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Xclusive 24
(G.C. 47-291-13)
Xclusive 30
(G.C. 47-291-14)
Xclusive 36
(G.C. 47-291-15)
Xtreme 24
(G.C. 47-291-10)
Xtreme 30
(G.C. 47-291-11)
Xtreme 36
(G.C. 47-291-12)
Smart Opentherm™
Smart Opentherm™
Boiler Service
Boiler Service
Procedure
Procedure
The complete boiler guide
High Efficiency Wall-Mounted Gas Boilers
Read this service procedure thoroughly to ensure continued safety and efficient
operation of the boiler.
Should you require further information please contact our Service & Technical
department by calling 01527 888000
The complete boiler guide
High Efficiency Wall-Mounted Gas Boilers
Read this service procedure thoroughly to ensure continued safety and efficient
operation of the boiler.
Should you require further information please contact our Service & Technical
department by calling 01527 888000
BOILERS
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Summary of Contents for Intergas Xclusive 24
- Page 1 Read this service procedure thoroughly to ensure continued safety and efficient operation of the boiler. Should you require further information please contact our Service & Technical department by calling 01527 888000 Xclusive 24 (G.C. 47-291-13) Xclusive 30 (G.C. 47-291-14) Xclusive 36 (G.C.
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Page 2: Table Of Contents
INTRODUCTION During a survey of existing Intergas boilers installed we have noted that many are not being serviced correctly. To ensure the appliance continues to operate safely and efficiently it is essential that the annual servicing is completed correctly. Any work undertaken must be performed by a competent, suitably qualified Gas safe registered engineer. - Page 3 Replace the front plate seal every years or if damaged, degraded or if the front plate has been removed using the Intergas OEM black Viton seal (Red silicon type seals must be replaced regardless of age). Check the burner has not delaminated also check the burner seal.
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Page 4: Service Procedure Explanation
Service procedure explanation. COMMENT ► There are 2 types of service procedures A = Interim service to be completed annually. B = Internal service to be completed bi-annually in conjunction with Interim service A. NOTE every year extra seals need to be replaced. A = Interim service to be completed annually. -
Page 5: Removing / Replacing The Room Sealed Cover (X-Range Boiler)
Removing/Replacing the Room Sealed Cover (X-Range) Removing the room sealed front cover. ► The front cover of the boiler must be removed to perform various maintenance activities however you must be a competent Gas Safe registered engineer before carrying out the following procedure! ►... -
Page 6: Annual Service
ANNUAL SERVICE (A) The boiler and the system must be inspected annually by an qualified competent gas safe registered engineer. The boilers heat exchanger should be cleaned and inspected as stated below at the correct service interval. CAREFUL ► After completion of the Annual service procedure all 26 (9) safety checks must be performed and the results recorded within the service &... - Page 7 ► Return the plastic ball to the syphon base and attach the circlip. ► Check that the ball and circlip have been installed correctly ca. 6 cm (6). Make sure that the top of the circlip is about 6 cm below the edge of the syphon base.
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Page 8: Annual Service B
Annual service (B) (cleaning) ► Clean the slats of the heat exchanger from top to bottom with a brush or Intergas comb (use a vacuum cleaner to remove debris). ► Clean the underside of the heat exchanger. ► Only clean the lower metal heat shield of the front panel. - Page 9 A Brass or Nylon bristled brush can be used to clean the surface followed by a mist spray to wash it down. ► The Intergas comb has been designed Intergas Heat exchanger comb Water Atomiser trigger spray to assist in the removal of any hardened Part number 460067 areas of Aluminium oxide.
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Page 10: Annual Service (Re-Assemble)
Please check sufficient ceramic grease has been applied and the correct torque settings adhered to before calling the Intergas service team. I01.000.09.0001 IMPORTANT Once the boiler has been serviced or ►... -
Page 11: Inspection Of Seals & Unions (X-Range Boilers)
INSPECTION OF SEALS & UNIONS (X-range boilers) † Burner fibre seal (fragile) Part number 877847 ¶ Front plate seal (Viton) † part number Burner retaining screw seal Large 086474 Part number 875917 (x 4) Medium 086504 Burner Earth spring PLEASE NOTE Front Plate Seal Replaced on... -
Page 12: Measuring The Flue Gas At Maximum Output
MEASURING THE FLUE GAS AT MAXIMUM OUTPUT Having cleaned the heat exchanger and boiler components and whilst the boiler is still safely isolated..A. Remove the cap of the flue gas sampling test point (3) on the appliance connector or bend on top of the boiler. B. -
Page 13: Measuring The Flue Gas At Minimum Output
MEASURING THE FLUE GAS AT MINIMUM OUTPUT Before measuring the flue gases at minimum output, the measurement at maximum output must be completed, as previously detailed. The measured CO (H) % at maximum output is important to determine equilibrium, this must be completed before checking the minimum output %. -
Page 14: Gas Valve Adjustment Procedure
GAS VALVE ADJUSTMENT (at minimum output) Before the minimum output correction is performed, the maximum output and minimum output measurements must be completed. The measured CO (H) value at maximum output is important for determining the correct value for the setting at minimum output. -
Page 15: Hre & Eco Rf Service Procedure
HRE & Eco RF Boiler Service Service Procedure Procedure HRE 24/18 (G.C. 47-291-01) HRE 28/24 (G.C. 47-291-02) HRE 36/30 (G.C. 47-291-03) HRE 36/40 (G.C. 47-291-04) HRE SB18 Eco RF 24 (G.C. 41-291-01) (G.C. 47-291-05) HRE SB24 Eco RF 30 (G.C. 41-291-02) (G.C. -
Page 16: Service Variations
Service variations (HRE & ECO RF) All Intergas boilers use the same Bithermic heat exchanger technology with only slight variations throughout the model range. The HRE & Eco boiler variations are shown in this section however the relevant service type (Service (A) page 6, or service (B) page 8) must be followed with the settings as per those set out in the previous tables 4a &... -
Page 17: Reassemble
Reassemble ► Replace the front plate seal as detailed in the previous section ensure it is the correct size and located correctly within the front plate channel. IMPORTANT All red silicon front plate seals must be replaced, regardless of age, with the new black Viton type. -
Page 18: Inspection Of Seals & Unions (Hre & Eco Rf Boilers)
INSPECTION OF SEALS & UNIONS (HRE & ECO RF boilers) † Burner fibre seal (fragile) PLEASE NOTE Part number 877847 Front Plate Seal Replaced on Date........¶ Front plate seal (Viton) † part number Burner retaining screw seal Large 086474 Part number 875917 (x 4) Medium 086504 Small 086514... -
Page 19: Rapid Service Procedure
Rapid Service Boiler Service Procedure Procedure Rapid 25 (G.C. 47-291-08) Rapid 32 (G.C. 47-291-09) BOILERS Smart Opentherm™... -
Page 20: Service Variations
Service variations (Rapid). ► The Rapid boiler variations are shown in this section however the relevant service type (Service (A) page 6, or service (B) page 8) must be followed with the settings as per those set out in the previous tables 4a & 4b page 14. ►... -
Page 21: Internal Maintenance
Annual service continued (internal maintenance) ► Lift and rotate the expansion vessel to the left side. ► Disconnect the electrical connector to the fan assembly. ► Close the gas isolation valve and check for tightness & let-by. ► Loosen both unions and the electrical connector, then remove the gas valve. -
Page 22: Inspection Of Seals & Unions (Hre & Eco Rf Boilers)
INSPECTION OF SEALS & UNIONS (Rapid & *HR22 boilers) † Burner fibre seal (fragile) Part number 877847 ¶ Front plate seal (Viton) † part number Burner retaining screw seal Large 086474 Part number 875917 (x 4) PLEASE NOTE Front Plate Seal Burner Earth spring Replaced on Date........ -
Page 23: Service & Interim Record
SERVICE & INTERIM BOILER WORK RECORD It is recommended that your boiler and heating system are regularly serviced and maintained, in line with manufacturers’ instructions, and that the appropriate service / interim work record is completed. Service provider When completing a service record (as below), please ensure you have carried out the service as described in the manufacturers’ instructions. Always use the SERVICE/INTERIM WORK ON BOILER SERVICE/INTERIM WORK ON BOILER Date:... - Page 24 All rights reserved. The information provided applies to the standard version of the product. Intergas Heating Ltd can therefore not be held liable for any damage ensuing from specifications that deviate from the standard version of the product. Although the available information has been composed with all possible care, Intergas Heating Ltd cannot be held liable for any errors in the information or for the consequences of such.
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