating Ltd Tel: 01527 888000 88324802 Building 94, Bay 1 Vantage Point Fax: 01384 279480 The Pensnett Estate info@intergasheating.co.uk Kingswinford www.intergasheating.co.uk West Midlands DY6 7FS...
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