Intergas Compact HRE18 SB (G.C. 41-291-01) Installation, Service And User Instructions Manual
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Intergas Compact HRE18 SB (G.C. 41-291-01) Installation, Service And User Instructions Manual

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Please read these installation instructions carefully before installing and using
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Summary of Contents for Intergas Compact HRE18 SB (G.C. 41-291-01)

  • Page 1 &RPSDFW +5(  6% *&   6% *&   6% *&   6% *&  ,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.

  • 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.

  • 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

    Procedures which must be followed to prevent frost damage. 1.6 Abbreviations and descriptions used Description Referred to as High efficiency Intergas Compact HRE SB wall mounted gas fired Appliance boiler 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

    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 wall mounted gas fired boiler and any associated accessories.

  • Page 7: Approvals

    Directive 90/396/EEC Directive 92/42/EEC The Intergas Compact HRE SB 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 8: 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 18 SB 24 SB 30 SB 40 SB Gas Council number G.C. 41-291-01 G.C.

  • Page 9: 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 18 SB 24 SB 30 SB 40 SB...

  • Page 10: Components

    2.6 Components CH pump Sight glass Gas valve Air supply cap Boiler controller Flue pipe adapter (only to be used in combination with the accompanying elbow in flue sets). Sensor S1 Connection block / terminal strip X4 Sensor S2 Condensate drain pan N.a.

  • Page 11: General Boiler Information

    The appliance can also be connected without the wall mounting jig using the robo kit. The Intergas Compact HRE SB wall mounted gas fired boiler carries the CE rating and IP44 electrical protection. The appliance is supplied as standard for natural gas (G20). For usage of propane gas (G31) the boiler can be modifed by changing the gas injector.

  • Page 12: Operation

    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 which, each time heat is...

  • Page 13: Clock Function (Heat Only)

    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 14: 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 15: 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 16: Accessories

    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 Outside sensor 203207...
  • Page 17 Description Article number Horizontal telescopic offset wall terminal 081298 Only to be used in combination with the base adapter on the boiler Vertical roof terminal 082973 (incl. boiler adapter 60/100) Plume management kit 081294 Elbow 90° ((for Plume management kit) 081284 Elbow 60°...

  • Page 18: Installation

    7 INSTALLATION 7.1 Overall dimensions Appliance inclusive wall mounting jig: Appliance + wall mounting jig + bracket Supply CH Ø22 Return CH Ø22 ½” Condensate drain Ø25 (flexible) Drain PRV Ø15 840 (*) Compact HRE SB 30 & SB 40 Compact HRE SB 24 Compact HRE SB 18 Flue pipe / air...

  • Page 19: 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 20: Assembly

    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 fitted as well.

  • Page 21: Installing The Appliance

    7.4 Installing the appliance Unpack the appliance. 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 mounting Check the appliance for possible damage: report damage immediately to the supplier.

  • Page 22: Connection

    8 CONNECTION 8.1 Connecting CH installation Flush the CH system thoroughly to clean. Fit the flow and the return pipe into the shut off valves. All pipes must be fitted unstressed in order to prevent the pipes from ticking. Existing connections must not be twisted, in order to avoid leakages. Make sure the compression fittings are thightened thoroughly to prevent leakage.

  • Page 23: Electrical Connection

    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.
  • Page 24 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 and 7, the loop in 6 –...

  • Page 25: Condensate Disposal

    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 powering up the boiler.

  • Page 26: Flue System

    60/100 included in the vertical roof terminal, Intergas article number 082973. When using a vertical flue system to reach an higher positioned wall terminal the adapter on the boiler has to be replaced with the adapter 60/100, Intergas article number 090547. NOTE...
  • Page 27 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 28 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 terminal but excluding the initial elbow from the boiler and 1 metre vertical condensing tube is 8 metre.

  • Page 29: 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 30 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 with these instructions; •...

  • Page 31: 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 SB) - button Desired temperature of CH or DHW in °C / Ch water pressure (bar) / Fault code/ Time + button Clock “on”...

  • Page 32: Setting And Adjusting The Clock Functions

    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-on 9.3.1 Setting the clock...

  • Page 33: 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. Adjust all valves to manual operation. 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 34: 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 35: Setting Via The Service Code

    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: Press the keys simultaneously until a appears on the service- and temperature display.

  • Page 36: Weather- Compensation Adjustment

    Max. fan rpm Adjustment range: nominal value ± 200 rpm. With this parameter the maximum rpm can be set. Legionella prevention 0 = Legionella prevention disabled. (only applicable when using 1 = Legionella prevention weekly external tank and W-plan) 2 = Legionella prevention daily Set point CH (flow temperature) Adjustment range 60°C to 90°C during heating external DHW tank...

  • Page 37: Setting Maximum Ch Power

    10.5 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 the fan rpm and the appliance power.

  • Page 38: 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 39: 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 40 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 41 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 42 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...

  • Page 43: 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 percentage at low setting see § 10.8.2. Place a sticker for the gas type set over the existing sticker next to the gas valve.

  • Page 44: 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 45: Other Faults

    11.2 Other faults 11.2.1 Burner does not ignite Possible causes: Solution: Gas tap is closed. Open gas tap. Air in the gas pipe. Remove air form gas pipe. Gas supply pressure to low. Contact the gas supply company. No ignition. Replace ignition electrode.
  • Page 46 11.2.5 No heating (CH) Possible causes: Solution: Check the wiring. Room thermostat / weather-dependent Replace the thermostat. adjustment not closed or faulty. Replace the weather-dependant adjustment. Check the wiring against the diagram. No current (24 V). Check the connector X4. Replace the faulty manager.
  • Page 47 11.2.9 Hot water does not reach temperature (only when an indirectly heated DHW storage cylinder is applied) Solution: Temperature setting for DHW storage cylinder Set the DHW storage cylinder temperature. See 10 Setting and adjustment. too low. 11.2.10 LED on CH pump is flashing alternately red and green. Possible causes: Solution: Mains voltage to high or to low.

  • Page 48: 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. Fork spanner 30 mm After servicing, complete the relevant Benchmark Service Record section located on page 51 of this document.

  • Page 49: Assembly

    § 10.8. When the CO percentage at high setting is not within the prescribed tolerance band please contact Intergas Heating. 03010083 ,QWHUJDV +HDWLQJ /WG...

  • Page 50: Electrical Diagram

    13 ELECTRICAL DIAGRAM 13.1 Electrical diagram HRE SB Earth connections heat-exchanger Fuse (2A T) 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 3,15 AT Connector X4 On/off room thermostat...

  • Page 51: Typical Y Plan Connection

    13.3 Typical Y Plan connection 13.4 Typical S Plan connection. ,QWHUJDV +HDWLQJ /WG...

  • Page 52: Short Spares List

    14 SHORT SPARES LIST Description Article number Fan 24 V, HRE 18 SB, 24 SB & 30 SB 074507 Fan 230 V, HRE 40 SB 074577 Fixing strip 145308 Temperature sensor (heat exchanger S1 & S2) 200117 Temperature sensor (DHW) 200127 CH Pump HRE 24/18, 28/24 &...

  • Page 53: Warranty Conditions

    6. The warranty is effective only if the annex to this warranty certificate has been signed by the purchaser and returned to us With due regard for the conditions indicated below, Intergas Heating within 8 days of the date of installation. By signing the warranty...

  • Page 54: Gas Boiler System Commissioning Checklist

    17 GAS BOILER SYSTEM COMMISSIONING CHECKLIST ,QWHUJDV +HDWLQJ /WG...

  • Page 55: Service Record

    18 SERVICE RECORD ,QWHUJDV +HDWLQJ /WG...
  • Page 56 Intergas boilers are manufactured in a Kiwa ISO 9001 certified production faccility. ,QWHUJDV +HDWLQJ /WG Intergas Heating Ltd Tel: 01527 888000 88322802 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...

This manual is also suitable for:

24 sb (g.c. 41-291-02)30 sb (g.c. 41-291-03)40 sb (g.c. 41-291-07 )

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