Intergas Compact HRE 18 OV Installation, Service And User Instructions Manual
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Intergas Heating Ltd
Compact HRE
18 OV
(G.C. 41-291-04)
24 OV
(G.C. 41-291-05)
30 OV
(G.C. 41-291-06)
Installation, service
and user instructions
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.
1
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Table of Contents
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Summary of Contents for Intergas Compact HRE 18 OV
- Page 1 (G.C. 41-291-05) 30 OV (G.C. 41-291-06) Installation, service and user instructions 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. Intergas Heating Ltd...
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Page 2: Table Of Contents
Accessories Installation Overall dimensions ..................................16 Installation location ..................................17 Installing the appliance .................................. 18 Connection Connecting CH installation ................................19 Gas connection ....................................19 Electrical connection ..................................20 Condensate disposal ..................................22 Flue system ....................................23 Intergas Heating Ltd... - Page 3 © 2014 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
Power consumption : full load Power consumption: partial load Power consumption: standby Boiler dimensions and weight Height Width Depth Weight We have a policy for continual improvement and development, therefore we reserve the right to change specifications without prior notice. Intergas Heating Ltd... -
Page 8: Components
Condensate trap Return CH Ionisation / Ignition electrode Sight glass Sensor S1 Gas valve Heat exchanger Position of data plate Sensor S2 Boiler controller Condensate drain pan Operating panel and read-out Connection block / terminal strip X4 Intergas Heating Ltd... -
Page 9: 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 10: Oeration
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 11: 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 12: Test Programs
If the appliance is out of operation ( on the service display) the appliance ’s internal frost protection is still active. However, this means there will be no response to a request for heat from an (external) frost thermostat. Intergas Heating Ltd... -
Page 13: 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 14: Accessories
Only to be used in combination with the base adapter on the boiler Horizontal telescopic wall terminal 081297 Only to be used in combination with the base adapter on the boiler Vertical roof terminal 082973 (incl. boiler adapter 60/100) Intergas Heating Ltd... - Page 15 Plume management kit 081294 Elbow 90° (for plume management kit) 081284 Elbow 60° (for plume management kit) 081285 081286 Extension L = 100 incl. wall bracket (for plume management kit) Intergas Heating Ltd...
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Page 16: Installation
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 Intergas Heating Ltd... -
Page 17: Installation Location
Proceed as follows: If cover plate (A), is used, remove to the front. • Unscrew the two screws (1) behind the appliance display window. • Pull the bottom of the front panel (2) forwards. • Intergas Heating Ltd... -
Page 18: Installing The Appliance
32mm diameter in order to prevent the condensate from freezing. 7.3.1 Fitting the cover plate Hang the flanged upper edge of the cover plate on the washers under the base of the appliance and slide the cover plate as far as possible towards the rear. Intergas Heating Ltd... -
Page 19: Connection
8.2 Gas connection Fit the enclosed gas isolation valve on the gas pipe under the boiler. Connect the appliance to the gas supply. Check the gas carrying parts for leakage at a maximum pressure of 500 mm Intergas Heating Ltd... -
Page 20: Electrical Connection
230 V. (connector X4) Frost thermostat 230 V 1 – 3 Remove link 6 – 7 (connector X4) Switch live from S-plan or Y-plan onto connector X2, no.1. See chapter 13.2 and 13.3 for complete electrical schedules. Intergas Heating Ltd... - Page 21 8.3.6 230 volt room thermostat To be connected to contacts 1 and 3 of connector X2 and remove link 6-7. See electrical diagram. Warning High Voltage Isolate the appliance from the electrical supply before connecting the thermostat. Intergas Heating Ltd...
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Page 22: Condensate Disposal
- the use of fittings, elbows etc should be kept to a minimum ans any internal ‘’burrs’’ on cut pipework should be removed so that the internal pipe section is as smoooth as possible. For more information about preventive measures against freezing please visit the HHIC website http://www.centralheating.co.uk/checklists/frozen-condensate-pipes. Intergas Heating Ltd... -
Page 23: 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 24 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 25 1. Check condensate trap is filled with water and correctly connected to boiler. 2. All flue joints are correctly made, unstressed and adequately supported. 3. All parts of the flue can be visually inspected -ensure suitable access where flue is positioned within voids- Intergas Heating Ltd...
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Page 26: Commissioning The Appliance
Ensure that this inlet pressure can be obtained with all other gas appliances in the property working. 9.1.4 Flue system The flue system must be connected correctly to the appliance in accordance with the manufacturer’s instructions. The flue termination should also be checked. Where Intergas Heating Ltd... -
Page 27: Commissioning The Appliance
For setting the clock see § 9.3. Notes The appliance is equipped with an electronic boiler controller, which ignites the • burner and continuously monitors the flame during each request for heat from the heating or from the hot water supply. Intergas Heating Ltd... -
Page 28: Setting And Adjusting The Clock Functions
2. c-on (continuous on). The boiler will respond on every CH demand from the room thermostat without any time limit. 3. OFF The boiler will not respond on any CH demand from the room thermostat. Intergas Heating Ltd... -
Page 29: Shutting Down
(See chapter 13). Note If an (external) frost thermostat has been fittted to the installation and connected to the appliance, this will not be active when the appliance is switched off at the operating panel on service display). Intergas Heating Ltd... -
Page 30: Setting And Adjustment
If no key is pressed during a period of 30 seconds, the settings menu is closed automatically and the changes are stored. 10.1.4 Maximum CH supply temperature Press the key until the LED at starts to flash. With the key s set the temperature between 30°C and 90°C (default value 80°C). Intergas Heating Ltd... -
Page 31: Setting Via The Service Code
With this parameter the maximum rpm can be set Set point CH (flow temperature) during Adjustment range 60°C to 90°C heating external DHW tank Waiting time after a DHW demand before Adjustment range 0 to 15 minutes a CH demand is answered Intergas Heating Ltd... -
Page 32: Setting Maximum Ch Power
650 l/h 22,8 kW 750 l/h 26,3 kW Appliance pressure loss graph, CH side Compact HRE 18 OV Compact HRE 24 OV Compact HRE 30 OV Flow in l/h Pressure loss / water head in mH 10.6 Weather– compensation adjustment... -
Page 33: Checking Gas-/Air Ratio
It is not possible to adjust the CO percentage on test program H. When the CO percentage is not in accordance with the value as listed in table 10.8, please contact Intergas Technical Services 01527 888 000. No adjustment to the CO percentage should be made without permission from Intergas Technical Services. -
Page 34: Setting Gas/Air Adjustment Procedure
Note: Check that the measurement nipples used are gas-tight. CAUTION Check that the Flue gas sampling point and the Gas test point are gas-tight. No adjustment should be made to the gas valve without prior permission of Intergas Technical Services. Gas type Natural gas H... -
Page 35: Examples
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 36: 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 37 Replace the weather-dependant adjustment. Check the wiring against the diagram. No current (24 V). Check the connector X4. Replace the faulty manager. Check the power supply. Pump not running. Check connector X2. Replace faulty pump. Intergas Heating Ltd...
- Page 38 Hot water does not reach temperature (only when an indirectly heated DHW storage cylinder is applied) Possible causes: Solution: Temperature setting for DHW storage cylinder Set the DHW storage cylinder temperature. See 10 Setting and adjustment. too low. Intergas Heating Ltd...
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Page 39: Maintenance
12.3 Cleaning Clean the heat exchanger from top to bottom with a plastic brush or compressed air. Clean the underside of the heat exchanger. Clean the condensate drain pan with water. Clean the condensate trap with water. Intergas Heating Ltd... -
Page 40: Assembly
§ 10.8. When the CO level at high setting is not within the prescribed tolerance band please contact Intergas Heating. 03010083 Intergas Heating Ltd... -
Page 41: Electrical Diagram
13.1 NTC resistances NTC 12kOhm T [°C] R[ohm] T [°C] R[ohm] T [°C] R[ohm] 76020 12000 2752 58880 9805 2337 45950 8055 1994 36130 6653 1707 28600 5522 1467 22800 4609 1266 18300 3863 1096 14770 3253 Intergas Heating Ltd... -
Page 42: Typical Y Plan Connection
13.2 Typical Y Plan connection 13.3 Typical S Plan connection Intergas Heating Ltd... -
Page 43: Short Spares List
877927 O-ring front plate Compact HRE OV 18 876467 Seal ring condensate collector (heat exchanger connection) 878147 O-ring flue pipe dia 68*4 878537 Seal ring flue pipe (outlet side) 878547 Condensate trap connection 878577 Sampling cap 847000 Intergas Heating Ltd... -
Page 44: Warranty Conditions
Conditions of Sale. A copy of these conditions will be sent to you free of charge on request. Conditions to the contrary With due regard for the conditions indicated below, Intergas Heating are expressly rejected. Ltd warrants to the authorised installer the soundness of the... -
Page 45: Gas Boiler System Commissioning Checklist
17 GAS BOILER SYSTEM COMMISSIONING CHECKLIST Intergas Heating Ltd... -
Page 46: Service Record
18 SERVICE RECORD Intergas Heating Ltd... - Page 47 __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ __________________________________________________________________________________________________________________ Intergas Heating Ltd...
- Page 48 Intergas boilers are manufactured in a Kiwa ISO 9001 certified production faccility. Intergas Heating Ltd 883247-08 Intergas Heating Ltd Tel: 01527 888000 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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