Intergas HSE-125-N Installation And Service Manual
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Intergas HSE-125-N Installation And Service Manual

Gas-fired condensing boiler and instantaneous water heater
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WARNING
If the information in this manual is not followed exactly, a fire or explosion may result causing
property damage, personal injury or loss of life.
• Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any
other appliance.
• WHAT TO DO IF YOU SMELL GAS
- Do not try to light any appliance.
- Do not touch any electrical switch; do not use any phone in your building.
- Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's
instructions.
- If you cannot reach your gas supplier, call the fire department.
• Installation and service must be performed by a qualified installer, service agency or the gas
supplier.
• Improper, installation, adjustment, alteration, service or maintenance can cause property damage,
personal injury or loss of life. Read all instructions before installation or service.
• Save this manual for future reference.
Manufacturers of Gas and Electric Boilers, Stainless Steel Tanks, Heat Exchangers and Electric Boosters.
94 Riverside Drive, North Vancouver, BC V7H 2M6 • Tel: (604) 929-1214 • www.alliedboilers.com
PN7331833
INSTALLATION AND SERVICE MANUAL
Allied Engineering Company
Division of E-Z-Rect Manufacturing Ltd.
Model: HSE – 125 – N/P
Gas-fired Condensing Boiler and
Instantaneous Water Heater
EEV 246473

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  • Page 1 INSTALLATION AND SERVICE MANUAL Model: HSE – 125 – N/P Gas-fired Condensing Boiler and Instantaneous Water Heater EEV 246473 WARNING If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life. •...

  • Page 2: Table Of Contents

    HSE Installation and Service Manual Table of Contents Section Page About Our Manuals............................5 Abbreviations and Names Used ........................5 Icons ................................5 Technical Support............................5 Technical Specifications ..........................6 Major Components ............................7 Dimensions ..............................8 Description of Appliance ..........................9 Section 1 –...
  • Page 3 HSE Installation and Service Manual 1.7.9.1 Horizontal Twin Tube Side Venting with a Combined Terminal Cap..........28 1.7.9.2 Horizontal Twin Tube Side Venting with Twin Terminal Caps ............29 1.7.9.3 Vertical (Roof Top) Twin Tube Venting with Twin Terminal Caps..........29 1.7.9.4 Vertical (Roof Top) Twin Tube Venting with Air Supply from Side Wall ........
  • Page 4 HSE Installation and Service Manual 4.2.8.2 Check the Gas-Air Ratio ....................... 53 4.2.8.3 Check Burner Flame ........................53 4.2.9 Completion of Inspection and Service ..................54 4.2.10 Review the Service with Owner ....................54 Service Checklist .......................... 55 Caution: Water Replenishment ..................... 56 Refractory Handling Procedure.....................

  • Page 5: About Our Manuals

    HSE Installation and Service Manual ABOUT OUR MANUALS Your Super Hot Intergas appliance has been provided with two manuals: User's Information Manual - This manual is intended for the owner or user of the appliance and • provides information on routine operation and maintenance, and emergency shutdown.

  • Page 6: Technical Specifications

    HSE Installation and Service Manual TECHNICAL SPECIFICATIONS HSE-125-N HSE-125-P Technical data Natural Gas Propane CH (central heating – BOILER) Nominal input rate* 1000 Btu/h (kW) 28.7 – 124 (8.4 – 36.3) Nominal output rate 1000 Btu/h (kW) 27.3 – 118 (8.0 – 34.5)

  • Page 7: Major Components

    HSE Installation and Service Manual MAJOR COMPONENTS CH pump Flue discharge Gas valve Wiring connecting block / terminal Burner controller with operating panel Condensate discharge Supply sensor S1 DHW sensor S3 Return sensor S2 Condensate trap Blower Heat exchanger DHW Flow switch Operating and display panel CH Pressure gauge Ionisation/ignition probe...

  • Page 8: Dimensions

    HSE Installation and Service Manual DIMENSIONS 17.7” 450mm 4.7” 4.7” 3.5” 120mm 120mm 90mm Y, Z 2.6” 65mm 5.3” 4.5” 7.9” 135mm 200mm 115mm 2.0” 2.6” 2.6” 2.6” [65mm] A,B,C 65mm 65mm 50mm 2.0” [50mm] 2.6” 2.6” 3.2” 1.2/1.4”[30/35mm] 65mm 65mm 80mm 10.6”...

  • Page 9: Description Of Appliance

    HSE Installation and Service Manual DESCRIPTION OF THE APPLIANCE The Super Hot Intergas HSE is a combined high efficiency condensing boiler and instantaneous water heater that is designed for providing Central Heating (CH) and/or Domestic Hot Water (DHW). The actual required input rate for CH and DHW can be independently programmed lower than the maximum input rate to match the user’s design heating load and required DHW supply.

  • Page 10: Section 1 - Installation Instructions

    HSE Installation and Service Manual Installation Instructions Section 1 RECEIVING, MOVING AND UNPACKING INSPECT SHIPMENT FOR POSSIBLE DAMAGE. All goods are carefully manufactured, inspected, checked and packed by experienced workers. The manufacturer's responsibility ceases upon delivery of goods to the carrier in good condition. Any claims for damage and/or shortage in shipment or non-delivery must be filed immediately against the carrier by the consignee.

  • Page 11: Location And Installations

    HSE Installation and Service Manual LOCATION AND INSTALLATION 1.3.1 LOCATION This appliance is intended for an indoor, wall hung installation using the wall mounting strip or optional mounting frame. The appliance should be mounted on a wall with sufficient bearing strength.

  • Page 12: Remove Front Panel

    HSE Installation and Service Manual 1.3.5 REMOVE FRONT COVER Remove the front cover on the appliance as follows, refer to Figure 3: 1. Unscrew both screws (B) at the bottom of the appliance. 2. Lift the front panel (C) and remove it forward. 1.3.6 MOUNTING There are two types of mounting methods.

  • Page 13: Install The Condensate Trap

    HSE Installation and Service Manual 1.3.7 INSTALL THE CONDENSATE TRAP (Refer to Figure 6) WARNING Risk of exhaust gases escaping to the appliance room! The condensate trap must always be filled with water or condensate so that it forms a liquid-filled trap. Check the trap and, if low, fill it until water begins to pour out of the drain.
  • Page 14 HSE Installation and Service Manual All pipes must be installed tension-free in order to avoid ticking of the pipes. The connections must not be twisted in order to avoid leaks at the joint points. 2. The CH system is recommended with: A make up water loop in the system below the appliance as shown in figure 8.

  • Page 15: Pressure Relief Valve

    HSE Installation and Service Manual 1.4.1.2 PRESSURE RELIEF VALVE WARNING The pressure relief valve discharges pressurized hot water which can turn into steam. Steam exiting the discharge outlet can explosively expand in all directions. Always maintain a safe distance from the discharge pipe outlet in order to avoid potential contact with exiting hot water or steam and injury.

  • Page 16: Corrosion Prevention (Internal)

    HSE Installation and Service Manual 1.4.1.6 CORROSION PREVENTION (Internal) The use of oxygen barrier tubing is recommended to protect the system and its components (e.g. pump) from corrosion. Should your system include "non-oxygen barrier” tubing please contact the factory or a heating professional for recommendations.

  • Page 17: Pressure Relief Valve Or Temperature And Pressure Relief Valve

    HSE Installation and Service Manual 1.4.2.3 PRESSURE RELIEF VALVE OR TEMPERATURE AND PRESSURE RELIEF VALVE A pressure relief valve must be installed near the domestic hot water outlet. If the unit is connected to a separate storage vessel, the separate vessel must have its own temperature and pressure relief valve.

  • Page 18: Electrical Connection

    HSE Installation and Service Manual outside the appliance jacket and as required in Section 1.2. The valve should be readily accessible for turning on and off. When a vertical section of gas piping is supplied on the upstream side of the gas controls, a drip pocket or sediment trap must be installed at the inlet of gas connection to the appliance (in the gas supply line upstream of the gas controls and as close to the appliance as possible), example shown in Figure 10.
  • Page 19 HSE Installation and Service Manual A Ground terminal heat exchanger Fuse (3.15A T) CH pump DHW sensor B Cable of ignition/flame sensor Gas valve Resistor Flow switch DHW C Burner controller Ionisation/Ignition probe CH Flow sensor High limit E Ground terminals burner controller Power supply CH Return sensor Flue sensor...

  • Page 20: Venting And Combustion Air

    HSE Installation and Service Manual VENTING AND COMBUSTION AIR DEFINITIONS A direct vent (a balanced flue) appliance – an appliance that operates with all air for combustion obtained from the outdoor atmosphere and all flue gases discharged to the outdoor atmosphere. A non-direct vent appliance –...

  • Page 21: Corrosive Atmosphere

    HSE Installation and Service Manual Installation Code, CAN/CSA B149.1. When re-sizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Part 11 of the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or the Natural Gas and Propane Installation Code, CAN/CSA B149.1.

  • Page 22: Vent Terminal Information

    HSE Installation and Service Manual PP venting tube and components: In Canada, M&G: PP system, certified type of ULC S636 • In USA, ANSI/ASTM, PP system, certified type • Stainless steel venting tube and components (certified types for Category IV): Flexmaster Canada Ltd.: Z-Vent •...
  • Page 23 HSE Installation and Service Manual b) on any wall that has an opening between the terminal and the open side of the structure. It is highly recommended that the vent terminal be located where it will not be exposed to normal prevailing winds.
  • Page 24 HSE Installation and Service Manual Table 2 Direct Vent Terminal Clearances (Refer to Figure 13) Canadian Installations US Installations A= Clearance above grade, 12 inches (30 cm) 12 inches (30 cm) veranda, porch, deck, or balcony B= Clearance to window or door 6 inches (15 cm) for appliances ≤...

  • Page 25: Direct Vent Configurations

    HSE Installation and Service Manual 1.7.5 DIRECT VENT CONFIGURATIONS WARNING Failure to ensure that tubes are connected, seated or sealed properly may result in leakage and eventual failure of the sealing gasket. Five venting configurations are available for the appliance: Twin Tube 3 inch CPVC twin tube venting system with 80 mm to 3 inch CPVC adapters •...

  • Page 26: Equivalent Vent/Air Intake Tube Length And Diameters

    HSE Installation and Service Manual 1.7.6 EQUIVALENT VENT/AIR INTAKE TUBE LENGTH AND DIAMETERS The resistance of the combustion air supply and the flue gas tubes depends on the length, the diameter, components used and venting configuration of the venting system. For the appliance to operate normally, the venting system, including air intake piping, flue tube and terminal, must not be overly restrictive.

  • Page 27: Vent Installations

    HSE Installation and Service Manual 1.7.9 VENT INSTALLATIONS The following installation procedure is a guide for all vent installations: 1. The appliance must be vented to the outdoors. Do not install the vent into a common venting system. The venting system does not require a vent damper.

  • Page 28: Horizontal Twin Tube Side Venting With A Combined Terminal Cap

    HSE Installation and Service Manual supply piping. Therefore, venting lengths must be within the specified minimum and maximum equivalent venting system length in Table 3. 8. Slide the adapters (if required) or air supply and flue tubes into the combustion air intake and flue outlet of the appliance so that the gaskets seal snugly around the adapter.

  • Page 29: Horizontal Twin Tube Side Venting With Twin Terminal Caps

    HSE Installation and Service Manual 1.7.9.2 HORIZONTAL TWIN TUBE SIDE VENTING WITH TWIN TERMINAL CAPS Figure 19 is a typical installation for a side venting installation using two 45˚ elbows as twin terminal caps and adapters (if required) for air inlet and flue outlet on the appliance. A space between the two terminal caps is required as shown in Figure 19.

  • Page 30: Concentric Connections With A Combined Terminal Cap

    HSE Installation and Service Manual Figure 23 Vertical Single Figure 22 Vertical Twin Tube Figure 21 Vertical Twin Tube Venting with Side Air Venting Venting Supply 1.7.9.5 CONCENTRIC CONNECTIONS WITH A COMBINED TERMINAL CAP CAUTION: In Canada, follow CAN/CSA B149.1 (current edition) and/or local code requirements for use of plastic venting Plastic vents shall be installed such that the first 3 feet (92 cm), or total vent run if less than 3 feet (92 cm) from the appliance flue outlet, is readily accessible for visual inspection.
  • Page 31 HSE Installation and Service Manual Max. 27.6” [700mm] 2.0” [50mm] 3 deg Ø4.3” [110mm] above horiz. Ø4.7” [120mm] (see note) 8.3” [210mm] 9.5” [240mm] Figure 25 Horizontal Twin Pipe to Concentric Figure 24 Horizontal Concentric Venting Concentric Pipe Adapter Figure 26 Vertical Twin Pipe to Figure 27 Vertical Concentric Venting Concentric Venting...

  • Page 32: Section 2 - Controller

    HSE Installation and Service Manual Controller Section 2 CONTROLLER OPERATION The appliance uses a microprocessor based controller to manage all functions including ignition and flame supervision, continuously modulating/monitoring each heat demand from the heating system or from the domestic hot water supply. The pump starts running when there is a heat demand from the heating system.
  • Page 33 HSE Installation and Service Manual Figure 28 Operating and Display Panel Table 5 Operating and Display Panel Display Operating Controls 7. DHW Eco mode LED 1. Power On/Off LED A. Power On/Off button E. ˚F/˚C button 8. DHW Comfort function LED 2.
  • Page 34 HSE Installation and Service Manual 1 Set temperature reached The burner controller can temporarily block the heat demand and stop the burner. This blocking takes place because the required temperature has been reached. When the temperature has dropped sufficiently, the blocking is cancelled. 2 Self-test The burner controller may regularly carry out a self-test and check the connected sensors.

  • Page 35: Pc Interface

    HSE Installation and Service Manual PC INTERFACE The controller has an interface for a PC. With a special cable and accompanying software, a PC can be connected. This provision makes it possible to follow the behaviour of the controller, the appliance and the heating system during a long period.

  • Page 36: Setting And Adjustment

    HSE Installation and Service Manual SETTING AND ADJUSTMENT The functioning of the appliance is mainly determined by the parameter settings in the controller. User parameters can be set directly through the operating panel without entering the service code, while the installer parameters only can be changed by entering the service code.

  • Page 37: Installer Parameter Settings

    HSE Installation and Service Manual d. Temperature selection (° F/° C) The temperature selection on the display can be toggled between Fahrenheit and Celsius as follows: Fahrenheit, ° F: Press the ˚F/˚C button. The Fahrenheit ° F LED will turn on and the •...

  • Page 38: Setting And Description Of Parameters

    HSE Installation and Service Manual 2.4.3 SETTING AND DESCRIPTION OF PARAMETERS The factory default settings and setting ranges for all parameters are shown in Table 8. The CH operating input rating can be changed by adjusting the CH input rating % and/or blower speed following the sections 2.4.2 and 2.4.4.

  • Page 39: Setting Ch And Dhw Operating Input Rating

    HSE Installation and Service Manual 2.4.4 SETTING CH & DHW OPERATING INPUT RATING CH or DHW operating input rating is determined based on the CH or DHW input rating % (parameter 3 & 4), blower speed (parameter h) and maximum input rating. Table 9 CH or DHW operating input rating CH or DHW input setting Input Rate...

  • Page 40: Outdoor Reset Function

    HSE Installation and Service Manual 2.4.6 OUTDOOR RESET FUNCTION T supply When the outdoor temperature sensor is connected, the appliance uses the outdoor reset function to control the °F °C supply water temperature. Outdoor reset automatically and continuously adjusts the CH supply T max.

  • Page 41: Section 3 - Startup Instructions

    HSE Installation and Service Manual Startup Instructions Section 3 WARNING If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life. WARNING Connect the appliance to the mains voltage only after filling and de-aerating! WARNING When an additive is added to the CH water, it must be suitable for use with the materials used in the appliance and system, such as copper, brass, stainless steel, steel, plastic and rubber.

  • Page 42: Dhw System

    HSE Installation and Service Manual 5. Operate circulating pump and vent the system at the highest points of the piping system. Fill the CH system again if the pressure has dropped too low as a result of the de-aerating. 3.2.2 DHW SYSTEM 1.

  • Page 43: Lighting Instructions

    HSE Installation and Service Manual 3.3.1 LIGHTING INSTRUCTIONS WARNING Should appliance overheat, or the gas supply fail to shut off, do not turn off or disconnect the electrical supply to the circulating pump. Instead, shut off the gas supply at a location external to the appliance. FOR YOUR SAFETY READ BEFORE OPERATING WARNING: If you do not follow these instructions exactly, a fire or explosion may result...

  • Page 44: Startup Instructions

    HSE Installation and Service Manual 3.3.2 STARTUP INSTRUCTIONS In the event of failure of any component, either the system will not operate or it will go into safety lockout. After placing the appliance in operation, the ignition system safety shutoff device must be tested. The method of testing is specified as follows: 1) Make sure the gas valve and all electrical power to the appliance is "OFF".

  • Page 45: Check Burner System

    HSE Installation and Service Manual 5) After flame is established, the controller will modulate the firing rate depending upon the sensed difference between the supply and return water temperatures and the set point of supply temperature. If an outdoor temperature sensor is connected to the appliance, the heating supply water temperature setting will automatically adjust as the outdoor temperature changes.

  • Page 46: Conversion To Propane

    HSE Installation and Service Manual CONVERSION TO PROPANE WARNING This conversion should only be carried out by a qualified heating installer or service technician. When the appliance is connected to a type of gas other than the type specified on the rating plate, the gas orifice ring must be changed and the gas inlet pressure must be adjusted.

  • Page 47: Adjust The Gas-Air Ratio By Measuring The Co

    HSE Installation and Service Manual Table 11 Appliance setting values Gas type Natural gas Propane See notes below See notes below % at low fire setting (L) ( ) with front cover off 9.4 ± 0.5 10.3 ±0.5 % at high fire setting (H) ( ) with front cover off Gas inlet pressure, in.

  • Page 48: Appliance For Use At High Altitude

    HSE Installation and Service Manual 7. Set the appliance to the maximum input rating by simultaneously pressing the Service buttons (twice) on the operating display panel of the controller until an H appears on the service display of the controller display panel. (See section 2.3.1) 8.

  • Page 49: Check Input Rating

    HSE Installation and Service Manual Use at Altitudes above 2000 feet (609 m) in U.S.A. In USA, for appliance installations at altitudes above 2000 feet (609 m) above sea level, the input rating of the appliance should be reduced at the rate of 4 percent for each 1,000 feet (305 m) above sea level. Use at Altitudes above 4500 feet (1370 m) in Canada In Canada, for appliance installations at altitudes above 4500 feet (1370 m), the certified high altitude input rating of the appliance should be reduced at the rate of 4 percent for each additional 1,000 feet (305...

  • Page 50: Installer's Checklist

    HSE Installation and Service Manual 3.12 INSTALLER'S CHECKLIST Reference Section The information printed on the appliance rating plate matches the application 3.7, 3.8 (i.e. altitude, input and fuel type). All applicable electrical codes have been met. 1.2, 1.6 Gas piping has been purged and checked for leaks with a soap solution, including all joints between the gas valve outlet and gas supply pipe when 1.5, 3.2.3 the appliance is on.

  • Page 51: Section 4 - Service & Maintenance Instructions

    HSE Installation and Service Manual Service & Maintenance Instructions Section 4 SERVICE & MAINTENANCE INSTRUCTIONS WARNING Electrical shock hazard – before servicing the appliance, disconnect the appliance and heating system from the power supply by switching off the emergency power OFF button or disconnect the relevant power circuit breaker of the house power grid.

  • Page 52: Inspect The Condensation Trap And Discharge Tube

    HSE Installation and Service Manual 4.2.2 INSPECT THE CONDENSATION TRAP AND DISCHARGE TUBE 1. Follow the maintenance schedule required by the neutralizer supplier. 2. Shut off the appliance and remove the condensate discharge tube from the outlet of condensation trap. Unscrew the slip ring nut from the condensation trap to disconnect it from the appliance. 3.

  • Page 53: Service The Heat Exchanger If Necessary

    HSE Installation and Service Manual 4.2.7 SERVICE THE HEAT EXCHANGER IF NECESSARY 1. Shutdown the appliance as described in the lighting instructions in section 3.3.1. 2. Remove the front cover of the appliance. 3. Wait until the appliance and the burner have cooled down. 4.

  • Page 54: Completion Of Inspection And Service

    HSE Installation and Service Manual 4.2.9 COMPLETION OF INSPECTION AND SERVICE 1. Replace the front cover. 2. Put the appliance into operation at the maximum input, and check the gasket joint of the appliance case, including the gasket joints connecting air intake and flue tubes to appliance case, for leaks.

  • Page 55: Service Checklist

    HSE Installation and Service Manual SERVICE CHECKLIST Reference Section Do not store anything against the appliance or allow dirt or debris to accumulate in the area immediately surrounding the appliance. The flow of air supply and exhaust 4.2.1 must not be obstructed. Check air openings are not restricted and complies with applicable code(s).

  • Page 56: Caution: Water Replenishment

    HSE Installation and Service Manual CAUTION: WATER REPLENISHMENT Avoid unnecessary replenishment of water in the CH system. It can allow oxygen to enter the system and cause serious corrosion problems for system components which are not anti-corrosion type. As well, an excessive amount of minerals may be deposited in the heat exchanger.

  • Page 57: Section 5 - Replacement Parts

    HSE Installation and Service Manual Replacement Parts Section 5 NOTE: To supply the correct part it is important that you state the appliance model, serial number and type of gas when applicable. Any part returned for replacement under standard company warranties must be properly tagged with Return Goods Authorization Form (R.G.A.), completely filled in with the appliance serial number, etc., and shipped to the Company freight prepaid.

  • Page 58: Section 6 - Troubleshooting Guide

    HSE Installation and Service Manual Troubleshooting Guide Section 6 6.1 POSSIBLE PROBLEMS AND SOLUTIONS When the service display or the operating panel is flashing, the burner controller has detected a fault. If multiple faults exist, the temperature display shows an additional code (Refer to table 12). After the fault has been resolved, the burner controller can be restarted by pressing the reset button on the operating panel.

  • Page 59: Burner Fails To Ignite

    HSE Installation and Service Manual 6.2 BURNER FAILS TO IGNITE Possible Problems Solutions Manual gas shutoff valve is not open. 1. Open the manual gas shutoff valve. Air in the gas supply line. 1. Purge the gas supply line. Gas inlet pressure too low. 1.

  • Page 60: Burner Ignites With Noise

    HSE Installation and Service Manual 6.3 BURNER IGNITES WITH NOISE Possible problems Solutions Gas inlet pressure too high. 1. The gas regulator may be faulty. Contact the gas company. Incorrect spark probe gap. 1. Replace the spark probe. 2. Adjust the spark probe gap. Gas-air ratio not adjusted properly.

  • Page 61: No Heating (Ch)

    HSE Installation and Service Manual 6.5 NO HEATING (CH) Possible problems Solutions Room thermostat not closed or outdoor 1. Check the wiring. reset sensor faulty. 2. Replace the thermostat. 3. Replace the outdoor reset sensor. No voltage (24 V) output from the 1.

  • Page 62: Ch Supply Water Does Not Reach Correct Temperature

    HSE Installation and Service Manual 6.7 CH SUPPLY WATER DOES NOT REACH CORRECT TEMPERATURE Possible problems Solutions Room thermostat settings not correct. 1. Check the setting and adjust if necessary. Supply water temperature set too low. 1. Correct the temperature setting, see section 2.4.1 item 2 a.

  • Page 63: Domestic Hot Water Does Not Reach Correct Temperature

    HSE Installation and Service Manual 6.9 DOMESTIC HOT WATER DOES NOT REACH CORRECT TEMPERATURE Possible problems Solutions Water flow rate higher than 9 l/min 1. Adjust water flow rate Water temperature setting too low 1. Set the hot water to desired temperature 1.

  • Page 64: Section 7 - Notes

    HSE Installation and Service Manual Notes...

This manual is also suitable for:

Hse-125-p

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